BOP Plant

A Maharatna Company
NETRA
BoP - Water Treatment and
Corrosion I ssues & Remedies
Ashwini K Sinha
AGM (NETRA)
ashwiniksinha@ntpceoc.co.in, ashwiniksinha@gmail.com
23
rd
May 2012
NTPC Energy Technology ResearchAlliance
Developing Economic and Green Energy Technologies
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1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
2.0 Issues Related to BOP
Summary of issues in BoP
Schematics of Power Plant & Water Treatment Technologies
Cost of Corrosion in Power Plants
Quantity of Water required for different applications
Quality of Water Required
Commercial
3.0 Issues related to:
Efficiency, Availability & Performance
Reliability of Structures & Pipelines
Optimizing COC & Recycling
R&D and New Technologies
4.0 Role of Service Providers
Presentation Outline
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The UN estimates that by 2050, half the Worlds population will live in nations
that are short of Water. Water is needed throughout the energy sector at each
step-energy for extraction & production, refining & processing, transportation &
storage and electric power generation it self. It is estimated that water
consumptionto generate electricitywill more than double over the next 40Years
Water footprint of an individual - sumof his or her direct and indirect freshwater
use. The direct water use is the water used at home, while the indirect water
use relates to the total volume of freshwater that is used to produce the goods
andservices consumed.
Water Foot Prints
S.No. Country/Type Water Foot Print m3/yr
1 Average Global 1385
2 USA 2842
3 China 1071
4 India 1089
5 Daily vegetarian diet 1500 lit
6 Daily Non-Vegetarian diet 3400 lit
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Water Foot Prints
Research by the Cranfield Universitycalculated the amount of water required to
produce various common foods in the United Kingdom:
S.No Product Amount of Water
Litres
1 1 cup of tea 32.4
2 1 imperial pint of beer 160
3 1 glass of wine 120
4 1 glass of milk 200
5 1 kilogram (2.2 lb) of beef 15,000
6 1 kilogram (2.2 lb) of poultry 6,000
7 250 grams (8.8 oz) packet of M &Ms 1153
8 575 grams (20.3 oz) jar
of Dolmio pasta sauce
202
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1.0 Introduction
Commercial
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Water withdrawal Water Consumption
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In India, the total utilizable water resource is assessed as 1123 BCM.
The per capita availability of water at national level has been reduced from
about 5177 cubic meters in 1951 to the estimated level of 1,820 cubic
meters in 2001 with variation in water availability in different river basins.
Given the projected increase in population by the year 2025, the per capita
availability is likely to drop to below 1,000 cubic metres, which could be
labeledas a situationof water scarcity
Water Demand (in BCM) for various Sectors
Sector Standing Committee of MoWR NCIWRD
Year 2010 2025 2050 2010 2025 2050
Irrigation 688 910 1072 557 611 807
Drinking 56 73 102 43 62 111
Industry 12 23 63 37 67 81
Energy 5 15 130 19 33 70
Others 52 72 80 54 70 111
Total 813 1093 1447 710 843 1180
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1.0 Introduction
Commercial
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Power Scenario of India
Consumptive Water foot print:
Thermal 394804 723817 M3/hr @ 3 5.5 m3/MWh
Installed Capacity of India as on 31.03.2012 (Source CEA)
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10 10
Note: Capacity includes capacity under construction; Map not to scale
Geographical spread of generating facilities
RIHAND
(3,000 MW)
RIHAND
(3,000 MW)
SINGRAULI
(2,000 MW)
SINGRAULI
(2,000 MW)
FARIDABAD
(430 MW)
FARIDABAD
(430 MW)
DADRI
(817 MW)
DADRI
(817 MW)
NCTPP
(1,820 MW)
NCTPP
(2,310 MW)
ANTA
(413 MW)
ANTA
(413 MW)
AURAIYA
(652 MW)
AURAIYA
(652 MW)
UNCHAHAR
(1,050 MW)
UNCHAHAR
(1,050 MW)
TANDA
(440 MW)
TANDA
(440 MW)
KAHALGAON
(2,340 MW)
KAHALGAON
(2,340 MW)
FARAKKA
(2,100 MW)
FARAKKA
(2,100 MW)
KORBA
(2,600 MW)
KORBA
(2,600 MW)
VINDHYACHAL
(4,260 MW)
VINDHYACHAL
(4,260 MW) GANDHAR
(648 MW)
GANDHAR
(648 MW)
KAWAS
(645 MW)
KAWAS
(645 MW) TALCHER KANIHA
(3,000 MW)
TALCHER KANIHA
(3,000 MW)
RAMAGUNDAM
(2,600 MW)
RAMAGUNDAM
(2,600 MW)
SIMHADRI
(2,000 MW)
SIMHADRI
(2,000 MW)
KAYAMKULAM
(350 MW)
KAYAMKULAM
(350 MW)
TALCHER Thermal
(460 MW)
TALCHER Thermal
(460 MW)
KOLDAM
(800 MW)
KOLDAM
(800 MW)
TAPOVAN VISHNUGAD
(520 MW)
TAPOVAN VISHNUGAD
(520 MW)
LOHARINAG PALA
(600 MW)
LOHARINAG PALA
(600 MW)
SIPAT
2,980 MW
SIPAT
2,980 MW
BARH
3,300 MW
BARH
3,300 MW
BTPS
(705 MW)
BTPS
(705 MW)
BONGAIGAON
(750 MW)
BONGAIGAON
(750 MW)
VALLUR
(1,500 MW)
VALLUR
(1,500 MW)
MAUDA
(1,000 MW)
MAUDA
(1,000 MW)
RGPPL
(1480 MW)
RGPPL
(1480 MW)
IGSTPP
(1,500 MW)
IGSTPP
(1,500 MW)
DURGAPUR
(120 MW)
DURGAPUR
(120 MW)
BHILAI
574 MW
BHILAI
574 MW
ROURKELA
(120 MW)
ROURKELA
(120 MW)
NABINAGAR
(1,000 MW)
NABINAGAR
(1,000 MW)
GAS POWER STATIONS
COAL POWER STATION
ONGOING HYDRO POWER PROJECTS
ONGOING THERMAL PROJECTS
NTPC Pan India Presence
JVs,
4364
Northern, 5
490
NCR,
4837
Western,
9973
Southern, 4
950
Eastern, 7900
No. of
plants
Capacity
MW
NTPC Owned
Coal 16 29195
Gas/Liquid fuel 7 3955
Sub-Total 23 33150
Owned by JVs
Coal & Gas 7 4364
Total 30 37514
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11 11
By 2032, NTPC targets a capacity of 128 GW
with 28% capacity from non-fossil sources
Coal Gas Nuclear Hydro Renewables
2032
~128 GW
2017
~75 GW
2010
~32GW
Consumptive Water footprint (Coal)
2010 77760 m3/hr (25920 MW), 2017 168750 m3/hr (56250 MW), 2032 215040 m3/hr (71680)
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1.0 Introduction
Commercial
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Quantity of water required & achieving required application
Effects of Quality of water on the performance of different systems
Reliability of various systems such as CHP, AHP, DM Plants, Cooling Towers,
Pipelines, RCC Structures, Firefighting systems, etc
Optimizing of COC & Water Recycling
R&D & New Technologies for water required
Corrosion Protection and improving the performance of Structures, Pipelines
Anticorrosive Coatings, Cathodic Protection, Water Treatment or Combination
Cleaning of Reservoirs
Control of Organic impurities
Use of Municipal Treated Sewage Water as a make up water
Recycling of Waters & waste Waters Technologies required
Summary of Issues of BoP
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1.0 Introduction
Commercial
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NETRA Typical Thermal Power Plant
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Key to Typical diagram of a coal -fired thermal power station
1. Cooling Tower 2. Cooling Water Pump 3. Transmission Line (3 Phase)
4. Step-upTransformer (3 Phase) 5. Electrical Generator (3 Phase)
6. Low pressure Steam Turbine 7. Condensate Pump 8. Surface Condenser
9. Intermediate pressure Steam Turbine 10. SteamControl Valve
11. High pressure Steam Turbine 12. Deaerator 13. Feed Water Heater
14. Coal Conveyer 15. Coal hopper 16. Coal Pulverizer
17. Boiler Steam Drum 18. Bottom Ash 19. Superheater
20. Forced draught (draft) fan 21. Reheater 22. Combustionair intake
23. Economizer 24. Air Preheater 25. Electrostatic Precipator
26. Induced draught (draft) fan hopper 27. Flue Gas Stack
Typical Thermal Power Plant
NETRA
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Typical Thermal Power Plant
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Typical Scheme for Water Usage
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Typical Scheme for Clarification
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Typical Scheme for Demineralization
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Typical Scheme for CPU
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Typical Scheme for Two Stage RO
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Typical Scheme for RO Treatment
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Typical Scheme for RO and Mixed bed
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1.0 Introduction
Commercial
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NETRA Typical Steam Water Cycle
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27 27
COST OF CORROSION
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28 28
COST OF CORROSION
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Costs of Corrosion Problems
Affecting Fossil Steam Plants
Corrosion Problem O&M Non- Fuel
Related
Corrosion Cost
US $
Depreciation
Corrosion Cost
US $
Total Corrosion
Cost
US $
All Corrosion Problems in
Fossil Steam Plants
3,43,50,00,000 1,14,20,00,000 4,57,70,00,000
Waterside/Steam side
Corrosion of Boiler Tubes
91,60,00,000 22,84,00,000 1,14,44,00,000
Turbine CF & SCC 45,80,00,000 14,27,50,000 60,07,50,000
Oxide Particle erosion of
Turbines
27,48,00,000 8,56,50,000 36,04,50,000
Heat Exchanger Corrosion 27,48,00,000 8,56,50,000 36,04,50,000
Fireside Corrosion of Water
wall tubes
18,32,00,000 14,27,50,000 32,59,50,000
Generator clip to strand Corro 18,32,00,000 2,85,50,000 21,17,50,000
Copper deposition in turbines 9,16,00,000 5,71,00,000 14,87,00,000
Fireside Corrosion of SH &
RH tubes
9,16,00,000 5,71,00,000 14,87,00,000
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Costs of Corrosion Problems
Affecting Fossil Steam Plants
Corrosion Problem O&M Non- Fuel
Related Corrosion
Cost US $
Depreciation
Corrosion Cost
US $
Total Corrosion
Cost
US $
Corrosion of FGD system 4,58,00,000 8,56,50,000 13,14,50,000
Liquid Slag Corrosion of
Cyclone Boilers
9,16,00,000 2,85,50,000 12,01,50,000
Backend dew point corrosion 9,16,00,000 2,85,50,000 12,01,50,000
Generator Cooling water
clogging & plugging
9,16,00,000 2,85,50,000 12,01,50,000
FAC of steam plant piping 9,16,00,000 2,85,50,000 12,01,50,000
Corrosion of service water,
circulating water and other
water systems
9,16,00,000 2,85,50,000 12,01,50,000
All other (Corrosion of
structures, ash handling
equipment, CHP, oil pipes &
tanks, electrical equipment,
45,80,00,000 8,56,50,000 54,36,50,000
Total 3,43,50,00,000 1,14,20,00,000 4,57,70,00,000
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1.0 Introduction
Commercial
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Water Requirements for Power Generation
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Water Losses from Power Generation
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NETRA Process Flow Schematic for Wet
Recirculating Cooling Water System
1 GPM = 0.2271 M3/hour
34
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Water Requirements
Water Requirements for a 500 MW Unit (Ref. Flow schematic)
S.No. Description
Flow rate
GPM M3/Hr
1 Boiler Feedwater 7645 1736.18
2 Circulating Water 187600 42603.96
3 Evaporation & Drift 6415 1456.847
4 Make up 9537 2165.853
5 Blowdown water 3161 717.8631
35
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Water Requirements for Thermal Power Plants
Water requirement for different type of Power Plants
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Typical Water Requirements of TPS
Water Requirement & Consumption in a Coal fired Power Plant
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Typical Water Requirements at Power Plant
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S.No Description 1 X 500 MW
M3/hr
2 X 660 MW
M3/hr
1 Evaporation & Drift from CT 1160 2555
2 HVAC System Losses 50 100
3 Potable Water System 70 100
4 Evaporation losses in Ash Dyke 200 570
5 Losses in Cycle make up 42 80
6 Losses in Service Water System 350 300
7 Evaporation Losses in Reservoir - 100
8 Total Consumptive Water 1872 3805
9 Water for Ash Handling 1410 1650
10 Water recovered in AWRS 1230 1190
11 Additional Make up 180 460
12 Total Water Drawl 33 Cusec
(Max)
38 Cusec (Normal)
50 Cusec (Max)
Water Optimization in New Plants
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1.0 Introduction
Commercial
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SOURCES OF WATER FOR
INDUSTRIAL APPLICATIONS
RIVER
SEA
PONDS
LAKES
IRRIGATION CANALS
BOREWELLS
RECYCLED WATER
RESORVOIRS
RECYCLED EFFLUENTS
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CHARACTERISTICS OF WATER & SOURCES
OF IMPURITIES
IMPURITIES IN WATER:
BACTERIA & VIRUSES
MICRO ORGANISMS
TURBIDITY
COLOUR
MINERALIZATION
METALLIC
DISSOLVED GASES
AMMONIA
ORGANIC MATTER
POLLUTANTS
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APPLICATIONS OF WATER IN
POWER PLANTS (THERMAL)
COOLING OF CONDENSATE
AUXILIARY COOLING
BOILER WATER
ASH HANDLING WATER
COAL DUST SUPPRESSION WATER
WASHING
DRINKING
SANITATION
FIRE WATER
SERVICE WATER
HVAC SYSTEM
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Typical Deionized water requirements
DM Water Quality requirements
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Summary of Primary and Secondary Targets for Drum-type
Boilers under Steady State Operation (expressed as ug/kg
unless otherwise stated)
Boiler Class
Parameter 60 Bar
Gas Fired
100 Bar
Coal Fired
160 Bar
Coal Fired
180 Bar
Coal Fired
Feed-water
Conductivity
(u/S/cm at 25C)
<-local decision to achieve primary target in boiler water->
Sodium (Na) <-local decision to achieve primary target in boiler water->
Sulphate (SO4) <-local decision to achieve primary target in boiler water->
Dissolved Oxygen-In
condensate
<50 <50 <50 <50
Dissolved Oxygen-In
Feed
<7 <7 <5 <5
Oil <200 <200 <200 <200
TOC
Hydrazine (N2H4) < 2 x Dissolved Oxygen concentration >
45 45
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Ammonia (NH3) < < 500 when copper alloys present >
< 1000 when copper alloy absent
i.e. when SS or Titanium are present
pH (at 25oC) < 8.8 - 9.2 (or 8.8 - 9.4 when copper >
alloys absent)
Total Metals <20 <20 <20 <20
Spray Water
Sodium (Na)
10
(without RH)
10
(without RH)
5
(without RH)
5
(without RH)
46 46
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Boiler-water
1. Non-volatile Phosphate Treatment
Chloride (NaCl) as
Chloride
< 3000 < 2000 < 1000 < 500
Silica (SiO2)
(at pH - 9)
< 5000 < 1500 < 300 < 200
Sulphate (SO4) <-local decision to achieve primary target in boiler water->
Disodium/ Trisodium
Phosphate
2000
To
6000
2000
To
4000
1000
To
2000
1000
To
2000
All Volatile Akali Treatment
Chloride (NaCl) as
Chloride
NA < 120 < 120 NA
Silica (SiO2)
(at pH - 9)
< 350 <250 < 150 < 100
Sulphate (SO4) NA LD LD NA
47 47
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Saturated Steam
Silica (Sio2) <20 <20 <20 <20
<10 (depending upon
design) with RH
Sodium (Na) < 20 < 10 < 6 < 5
< 3 (On AVT
48 48
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EPRI Guidelines for Cooling Waters
Water Quality EPRI
Guidelin
es
Remarks
Paramet
er
Units
Ca Mg/l
CaCO3
900
(max)
Ca X SO
4
(Mg/l)
2
500000
M
Alkalinity
Mg/l
CaCO3
30 50
220 - 250
Without Scale
Inhibitor
With Scale
Inhibitor
Mg X
SiO
2
Mg/l
CaCO3
X
Mg/l
SiO2
35000
SO
4
Mg/l
SiO
2
Mg/l 150
PO
4
Mg/l
Fe (Total) Mg/l < 0.5
Mn Mg/l < 0.5
Cu Mg/l < 0.1
Al Mg/l < 1
S Mg/l 5
NH
3
Mg/l < 2 For copper based
alloys present in the
system
pH 6.0 7.2
7.8 8.4
Without Scale
Inhibitor
With Scale Inhibitor
(Higher operating pH
is possible with new
alkaline treatments)
TDS Mg/l 70000
TSS Mg/l < 100
< 300
For Film type Fill
Splash type Fill
BOD Mg/l
COD Mg/ l
LSI < 0
RSI > 6
PSI > 6
Desirable: BOD < 5 ppm, Turbidity < 2 NTU, Sulphide < 0.1 ppm (for Cu based systems), Chloride <
200 ppm for SS 304 (upto 500 ppm short duration & < 500 ppm for SS 316 (3000 ppm short duration)
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1.0 Introduction
Commercial
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Commercial Aspects of Water Use
S.No State Water
Charges
Cess Remarks
1 Kerala Re 1/m3
2 Delhi Rs. 1.5 Lac
per Cusec
3 Andhra Pradesh Rs.7.98/m3
4 Uttar Pradesh Rs. 1.16/m3
5 Gujarat Rs. 13.31/m3
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Commercial Aspects of Water Use
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Cost of Chemicals used in CW Treatment
S.No. Chemical Rate Rs.
(Per Kg/L)
Annual Cost of Chemical per 1000 m3/hr make up (Rs.)
1 ppm 2 ppm 3 ppm 4 ppm 5 ppm
1 HEDP 50% 50 438000 876000 1314000 1752000 2190000
2 PBTC 50 % 180 1576800 3153600 4730400 6307200 7884000
3 Polyacrylate 100 876000 1752000 2628000 3504000 4380000
4 Polymaleic 150 1314000 2628000 3942000 5256000 6570000
5 Zinc sulphate 25 219000 438000 657000 876000 1095000
6 BTA 450 3942000 7884000 11826000 15768000 19710000
7 HEDP 60 % 60 525600 1051200 1576800 2102400 2628000
8 ATMP 50 438000 876000 1314000 1752000 2190000
9 Carboxylate/
Sulphonate
150 1314000 2628000 3942000 5256000 6570000
10 Carboxylate/
Sulphonate/
nonionic
200 1752000 3504000 5256000 7008000 8760000
11 Si & Mg
inhibitor
400 3504000 7008000 10512000 14016000 17520000
12 SHMP 35 306600 613200 919800 1226400 1533000
13 Molybdate 250 2190000 4380000 6570000 8760000 10950000
14 silicate 180 1576800 3153600 4730400 6307200 7884000
1 ppm = 1 Kg
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1.0 Introduction
Commercial
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Water Treatment Concerns
Particle Entrapment
Growth Sites
Corrosion
Deposition
Biofouling
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Table 1
Thermal conductivity comparison of deposit-forming compounds
and bio-film
Substance
Thermal Conductivity
(W m
-1
K
-1
)
CaCO
3
2.6
CaSO
4
2.3
Ca
3
(PO4)
2
2.6
Fe
2
O
3
2.9
Analcite 1.3
Bio-film 0.6
Optimizing COC
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Table 2 - Effect of CaCO3 scale (of varying thickness) on overall heat transfer coefficient
Scale Thickness,
Inches
Overall heat transfer coefficient, BTU per
sq ft per deg F
Percent loss in BTU per sq ft
per deg F
0.000 92.77 0
0.012 73.68 20.58
0.024 61012 34.12
0.036 52.20 43.73
0.048 45.60 55.85
0.060 40.46 56.39
0.0625 (1/16 in.) 39.52 57.40
Optimizing COC
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Table 3 - Effect of CaSO4 scale (of varying thickness) on overall heat transfer coefficient
Overall heat transfer scale
thickness, inches
Coefficient, BTU per sq ft
per deg F
Percent loss in BTU per sq ft
per deg F
0.000 92.77 0
0.012 63.10 31.98
0.024 47.81 48.46
0.036 38.49 58.51
0.048 32.20 62.00
0.060 27.69 70.00
0.0625 (1/16 in.) 26.89 71.00
Optimizing COC
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Relative increase in power for condenser and chiller units
calculated according to fouling factors
Fouling Factor Condenser Factor Chiller Factor
0.0005 1.00 1.00
0.001 1.05 1.04
0.002 1.14 1.09
0.003 1.22 1.17
0.004 1.30 1.24
Optimizing COC
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0.01 ata increase in Condenser Back-pressure
= 10 Kcal/ KWH increase in Heat Rate of Turbine
Loss due to variation in Condenser Back-pressure
Rating Annual Loss Life Time Loss
Rs. Lacs (Aprox.) Rs. Lacs
210 MW 30.25 756.25
500 MW 71.05 1776.25
Optimizing COC
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NETRA Effects of Corrosion, Erosion-Corrosion,
Cavitations on the Performance of Pumps
According to the U.S. DOE, pumps consume about 20% of all generated
electricity
Unlike motors, the efficiency of pumps is highly influenced by the system
they are supplying
In a typical surface water treatment and distribution system approx. 70-
90% of energies used are for pumping
Over an expected life span of 20 years, only 2.5 3% of the cost of pump
operation related to the purchase of the equipment. Further 2 2.5% relates
to maintenance costs. 95% is towards the cost of electricity to run the unit
In any pumping system, over the years, the hydraulic passages of
casings & impeller vane shape gets damaged due to wear, tear &
corrosion, also the clearance in wear rings increases substantially. All
these damages lead to head and flow losses & ultimately deteriorate
hydraulic performance. Due to this deterioration of performance the
power consumption increases putting pressure on energy demand due
to inefficient operation of pump.
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NETRA
The power required for flow of water through pipelines is as follows:
To overcome physical level difference from start of pipeline, which is at
low level to end of pipeline which is at higher level. The power required is
constant as the static head is constant.
To overcome the frictional resistance to the flow of water. This is known
as frictional head loss.
There are two types of friction losses:
Major Friction Loss This is the friction of inside surface of pipeline to the
flow of water. For large diameter and long lines this loss consumes large
power and therefore energy.
Minor Friction Losses Minor friction losses are:
Contraction loss
Enlargement loss
Gate valve, check valve loss
Bend loss
Effects of Corrosion, Erosion-Corrosion,
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Friction Head Loss:
Inside surface of pipelines in contact with water exerts friction on the flow.
This friction depends on the roughness of the inside surface coming in
contact with flow of water.
The laws governing frictional head losses are as follows:
Frictional loss generally increases with roughness of the pipe.
Frictional loss is directly proportional to the area of the wetted
surface.
Frictional loss varies inversely as some power of the pipe diameter.
Frictional loss varies as some power of the velocity.
Frictional loss varies as some power of the ratio of viscosity to density
of
the water.
Friction loss due to water flow through piping systems can be evaluated
using various flow coefficients. One such factor is the Hazen-Williams
C factor.
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Hazen Williams Equation:
Q = 0.278 CS
0.54
D
2.63
Q in m3/s, D in m, S = H/L
V = 1.318 C R h
0.63
S
0.54
(USC Units)
V = 0.849 C R h
0.63
S
0.54
(SI Units)
Where, Rh is the hydraulic radius, S is the head loss per unit length (hf/L), and C is a
roughness coefficient associated with the pipe material
Friction loss based on the Hazen-Williams formula is:
f = 0.2083 x (100/ C)
1.852
x (Q
1.852
/ d
i
4.8655
).
In this formula, the following apply:
f = friction head loss in feet of water per 100 feet of pipe;
C = constant for inside pipe roughness;
Q = flow in US gallons per minute (gpm);
d i = inside diameter of pipe in inches
(1 US GPM = 0.227 m3/hr)
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Value of C would depend upon the roughness only and for any given
roughness C would be a constant.
h
f
= (1.1758 V/ CR
0.63
) x L
Low value of C means very rough surface
High value of C means smooth surface
Material Manning (n) Hazen-Williams (C)
Plastic, copper 0.009 160
Concrete - Smooth 0.011 120
Concrete - Design 0.013 100
Corroded Cast Iron 0.020 60
Welded Steel 110
Internally coated Steel 150
A Maharatna Company
NETRA
Expected life of friction factor at its original value
Cement mortar lining 5 years
Epoxy lining around 30 years
Thickness of linings
Cement Mortar lining 30 mm
Epoxy lining 0.50 0.70 mm
A Maharatna Company
NETRA
Scaling in Heat Exchangers
A Maharatna Company
NETRA
Pump designed for 630 m3/ hr was delivering 450 m3/ hr due to
Severe fouling. Corrosion products
Losses in Pipes due to Biofouling
A Maharatna Company
NETRA
Biofouling & MIC
A Maharatna Company
NETRA
Severe Corrosion of CW System
A Maharatna Company
NETRA
Control Measures
A Maharatna Company
NETRA
Loss of around Rs. 1.2 Crore per 500 MW unit per year
Severe Fouling of PVC Fills
A Maharatna Company
NETRA
Heat Rate Improvement = 183 Kcal/ kwh
Annual Gain = Rs. 15 Crores
Full Load operation against 80% before cleaning
Restoration of Heat Transfer
A Maharatna Company
NETRA
Other Problems of CW System
80
Eutrefication of reservoir
RCC corrosion of Cooling tower structure
Severe foaming at CW Pump and in CW Foreway due to organic contamination
A Maharatna Company
NETRA
1.0 Introduction
Commercial
A Maharatna Company
NETRA
Condition Assessment of RCC Structures
A Maharatna Company
NETRA
A Maharatna Company
NETRA
A Maharatna Company
NETRA
A Maharatna Company
NETRA
A Maharatna Company
NETRA
A Maharatna Company
NETRA
A Maharatna Company
NETRA
Condition Assessment Criteria
S.No. Concrete
Design
Strength
(N/ mm2)
Potential
(mVVs
Cu/ CuS04)
Corrosion
Condition
Electrical
Resistivity
(KiloOhm
cm)
Corrosion
Condition
1 M - 30 > - 200 Low > 20 Negligible
2 M - 30 - 350 to -
200
Intermediat
e
10 to 20 Low
3 M - 30 < - 350 High 5 to 10 High
4 M - 30 < - 500 Severe < 5 Very High
Condition Assessment Criteria
A Maharatna Company
NETRA Condition Assessment Criteria
A Maharatna Company
NETRA
Water Treatment & Corrosion Issues in
Fire Water System
Water Side related issues
Stagnancy of fire water causes depletion of oxygen & chlorine
Microbiological Influenced Corrosion leading to formation of Tubercles & Blockage
Treatment of fire water with microbiocide (chlorine/hypochlorite)
Regular Flushing of Fire water in the system (every fortnight)
Possibility of applying anticorrosive coatings or wherever possible use of HDPE/GRP
A Maharatna Company
NETRA
Water Treatment & Corrosion Issues in
Fire Water System
Soil Side issues
Soil causes corrosion of the underground pipelines
Soil characteristics, location, other structures, etc contribute towards corrosion
Bringing the pipelines over-ground wherever feasible
Proper anticorrosive Coatings to be applied
Application of Cathodic Protection for UG Pipelines
A Maharatna Company
NETRA
Structural Corrosion Issues
A Maharatna Company
NETRA
Online Monitoring of CW Systems
A Maharatna Company
NETRA
1.0 Introduction
Commercial
A Maharatna Company
NETRA
Some Cases of effect of Organics & Microbiology
96
1. Problem of High Conductivity of DM Water, Condenser tube leakage,
Problem of control of boiler tube, tripping of SPU reason Untreated sewage
2. Biofoulingin condenser tubes, microbiologically induced corrosion (MIC)
3. Severe biofouling, scaling & MIC in condenser tubes (loss of generation)
4. Severe biofouling, scaling & MIC in condenser tubes (loss of generation),
Problem of non-availability of sufficient DM water, Fouling of PVC fills (stage II)
5. Fouling of PVC fills, Eutreficationof make up water reservoir, pH variation
6. Severe foaming in CW system, (Casuarina tree leaves)
7. Foaming in CW system, Yellow colour in water, choking of NOx filters, Severe
biofoulingin raw, CW pipelines, HVAC lines, DM feed lines
8. Fouling of PVC film type fills
9. MIC in clarified water pipelines
10. Contamination of water reservoirs resulting in poor quality of make up water
A Maharatna Company
NETRA
Condenser tube Condition
A Maharatna Company
NETRA
Corrosion Control & Performance Improvement Options for
Cooling Water System
Expected Cooling water quality at different based on Raw water as make up to CW
09-10 Maximum
S.No Parameter Unit
Cycles of Concentration
1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 8
1 pH 7.56 9.26 9.89 10.06 10.21 10.33 10.43 10.52 10.61
10.6
8
10.7
5
10.8
1
10.8
7
10.9
2 10.97
2 cond mhos/cm 1646 2469 3292 4115 4938 5761 6584 7407 8230
905
3
987
6
106
99
115
22
123
45 13168
3 Turbidity NTU 138 207 276 345 414 483 552 621 690 759 828 897 966
103
5 1104
4 CaH ppmas CaCO
3
196 294 392 490 588 686 784 882 980
107
8
117
6
127
4
137
2
147
0 1568
5 MgH ppmas CaCO
3
124 186 248 310 372 434 496 558 620 682 744 806 868 930 992
6 Total hardness ppmas CaCO
3
320 480 640 800 960 1120 1280 1440 1600
176
0
192
0
208
0
224
0
240
0 2560
7 P alk. ppmas CaCO
3
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
8 M alk. ppmas CaCO
3
336 504 672 840 1008 1176 1344 1512 1680
184
8
201
6
218
4
235
2
252
0 2688
9 T. alk. ppmas CaCO
3
336 504 672 840 1008 1176 1344 1512 1680
184
8
201
6
218
4
235
2
252
0 2688
10 Chloride ppmas Cl 250 375 500 625 750 875 1000 1125 1250
137
5
150
0
162
5
175
0
187
5 2000
11 Shulphate ppmas CaCO
3
80 120 160 200 240 280 320 360 400 440 480 520 560 600 640
12 EMA ppmas CaCO
3
334 501 668 835 1002 1169 1336 1503 1670
183
7
200
4
217
1
233
8
250
5 2672
13 Silica ppmas SiO
2
18.5 27.75 37 46.25 55.5 64.75 74 83.25 92.5
101.
8 111
120.
3
129.
5
138.
8 148
14 Chloride demand ppm 200 300 400 500 600 700 800 900 1000
110
0
120
0
130
0
140
0
150
0 1600
15 BOD 72 108 144 180 216 252 288 324 360 396 432 468 504 540 576
16 COD 176 264 352 440 528 616 704 792 880 968
105
6
114
4
123
2
132
0 1408
17 KMnO
4
No 54 81 108 135 162 189 216 243 270 297 324 351 378 405 432
PSI 5.39 4.46 3.81 3.30 2.88 2.53 2.23 1.96 1.72 1.50 1.30 1.12 0.95 0.79 0.65
RSI 6.03 3.66 2.56 2.02 1.57 1.20 0.87 0.59 0.33 0.10
-
0.11
-
0.31
-
0.49
-
0.66 -0.81
A Maharatna Company
NETRA
Problems due to Organic Matter, Microbiolgy
Case 1
HIGH ORGANIC MATTER LOADING (UNTREATED SEWAGE) IN RAW WATER:
Acute problem of obtaining required quality of DM water throughout the year
Problem more severe in summers
Due to high untreated sewage proper clarification is very difficult
Chlorine demand is very high (100 200 ppm)
DM water conductivity goes as high as 0.8 us/cm (4 us/cm in DM tanks)
pH of Boiler water drops to 7.5 requires caustic dosing
High Conductivity water causes deviations in Boiler & Stator water Chemistry
REMEDIAL MEASURES:
Aeration of the make up water to remove BOD/COD
Installation of Sewage Treatment Plant prior to clarifiers & Chlorine Dioxide
Installation of Ultrafilteration system/RO water system prior to DM Plant
Alternate source of raw water borewell for DM plant
99
A Maharatna Company
NETRA
100
Analysis of Water Sample
Water Extract ( 1gm plant fruit in 500 ml)
Sample COD TOC
mg/ l mg/ l
Extract ( as such)
470-500 175-200
Extract after filtration through 0.45 U
270-300 100-125
In the presence of high Organic matter, clarification of water is not effective even with
Alum/Polyelectolytes(cationic or anionic)
% Reduction
Water Extract ( 1000 ppm solution of plant fruit) 120
Water Extract ( 400 ppm solution of plant fruit)
64
Water Extract ( 400 ppm solution of plant fruit)+2
ppm KMnO4
56 12.5
Water Extract ( 400 ppm solution of plant
fruit)+Aeration
48 25
Case 2
A Maharatna Company
NETRA
101
0
10
20
30
40
50
60
I
N
T
A
K
E

R
E
S
E
R
V
O
I
R
L
I
V
E

R
E
S
E
R
V
O
I
R
D
E
A
D

R
E
S
E
R
V
O
I
R
C
L
A
R
I
F
I
E
D

W
A
T
E
R
C
I
R
C
U
L
A
T
I
N
G

W
A
T
E
R
C
o
n
c
e
n
t
r
a
t
i
o
n

i
n

p
p
m
Nature of water
TOC, COD & BOD Trend
BOD
COD
TOC 1
TOC 2
Case 3
A Maharatna Company
NETRA
1.0 Introduction
Commercial
A Maharatna Company
NETRA
1 2 3 4 5 6 7 8
Cycles of Concentration
Cooling Tower Cycles
5000 --
4000 --
3000 --
2000 --
1000 --
0
Makeup
Blowdown
RR = 100,000 gpm
dT = 20 F
Internal Water Conservation
Optimizing COC
A Maharatna Company
NETRA
S.N
o
COC Circulating
Rate m3/hr
Drift
M3/hr
Evaporati
on
M3/hr
Blow
Down
M3/hr
Make
up
M3/hr
Consumption of
Inhibitors l/day
Cost of
Inhibitors @ Rs.
33/litre
Rs/day
5 ppm 10 ppm 5 ppm 10
ppm
1 1.5 32000 160 576 1152 1888 227 453 7476 14953
2 2.0 32000 160 576 576 1312 157 315 5196 10391
3 2.5 32000 160 576 384 1120 134 269 4435 8870
4 3.0 32000 160 576 288 1024 123 246 4055 8110
5 3.5 32000 160 576 230 966 116 232 3827 7654
6 4.0 32000 160 576 192 928 111 223 3675 7350
7 4.5 32000 160 576 165 901 108 216 3566 7133
8 5.0 32000 160 576 144 880 106 211 3485 6970
COC Optimization
A Maharatna Company
NETRA
Evaporation+drift
700 M
3
/Hr
Induced
draft
COOLING
TOWER
CONDENSER
40000 M
3
/hr
AUX
N
a
r
m
a
d
a

R
i
v
e
r
I
n
t
a
k
e

w
e
l
l
MakeUp
1100 M
3
/Hr (Design)
800-900 M
3
/Hr
(Actual)
2x275 M
3
/hr
BLOW DOWN
240 M
3
/Hr (Design)
190 M
3
/Hr
DMP Effluent
250 M
3
/day
Raw Water
Pumps for CW
CW
Pumps
COC = 4-5
Clariflocculators
STP Effluent
200 M
3
/day
DM Plant
Gravity
Filter
Clarified
water
tank
C
M
B
Clarifier
Raw Water Pumps for DM
Plant
3x900M
3
/hr 2 x 1100 M
3
/Hr
One Standby
Drinking
water
D
i
s
c
h
a
r
g
e

t
o

9

K
m

d
i
s
t
a
n
c
e

275 M
3/
Hr
Softening plant
R
E
S
E
R
V
O
I
R
u
n
l
i
n
e
d
3x600M
3
/hr Softening plant regn
waste 3 M3/day
Water Balance
Waste Water Recycling
A Maharatna Company
NETRA
CT BLOW DOWN
5760 M
3
/Day (Design)
4500 M
3
/Day
DMP Effluent
250 M
3
/day
STP Effluent
200 M
3
/day
Softening Plant
Regeneration Waste
3 M3/day
C
M
B
Discharge
Effluents discharged from Plant
A Maharatna Company
NETRA
275 m3/hr
Reactor
Clarifier
275
M3/hr
GSF
FWST
2*150 m3/hr
MB
D/G pumps
4*125 m3/hr
FW pumps
4*125 m3/hr
3*11
0
m3/h
r
ACF
SAC SBA
D/G tank
3*55 m3/hr
3*110
m3/hr
3*110
m3/hr
WBA
3*110
m3/hr
3*11
0
m3/h
r
Proposed DM Plant Scheme with UF+RO
Effluents
PAC+Chlorine
FeCl3+lime+Dolomite
Proposed
UF+RO
system
By
Gravity
A Maharatna Company
NETRA
Effluent 200 M3/Hr
4800 M3/day
Permeate 150 M3/Hr taken as 75%
3600 M3/day
Sl.
No
Parameter Benefit Amount per
month
(Rs)
Total Amount
per year
(Rs.)
1 Pumping cost to 9 kms 0.6 KWh/M3@Rs 3.00/- per KWh 1,94,400.00 23,32,800.00
2 Water Charges on a/c of
CWwater
Rs 12.10/- per M3 for 3600 M3
daily
13,06,800.00 1,56,81,600.00
3 Cess charges Rs 0.05 per M3 for 3600 M3 daily 5,400.00 64,800.00
4 Makeup water to boiler Improvement in the makeup water
quality will subsequently have less
blowdownrate inboiler.
25000Approx. 3,00,000.00
5 Regeneration chemicals Rs 5.5/- per M3 5,94,000.00 71,28,000.00
6 lifeof resins Resincost savings 5,00,000
7 Pretreatment chemicals
Alum/lime/PAC
Rs 0.25 per M3 27,000.00 3,24,000.00
8 Brine treatment cost Rs 0.10 per M3 14,400.00 1,72,800.00
TOTAL 2,60,04,000.00
Cost Benefit of Recycling
A Maharatna Company
NETRA
Ash Water Recycling
Earlier the Ash to Water Ratio was 1:13 to 1:15
The Ash slurry is transported to a distance 5 15 Km through pipes
The Ash Slurry is collected in Ash Dykes and the decanted water disposed off
Schemes have been developed to recycle the decanted Ash water with suitable
Treatment programs and only limited make up is provided to meet the requirements
A Maharatna Company
NETRA
1.0 Introduction
Commercial
A Maharatna Company
NETRA
Water Requirements for Power Generation
A Maharatna Company
NETRA
Table : Makeup Water Treatment Methods for Removing Impurities
Treatment Technologies
A Maharatna Company
NETRA
Figure: Effects of Treatment on Raw Water
Treatment Technologies
A Maharatna Company
NETRA
New Technologies
Adoption of high density Ash Slurry disposal technology
Emphasis on dry ash collection & disposal for ash utilization purposes
Recycling of CW blow down by treatment with UF/RO
Studies on adopting recycling of STP effluents from townships for process
water
Setting up of sewage treatment plants for treating organically contaminated
water for make up DM and CW systems
Adoption of site specific chemical treatment programs based on commercially
available chemicals with optimized COC
Studies on dry cooling systems for extreme scarcity areas
Studies on adopting combinations of technologies like UF/MF, RO, EDI and
Ion exchange
Desalinated water at Coastal power plants for sweet water applications
Application of polymeric materials (HDPE/GRP) & Organic coatings for
reducing frictional losses in pipes
A Maharatna Company
NETRA
Affordability (New Plant) NTPC Technology Vision
Technology Drivers
40
35
25
7
2009 2017 2025 2032
Water Requirement (Cusec/1000 MW)
- Extreme Water Scarcity
40
35
25
20
2009 2017 2025 2032
Water Requirement (Cusec/1000 MW)
- Business As Usual
NETRA
A Maharatna Company
Water Extraction from Flue Gas
Expected Water Recovery from flue gas of a gas station =95 m3/hr
A Maharatna Company
NETRA
Pilot Heat Exchanger Installed
Coal power station :
Para-
meters
unit Flue gas Analysis
ID Fan Outlet of HXe
SOx mg/Nm3 560 152
NOx mg/Nm3 260 215
SPM mg/Nm3 90 52
CO
2
% 11.2 11.4
Gas power Station:
Sampling point HE Inlet HE outlet
parameter/fuel type unit Natural gas
T-gas
o
C 101.3 35.8
T-Air
o
C 30.1 30.1
O
2
% 14.17 14.15
CO
2
% 3.5 3.5
CO ppm 1 1
NOx ppm 50 50
SO
2
ppm 0 0
Flue Gas Quality variation due to moisture extraction
A Maharatna Company
NETRA
Pilot Heat Exchanger Installed
Coal power station:
Parameters unit Value
pH - 2.55
Conductivity S/cm 2890
Total
Hardness
ppm as
CaCO
3
Nil
Cl ppm as Cl
-
Nil
M-alk ppm as Cl
-
Nil
EMA - 1500
Acidity - 450
Quality of Water condensed from flue gas
Gas power Station:
PARAMETERS Unit Value
pH - 4.3
K S/cm 213
TDS ppm 107
Salinity % 0.1
Sodium ppm as Na 1
Potassium ppm as K 0.7
Total Hardness ppm as CaCO
3
Nil
Ca Hardness ppm as CaCO
3
Nil
p-Alkalnity ppm as CaCO
3
Nil
m-Alkalnity ppm as Cl
-
Nil
Chloride ppm as Cl
-
1
Sulphate ppm as SO
4
2-
58
Nitrate ppm as NO
3
-
6
A Maharatna Company
NETRA
Water Related R&D US DOE
A Maharatna Company
NETRA
Conceptual Design of Liquid Desiccant Process
120
A Maharatna Company
NETRA
1.0 Introduction
Commercial
A Maharatna Company
NETRA
Role of Service Providers
Development of less energy intensive technologies for water treatment
Development of Modular treatment technologies requiring lesser space
Improving the performance of RO systems for higher output at lower
maintenance
Developing economic treatment technologies/combination of technologies
Improving sewage treatment plants for better output & quality of water for
reuse
Developing transparent techno-economic chemical treatment programs
Creation of Institute for improving the quality of manpower & techniques
Developing proper quality & target values for treatment programs
Developing low temperature desalination technologies
A Maharatna Company
NETRA
12
3
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