NTPC SIMHADRI

NTPC SIMHADRI
WELCOMES
YOU
NTPC Simhadri Pride of India
NTPC Simhadri Pride of AP

SIMHADRI
Simhadri
Salient Features of Simhadri
Capacity : 2 x 500 MW
Location : 40 Km from Visakapatnam,A.P.
Land : 3384 acres
Fuel (Coal) : 5.04 million Tons / Year
from Mahanadi Coal Fields, Orissa
Water : 600 Cum / Hr Sweet water from
(Makeup) Yeleru canal (River
Godavari)
9100 Cum/Hr Cooling water from
Sea (Bay of Bengal)
Beneficiary State : Andhra Pradesh.
NTPC SIMHADRI

ELECTROCHLORINATION
SYSTEM
WHAT IS ELECTROCHLORINATION

IT PRODUCES A BIOCIDE CALLED

SODIUM HYPOCHLORITE BY THE
ELECTROLYSIS OF SODIUM
CHLORIDE IN SEA WATER

SODIUM HYPOCHLORITE NaOCL

SODIUM CHLORIDE NaCL

WHY ELECTROCHLORINATION
SEA WATER REQUIREMENT AS COOLING WATER
WHICH CONTAINS HUGE MARINE ORGANISMS.
THEIR GROWTH MULTIPLIES & AFFECTS EQUIP-
MENT PERFORMENCE IN MANY WAYS.
ACCELERATES CORROSION / SCALING/GENERAL
FOULING LEADING EQUIPMENT OUTAGES

REDUCES CONDENSER VACUUM AND IN TURN

LOAD REDUCTION/ GENERATION LOSS.

HENCE COOLING WATER STERILISATION

IS WARRANTED
Electro-chlorination plant
Mussel growth in a sea water pipe
JETTY TO SEA WATER PUMP
HOUSE
To Sea water pump house
Condenser ( before Overhauling)
Condenser (before Overhauling)
 PLANT DETAILS
1. ELETROLYZERS SUPPLIED BY ELCAT UK.
INDIAN AGENT IEC FABCHEM

2. THE ELECTROLYZERS ARE IMPORTED.

TWO WORKING AND ONE SPARE

3. OTHER EQUIPMENTS SUCH AS PUMPS

TANKS ETC ARE INDEGINIOUS.

4. TOTAL PACKAGE COST IS ABOUT

2.0 CRORES
COOLING WATER SYSTEM
SCALING CORROSION

PROBLEMS

BIOFOULING
GENERAL OR MARINE
FOULING FOULING
SCOPE OF DISCUSSIONS

MARINE FOULING

ELECTROCHLORINATION
SYSTEM
 MARINE/ BIO FOULING
(GROWTH & DEPOSITION OF MICRO & MACRO-
ORGANISMS)

MICRO MACRO BIOLOGICAL

BIOLOGICAL FOULING
FOULING

CAUSED BY CAUSED BY MUSSELS,

ALGAE FUNGI BARNACLES, HYROIDS &
& BACTERIA OTHER FOULING
ORGANISMS
PROBLEMS

COLONIZATION OF MACRO-ORGANISMS AT
INTAKE STRUCTURES, CW INTAKE TUNNELS ETC

BLANKETING THE SCREENING PLATE &

CONDENSER TUBE PLATES, ETC WHEN
MACRO ORGANISMS GOT DETACHED

REDUCTION OF FLOW & INCREASE PUMPING

COST

PERFORATION OF TUBES DUE TO EROSION

CORROSION
 CAUSING BIOLOGICAL SLIME FORMATIONS
ON WATER SIDE SURFACES OF CONDENSER TUBES
THUS IMPAIRING HEAT TRANSFER AND LOSS OF
CONDEN VACUUM.

BIOFILM ATTRACTS SILT MUD & OTHER

DEPOSITS FURTHER IMPAIR HEAT TRANSFER

SLIME FORMATIONS ON TITANIUM TUBES ARE

MORE. IN SIMHADRI CONDENSER TUBES ARE Ti.
NATURE OF MACROFOULING IN VISAKHAPATNAM

50 species of macrofoulers reported in

Visakhpatnam area. Of these M.Sallei is the
most dominant

Growth is very rapid (30 mm in 15 days)

About 100 Kg/Sq.M of fouling debris

accumulate per annum.

The metabolism is temperature

independent.
 CONTROL MEASURES

THE THREE ANTI FOULING TECHNIQUES

ARE

MANUAL CLEANING
MECHANICAL CLEANING (SPONGE
BALL SYSTEM)
CHEMICAL BIOCIDES
(HYPOCHLORITE OR CHLORINE)
CHLORINE & HYPOCHLORITE AS
BIOCIDES

To control marine fouling or bio-

fouling chlorine or hypochlorite is
considered to be most economical &
environmental friendly compare to
other biocides
CHMICAL REACTION OF CHLORINE
& HYPOCHLORITE IN WATER
SIMILAR PRODUCTS ARISE WHEN CHLORINE OR
SODIUM HYPOCHLORITE IS ADDED IN WATER
CL2 +H2O HOCl +HCL

NaOCL + H2O HOCl + NaOH

THE HYPOCHLOROUS ACID ( HOCl) FORMED AS

ABOVE IS THE EFFECTIVE BIOCIDE
 PRODUCTION OF SODIUM HYPOCHLORITE IN AN
ELECTROCHLORINATION PLANT

Direct current
+ Anode reaction Cathode reaction -
2Cl-- Cl2+2e 2Na++2e 2Na
Sea water 2Na+2H2O 2NaOH+H2
Na+ Cl-
As the cathode and anode products are not separated the
overall
Reaction is

2NaOH+Cl2 NaOCl+NaCl+H2
STORED IN CONTAINERS
 ELECTROCHLORINATION PLANT ELCAT UK
H2
DESILT
BLOWERS BASIN
HYPO STORAGE 1025M3/hr
TANK
30M3 EFFL
RECTIFIER MAKE UP
120V 850A WATER LINELINE
TO
SEA
BED

ELECLYZERS NaCL
5% ACID NaOCL+
STORAGE
TANK 1.5M3H2 CW MAKE UP
PPS

HYPO DOZING
PUMPS 20M3/HR
20M3/hr well
BOOSTER PPS
15M3/hr
 SEA WATER TWO CONCENTRIC
NaCL NaOCL
Ti TUBES

ELECTROLYTIC GENERATOR
2X20KG/HR CAPACITY ELECTROLYSERS

THREE MODULES IN EACH 1A,1B,1C & 2A,2B,2C

THE CELLS ARE TUBES SHAPE CONNECTET

ELECTRCALLY IN SERIES. AS SEA WATER FLOWS
HYPOCHLORITE THROUGH ANNULAR SPACE
CONC. INCREASES.
Hydraulic arrangement
24 cells are connected in series to form a module
As the sea water flows from cell to cell, the product
hypochlorite conc increases in a step wise fashion.
Each module requires a min of 5m3/hr of sea water to ensure
Highly turbulent flow
Modules are arranged in parallel
 Electrical arrangement
A module comprises
CHLOROPAC cells
connected hydrolically
in series
The module is divided
into two equal sections
with a series of electrical
connections for individual
sections.
The first half section is called inlet,
the second half is called the out let
section
Each section contains the same
number of cells. The first & the last cells in the module are connected
to the -ve bus(ground potential). The two middle celle are connectedto the +ve
bus through the two individual poles of the DC circuit breaker.
 CELL VOLTAGE
V1 V2 V3 V4
DC cable DC cable
connect connect

Sea water
in
out

V1 + V2 +V3 + V4 = Vt

Both cathode and anode is made of Ti

The anode is coated with Platinum The electrical connections of the
electrode assembbly are placed on
The electrical cells are bipolar in design.
That means the anode of every cell are
the flanges of the electrolyzer body
directly connected to the cathodes of
the next cell
MAJOR DESIGN ASPECTS

HYPOCHLORITE SOLUTION STRENGTH 1500

PPM (MG/LITER)

ELECTROLYZERS DESIGNED FOR 120V DC

SUPPLY

ELECTROLYZER PLATES BASE METAL Ti 265

GRADE FOR BOTH CATHODE & ANODE. THE
ANODE IS COATED WITH PLATINUM.

POWER CONS 4.5 KW/KG OF CL2

GENERATIONS.
 IMPORTANT PROTECTIONS

IN CASE OF LOW FLOW LEVEL THE DC CURRENT

AUTOMATICALLY CUT OFF.

IF THE OUTLET HYPOCHLORITE TEMP EXCEEDS

THE DC SUPPLY TO GEN MODULE IS CUT OFF
AUTOMATICALLY.

HYDROGEN GAS PRODUCED IN THE ELECTROL-

YZER IS DILUTED. 2%V/V& IS DRIVEN OFF FROM
SYSTEM BY THE BLOWERS
.
 IMPORTANT PROTECTIONS

D.C SUPPLY CUT OFF IN CASE OF LOW AIR

FLOW TO THE HYPO TANK.

LEVEL IN THE HYPO TANK FALLS THE

DOZING PPS TRIPS.

HIGH LEVEL IN THE TANK REDUCE THE SEA

WATER TO THE ELECTROLYZERS.
 DOZING CALCULATIONS

ELECT GEN CAPACITY 20 KG/HR

MAKE UP PP CAPACITY 9000M3/HR

CONT DOZING RATE 1 TO 1.5 PPM

TOT. CL2 GEN/DAY 20X24=480KG

DUR. OF CONT OPNS 20HRS/DAY

CL2 DOZING IN 20HRS 9000X1.5X20/1000=270KG/DAY

DUR OF SHOCK DOZ 4HRS/DAY

SHOCK DOZ CAPACITY 210KG/DAY

RATE OF SHOCK DOZ 210X1000/9000X4=5.84PPM

 SUMMARY
CONTROL OF MARINE FOULING IN COOLING
WATER SYSTEM IS VERY ESSENTIAL
WATER

ELECTROCHLORINATION PROCESS TO PRDUCE

SODIUM HYPOCHLORITE AS A BIOCIDE
SODIUM HYPOCHLORITE IS A SAFE , EFFECTIVE,
ENVIRONMENT FRIENDLY & EASY HANDLING
BIOCIDE.
NTPC SIMHADRI

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