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Thailand Power Workshop Grouping

Bangkok office 29 & 30-Mar-2012

Executive Summary
Boiler System: Found the problem of Hydrogen damage issue. The root-cause was come from condenser in-leakage issue from cooling part.

Solution Review the chemical treatment program to effective control corrosion in system with Nalcos product. Implement @T ORP on BFW to monitor the . Cooling System: High chloride issue in cooling system anytime. Induce to face the stress corrosion cracking (SCC) on SS304 condenser tube. Solution Review the chemical treatment program to effective microbial and also control chloride in system with Nalcos product. Implement 3DTRASAR for cooling system. Implement the condenser performance monitoring to ensure the treatment program.

General Information

Nov 2011: Low pH in BFW

Jan 2012: Normal run

June 2011: Condenser inleakage issue

Dec 2011: T/A to fix the condenser

Problem analysis for Boiler system

MB (Demin

Condensate Return

MU)

Cooling tower
DEAERATOR

Low pressure steam

Hot well LP Steam To boiler as feed water

Generator Turbine HP Steam Valve

Speed Governor

Shaft speed

Variable Loading
(Operating range 40-50 MW)

HP Boiler

LP Boiler

Boiler System 1 unit CFB Boiler HP = 70 bar, 130 tons/hr Consisting of Economizer, Boiler, Superheater #1 and #2 Deaerator 2 bar, 115-118 C, DO<10 ppb 1 Steam Turbine, 30 MW LP heater: CS Surface condenser Tubes: SS 304 Sheet: carbon steel coated with epoxy Design back pressure = 8,0 kPaa (46,23 mm Hg absolute)

Important Issue
Boiler System The plant experience with 2 (two) tube failures in December 2011. The failures were occurred in the water wall tubes about 5 m above the burner as showing in the picture below

Hydrogen Damage

The main problem with this failure is that it gets spread across the water wall tubes in totally an unpredictable way. Hence to find out the regions affected in the water wall by condenser leakage, exhaustive special probe ultrasonic testing is required.

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Characteristics of Hydrogen Damage, Caustic Gouging and Acid Phosphate Corrosion

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Determine the root cause

Major Root Cause Influence
Influence of excessive deposits

Confirmation
Yes

Remark
Deposit in steam drum (Boiler inspection May & Sep 2011) Heavy deposition in sampling tube (Sep 2011) Flow disruption only influence by deposition pH of boiler drop to ~8.5 on May 2011 pH of boiler dropped to ~8.4 Hardness in condensate went up to >0.5 ppm Chloride concentration in HP evap. went up >10 ppm

Flow disruption: deposits, DNB, bend/sharp changes in tube direction, locally high heat transfer, etc. Influence of acidic contamination Condenser leak-minor but occurred over an extend period

Yes

Yes Yes

Water treatment plant up set leading to low pH condition Error in chemical cleaning process

No No No chemical cleaning conducted in 2011

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BFW data trend

pH 8.5-9.2
9.2 9 8.8 8.6 8.4 8.2 8 8.2 8.1 8.0 7.9 7.8 7.7 7.6 7.5 7.4 7.3

Conductivity <20 mS/cm

pH 8.5-9.2

Conductivity <20 mS/cm

11/28/2011

Total Fe <20 ppb

25.00

11/30/2011

11/10/2011

11/12/2011

11/14/2011

11/16/2011

11/18/2011

11/20/2011

11/22/2011

11/24/2011

11/26/2011

11/2/2011

11/4/2011

11/6/2011

11/8/2011

SiO2 <20ppb
20 19.5 19 18.5 18 17.5 17 16.5

20.00
15.00 10.00 5.00 0.00 Total Fe <20 ppb

SiO2 <20ppb

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Solution for Boiler system

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Immediate Solution

Isolate the condenser and plug all the leaking tubes and tubes with high depth wastage. Ensure there is no cooling water in-leakage by checking condensate quality (cation conductivity, hardness, chloride; etc) Selective tube sampling for deposit measurement. Inspection using fiber optic (boroscope) can provide useful information Tube replacement for all tubing with hydrogen damage and/or significant wall loss be replaced Check the efficacy of chemical cleaning

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Long Term Solution

Chemical cleaning
Proper chemical cleaning method/procedure

Prevent condenser in-leakage by improving integrity of surface condenser

Install on-line instrumentation to improve condenser leakage detection capability and cycle chemistry control
On-line cationic conductivity @CPD and outlet DA DO meter @CPD and outlet DA @Temp. ORP @ CPD/Inlet DEA and Outlet DA (optional)

Develop specific cycle chemistry targets, action levels and shutdown policies to maintain good HRSG cleanliness.

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Problem analysis for Cooling system

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Open Cooling Water RR = 6,000 M3/hr, HV = 1,000 M3 5 cell cross flow cooling tower with high efficiency fill Temperature Supply: 34 0C Temperature Return: 42 0C Pipe: carbon steel Condenser DT cooling water (design) = 8 0C Tubes: SS 304 Tubes Sheet: CS with epoxy coating Lube Oil Coolers Served by open cooling water system Tubes: Cu:Ni = 90:10 Tubes Sheet: CS with epoxy coating Air Coolers Served by open cooling water system Tubes: Cu:Ni = 90:10 Sheet: carbon steel coated with epoxy Make-up water : clarified water Source: river water Pretreatment: clarifier filter raw water tank cooling tower

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Important Issue
Cooling Water System There were condenser tube leak event occurred in the surface condenser in year 2011. The tube failure occurred on June 2011, 5 tubes were cracked and leaked cause very high conductivity of condensate and low pH of boiler water (<6.0 for more than 4 hours). This tube failure has forced the plant to have unscheduled shutdown for 2 days. Most of the cracking they found are occurred close to the tube attachment/support, no metal loss happened and branching.

Figure 4: Surface Condenser Tube Failure Fractures The root-cause come from Stress Corrosion Cracking (SCC)

Nalco 3DTRASAR Optimizer

The cooling water quality at 6 cycle with no NaOCl were not aggressive for Stainless 304

Nalco 3DTRASAR Optimizer

When we run simulation program with NaOCl to control FRC 0.2-0.5 ppm.

Higher chloride in cooling water will increase potential for stainless corrosion

From above snapshot we found there are issue of SS-304 corrosion that may be the root cause for this issue that make the penalty from unplan shutdown for 2 day around (3Bahtx20kwx1000x24hrx2day = 2.88 MB/time)

Water Quality MU vs CW

Trend of Make up & cooling water quality seem stable, so the problem may be hidden such as - not matching treatment program, - not matching control target

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Solution for Cooling system

SOLUTION
To prevent stainless corrosion in condenser and H2 damage in Boiler tube We recommend follow.1. Replace the oxidizing biocide form chloride to bromine base 2. Replace treatment program 3. Use automation system control feeding system to increase system reliability 4. Replace treatment program for more reliability 5. Use automation system to monitor and control feeding system in Boiler system

SOLUTION
1. Replace the oxidizing biocide form chloride to bromine base

To prevent SS-304 corrosion, we recommend to use stabilize bromine for oxidizing biocide that will not increase chloride in water.

SOLUTION
NALCO TREATMENT

Nalco 3DTRASAR Optimizer

With Nalco solution, we can run cooling system at 7 cycle without SS-304 corrosion or scale from Calcium Phosphate

All field are green

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Summary of Commercial part

Commercial part
1) Chemical
Product Category or Control Parameter Dosage or Product Number or Control Set Additive Point Control Method Annual Usage Units

303,309.14 Bht/m
Price per Unit Annual Cost

Cooling System
Cycles of Concentration pH Scale Inhibitor Mild Steel Corrosion Inhibitor Oxidizing Biocide Total Treatment Costs H2SO4 3DT104 3DT129 ST-70 7.0 7.6 31 25 0 3D Scale Control Automatic Tag Polymer TRASAR Timer Control 7,190 3,245 2,649 8,675 Kg/Year Kg/Year Kg/Year Kg/Year 6.00 165.00 155.00 198.00 43,138.1 535,448.8 410,643.8 1,717,567.0 2,706,797.7

Boiler System
Oxygen Scavenger Condensate Treatment Internal Treatment Total Treatment Costs Total Cont/Year Eliminox N-356 BT-3000 0.5 Continuous Feed 1.5 Continuous Feed 4 Continuous Feed 562.0 1,685.0 5,616.0 Kg/Year Kg/Year Kg/Year 113.00 246.00 81.00 63,506.0 414,510.0 454,896.0 932,912.0 3,639,709.7

2) Equipment rental -3DTRASAR for CW + 4 pump + Solenoid valve -3DTfB (CONTROLLER & NCSM) Total Treatment Cost

15,000 Bht/m 33,600 Bht/m 351,909 Bht/m 4,222,909 Bht/Y

Commercial part
3DTRASAR Value Package

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Workshop grouping