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TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 1 of 13
pH : The steam which is finally used for power generation, i.e the steam which
goes to the turbines has to be ultra pure. This implies that the water used for
generating this steam should be in its purest form. Monitoring the pH value of the
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 2 of 13
feed gives direct indication of alkalinity or acidity of this water. The ultra pure
water has pH value of 7. In steam circuitit is normal practice to keep the pH
value of feed water at slightly alkaline levels. This helps in preventing the
corrosion of pipe work and other equipment. Typical points in the steam circuit
where pH should be monitored are: Drum, High pressure heaters, Make-up
condensate, Plant effluent, Condenser, Cooling water.
Conductivity: Conductivity measurements give indication of contamination of
water / steam with any kind of salts. These salts can get added to water / steam
from atmosphere or due to leakage in heat exchanger etc. The conductivity of
ultra pure water is almost close to zero (say 1.2 micro siemens / cm), while with
addition of even 1 ppm of any salt, the conductivity can shoot up to even more
than 100 micro siemens / cm. Thus conductivity is a very good general purpose
watch dog which can give a quick indication of plant malfunctioning or possible
leakage. Typical points in the steam circuit where conductivity should be
monitored are : Drum water, Drum steam, High pressure haters, Low pressure
haters, Condenser, Plant effluent, D.M Plant, Make up water to D.M Plant.
Silica: The presence of silica in the steam and water circuits of power generation
plant is associated with a number of problems both in the superheater and
turbine sections.
The solubility of silica in steam increases with pressure. The presence of silica in
steam can lead to deposition in superheater tubes and on turbine blades. Small
deposits on the turbine blades can result in loss of efficiency, whilst larger
deposits can cause permanent mechanical damage.
In order that the turbines are operated at maximum performance, continuous
monitoring of silica in steam, boiler water and feed water is highly recommended.
The monitoring of anion and mixed bed ion exchanges safeguards and optimizes
the operation of Demineralising plant. Silica analysis is required at this stage
also.
Thus the typical points in steam circuits where silica analysis required are. High
pressure and Low pressure turbines, Drum steam, Drum water, CEP discharge,
Make-up water, D.M. plant, Supply water to D.M.Plant.
Dissolved Oxygen: Within a temperature range of 200 --- 250 degree centigrade
(feed water), Dissolved oxygen causes corrosion of components and piping, i.e.,
Condensers, Low pressure pre heaters, Feed water tanks, High pressure pre
heaters and economizers. The resulting pitting may eventually cause puncturing
and failures.
Dissolved oxygen also promotes electrolytic action between dissimilar metals
causing corrosion and leakage at joints and gaskets.
To minimise corrosion under alkaline operating conditions, mechanical deaeration
and chemicals scavenger additives are used to remove the dissolved oxygen. An
analytical check of process efficiency, therefore, is essential.
Dissolved oxygen monitoring is imperative in power stations using neutral or
combined operating conditions (pH 7.0-7.5 or 8.0-8.5). The typical points in
steam circuit where dissolved oxygen monitoring is required are. Condenser
outlet, L.P. heaters, Economiser inlet.
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 3 of 13
All the analysers mentioned above work efficiently if the temperature, pressure
and flow conditions of sample are maintained properly. Further , the sensors are
capable of handling the water/steam samples at particular temperatures and
pressures only. This necessitates the use of the sample conditioning system i.e.
Wet panel.
Sample conditioning systems have several functions. The sample must be:
Probably the most common problem in sample – system design is the lack of
realistic information concerning the properties of the process at the sampling
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 4 of 13
point. Also, while the sample is being conditioned, utmost care has to be taken to
see that the sample does not get contaminated and it is truly representative. The
condition of sample reaching at the end point i.e. the analyser should match
exactly with that at the tapping point. Thus the first important component the
sampling system is the sample extraction probe. The correct choice of probe
should never be over looked, since the validity of analysis will be questionable, if
representative sample are not withdrawn. Being directly attached to the process
pipe work, the probe may be subject to severe service conditions, and for most
applications, this item is manufactured to the stringent codes applicable to high
pressure, high temperature pipe work. The type of probe to be used will depend
on the process steam parameter to be measured, the required sample flow rate
and the position of the sampling point in the system.
Sample Coolers:
The sample coolers form the heart of the sampling system. These should be
preferably coil in shell type design. This should make use of counter flow type of
heat exchange principle. Double helix are in vogue now a days. The coolers with
double helix type coil design give better approach temperature than conventional
single coil designs apart from being compact in size. A built in shell relief valve
takes care of possible mishap due to high pressures caused by coil rupture etc.
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 5 of 13
Filteration:
The majority of online analyzers from dissolved solids or volatile species, and the
presence of unwanted particulate matter can be damaging, both to the
instrumentation and to certain components in the sampling system, such as
pressure reducing valves, capillaries or solenoid valves. For many applications all
that is required is a small high-pressure filter with sintered stainless steel
element. However, for plants with a high particulate burden, larger stainless steel
or alloy steel high-pressure y filters may be necessary and these can be supplied
with integral valves to permit regular cleaning without disassembly.
Pressure Reduction:
An important aspect of sample conditioning lies in making suitable provision to
ensure that the analyzers can never be subjected to a pressure higher that the
safe limit. With source pressures as high as 250 bar, this warrants serious
consideration, and the use of components of high integrity. A pressure regulator
that can maintain the down stream pressure at constant set limit irrespective of
up stream fluctuations becomes an ideal choice. On closing fully, the regulator
should ensure zero flow condition and should withstand the total up stream
pressure. A built in safety valve to this pressure regulator makes the unit fool
proof.
In the event of cooling water failure, on line systems require a reliable means of
immediate sample shut off and alarm, before high temperature samples can
reach instrumentation. Temperature sensing can be done by means of electrical
contacts on the outlet temperature gauge, or by a dedicated sample thermo
switch. The electrical output of the above can be used for sample shutoff, by
means of solenoid valve. In this manner a pressure switch also can be added for
additional safety.
Chilled Water:
Use of chilled water becomes necessary when the cooling water available on site
is not capable of cooling the sample to the temperature required by analyzers. If
available cooling water is upto 40 Deg C, a well designed sampling system can
ensure sample outlet temperature of 45 Deg C. Most of modern analyzers can
work comfortably with these sample temperatures. However if cooling water
temperature exceeds 40Deg C, use of chilled water becomes necessary. Normal
practice is to make use of available cooling water for extracting as much as heat
as possible from the sample and using the chilled water for the removing the
remaining fraction of heat. Chiller with isothermal bath is a compact unit which
saves a lot of space. In this unit the chiller unit provides the chilled water to a
container called isothermal bath. In this container the sample coils are immersed.
Thus one can save use of individual heat exchangers.
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 6 of 13
System Description :
The steam and water analysis system at Vimagiri consists of following major
parts:
1. Sample Handling system (SHS)
2. Analysers
Isolation Valve: This is provided for isolating the sample during maintenance of
the components mounted on the panel / rack / wall mtg. plate. There are two
isolation valves provided in the system for this purpose. One for low temperature
application and the other is for high temperature application.
Sample Cooler: Indoor located, coil in coil type sample coolers with counter flow
operation are provided to reduce the temperature of sample to the acceptable
temperature of the sensor. Material of the inner tube will be Inconel 600/316 SS
and
material of outer tube will be AISI 316 SS. Both the root sample coolers and
primary cooler will employ plant auxiliary cooling water as the cooling medium
and the secondary sample cooler will employ chilled water as the cooling
medium. Necessary Isolation Valves are provided at the cooling water/chilled
water inlet and outlet.
SR FLUID/ Sample PRESS. SAMPLE FLOW (cc/min.) COOLING WATER HEAT SAMPLE
SERVICE in (Kg/ LOAD OUTLET
TEMP. cm2 g) (KJ/hr) TEMP.
FLOW INLET OUTLET
Ltr/Hr TEMP. TEMP.
Grab Total Total 120%
Ana Sample Sample
Flow
1 Hotwell 47 4 425 200 625 750 1,500 39 39.5 2,965 39.2
make-up
pump
discharge
2 CEP 50 15 430 400 830 1,000 1,500 39 42.2 20,24 39.5
Discharge 2
Header
3 HP/IP BFP 159 6.3 425 200 625 750 1,500 39 42.9 24,27 29.4
suction 8
4 Cooling 39 2.6 625 --- 625 750 1,500 39 39 --- 39
water in
condenser
Note: The cooler calculations are based on 120% sample column.
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 7 of 13
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 8 of 13
Pressure Regulator :
Pressure Regulator is used to reduce the sample pressure from high pressure to
low pressure. Pressure Regulator is used for below sample pressure of 35
kg/cm2. Setting is done through the knob. Outlet pressure of the pressure
regulator must be set at 2 kg/cm2. More pressure may damage the sensors.
For pressure above 35 kg/cm2 Variable Pressure Reducing Element (VREL) is
used. This is provided to reduce the sample pressure from high pressure to low
pressure.
Strainer
Strainer is mounted to filter the impurities less than 40 micron from sample.
Cation Column
Cation Column is used to remove cations from the sample. This will eliminate
effect of conductivity of cations from the sample.
Flow Indicators
Flow indicators are provided both streams to measure sample flow rate.
Needle Valve
Needle valve is provided to control the flow of sample to the sensors during
sample cycle.
Gate Valve
Gate valve is provided for isolating the cooling water outlet from sample cooler.
This is useful during cooler maintenance.
Temperature Gauge
Temperature Gauge will indicate the temperature after the sample cooler. The
temperature must be below 40 Deg C.
Pressure Gauge
Pressure Gauge (0-10 kg/cm2) are provided for monitoring the pressure in the
sample line. This will indicate the actual pressure of sample.
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 9 of 13
Analyser:
pH Analyser: Microprocessor based system with system accuracy of 0.02 pH, auto
temperature compensation, auto zero check, manual zero and span calibration,
integral indicator, automatic ultrasonic cleaner, isopotential adjustment having
flow type cells. Housing for electrode and analyser will be IP65. Output will be
isolated 4-20 mA DC linear signal. Accessories will include preamplifier, screened
junction box for electrode.
All necessary steam and water samples for safe and efficient operation of the
plant is taken from the following locations for each pressure level as a minimum:
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 10 of 13
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 11 of 13
The various analytical instruments complete with their sampling system and
sampling racks will be provided for continuous monitoring of the quality of the
Cycle Water & Steam as per table below:
6. HP/IP/LP
SUPERHEATED
√ √ √ √
STEAM
7. DEAERATOR
√ √ √ √
8. COOLING
WATER TO √
CONDENSER
9. HP/IP/LP
SATURATION √ √ √ √
STEAM
10. DRUM WATER
(HP/IP/LP) √ √ √
LARSEN & TOUBRO LIMITED EPC POWER
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 12 of 13
SAMPLING SYSTEM:
TRAINING MANUAL
PROJECT 388.5 MW Combined Cycle Power Plant DOC No. IBDC/ L&T/ VCCPP/ 12
DOC. TITLE Steam and Water Sampling System Page No. Page 13 of 13