EN ISO 9001Certif icate 041004422:

Steam & Water Analysis System Overview

Specialists in Process Efficiency and Energy Conservation

About Power industry and water chemistry and importance of SWAS

Today in power industry, high pressure boilers & steam turbines are under constant attack from erosive & corrosive elements such as Silica, Sodium, Dissolved Oxygen, Calcium, Chloride and Phosphates.Without accurate measurement and monitoring, the plant may suffer heavy mechanical damage that can be caused due to imbalance of turbines, reduced efficiency, deposition on turbine blades, corrosion of steam pipe work & so on.We have designed our Steam and Water Analysis System (SWAS), to keep you in power. SWAS assures safety of your boiler and turbines, by taking along and analyzing up to a dozen samples from all your water & steam circuits. In today's power industry, sample conditions as high as 560 degree Celsius & 200 bars are quite common. Forbes Marshall SWAS can easily take care of these samples. To protect your equipment, our SWAS works in two stages:1. Sample Conditioning 2. Sample Analysis

1. Sample Conditioning

First section of any SWAS is the Sample Conditioning section or Wet Panel

Enclosed type Wet Panel

Here the sample is first cooled in Sample Coolers, de-pressurized in Pressure Regulators & then fed to various analyzers while keeping the flow characteristic constant by means of a Back Pressure Regulating device. The schematic diagram here shows how this happens :

Open frame free standing Wet Panel

ITEM NO

LEGEND

01a

0405a06

ROTAMETER

0908

1110

14

1615

13

REGULATING VALVE

DESCRIPTION

COOLANT FLOW INDICATOR

SAMPLE FILTERPRESSURE REGULATORSAMPLE RELIEF VALVETEMPERATURE GAUGEPRESSURE GAUGE

COOLANT ISOLATION VALVE

HT SAMPLE ISOLATION VALVE (GLOBE TYPE)

PRESSURE SWITCHSOLENOID VALVE

2223 THREE WAY BALL VALVE

BACK PRESSURE REGULATORTUNDISH (FOR GRAB SAMPLING FACILITY)17

02 SAMPLE COOLER

12 TEMPERATURE SWITCH

BULKHEAD UNION (1/2"NB S/W x 1/4" OD)27

COND. CELL WITH FLOW THROUGH CHAMBER CESINGLE CONDUCTIVITY TRANSMITTERCTPH ELECTRODEPHEPH TRANSMITTERPHTDISSOLVED OXYGEN SENSORDOEDISSOLVED OXYGEN TRANSMITTERDOT

SILICA ANALYZER (MULTICHANNEL)SI

(REFER SAMPLE COOLER SIZING)

01b LT SAMPLE ISOLATION VALVE (NEEDLE TYPE)

SODIUM ANALYZER (MULTICHANNEL)NA

HYDRAZINE ANALYZERHZ

ANY OF ANALYSER GIVEN BELOW

4. WASTE DRAIN HEADER (DEFAULT) : 2"NB, ASTM A106,GR.B, SCH. 40 C.S,PIPE FLANGED TO 2"NB, ANSI B16.5, CLASS 150 R/F

2. BLOWDOWN HEADER (DEFAULT) : 2" NB, ASTM A106, GR.B, SCH-80, PIPE FLANGED TO 2" NB, ANSI B16.5, CLASS 300 R/F

5. COOLING WATER PIPING : 3/4"NB, SS304 PIPING

3. COOLING WATER HEADERS (DEFAULT) : 2"NB, ASTM A106, GR.B, SCH.40, PIPE FLANGED TO 2"NB, ANSI B16.5 CLASS 150R/F

1. SAMPLE TUBING : 1/4" OD, 16 SWG, ASTM A 213, TP-316, SEAMLESS TUBE

NOTE :

6. SAMPLE INLET CONNECTIONS : BULKHEAD UNION FOR SR.NO.27

OTHERS

FM

4

5a

27

LINE - 1

SAMPLE INLET

02

01a01a

BLOWDOWN HEADER

COOLING WATER OUTLET HEADER

COOLING WATER INLET HEADER

BOILER FEED WATER

5a

AL

12

13

WASTE DRAIN HDR

11

10

9

P115

T1

8

14

6

9

DRAIN

DENOTES SAMPLE LINEDENOTES COOLING WATER LINE

NA

16

WASTE DRAIN HDR

DRY PANEL

22

23

17

CE

CT

16

19

TS

PS15

Forbes Marshall Sample Coolers are coil-in-shell type contra-flow heat exchangers. Validated by a premier institute like IIT, we are one of the few sample cooler manufacturers in the world who can offer guaranteed performance. With in-house test set up for performance testing, world class manufacturing and welding facilities, we can offer one of the most trusted sample coolers in power sector. Various options of coil materials are available such as Stainless Steel AISI 316, Monel 400, and Inconnel 625 & so on.

Sample Cooler

Some of the important components of Sampling Systems (Wet Rack)

Forbes Marshall offers Piston Type High Pressure Regulators. These are used in Primary conditioning where sample pressures are higher than 100 Kg/cm2 & temperatures higher than 350 Deg C. As these are piston type pressure regulators, there is no fear of diaphragm rupture etc.

For lower pressure / temperature rating, Forbes Marshall offers Spring Loaded Diaphragm type Pressure Regulator to offer safety against a remote possibility of diaphragm rupture, in-built safety valve is a regular feature.

High Pressure Regulator

Forbes Marshall offers Back Pressure Regulator (BPR). The BPR avoids low flow (or fluctuating flow) conditions to analyzers in the event of grab sample valve operation. In absence of such device, the sample would flow to grab sample line when the grab sample valve is opened. This can create low flow alarm conditions in samples going to analyzers. A Pressure Regulator & Back Pressure Regulator combination provides very stable pressure & flow conditions, thereby ensuring condition where a very reliable, efficient & accurate analysis can be done.

Back Pressure Regulator

Forbes Marshall offers Sample Flow Indicator (Sight Glass) to view the sample flow inside the sample line. A rotating wheel indicates presence of cooling water. The sight glass is made of high grade stainless steel & is manufactured by Forbes Marshall.

Sight Glass

Sample Filter

Forbes Marshall also manufactures the Filter which is required to ensure particle free sample. Any particle of size up to 40 microns size can be filtered out. Forged stainless steel body and hexagonal cap helps easy cleaning of filter element.

Forbes Marshall Pressure Relief Valve comes fitted with Sample cooler. Pressure relief valve is important as it protects sample cooler in case cooler coil fails. This also important for human safety as pressurized cooler may burst due to full sample pressure.

Pressure Relief Valve

The duplex type cation conductivity column is a field proven Forbes Marshall design. The cation conductivity measurements are considered to be more reliable than ordinary conductivity measurements, as this method ensures elimination of masking effects of desired chemicals used in treating the water. This provides a more realistic picture of dissolved impurities in the sample. The FM cation column is easy to operate, regenerate & maintain.

Cation Column

Cooling Water Isolation Valve

Cooling water isolation valve is a ball valve. Its brass body makes it good corrosion resistant and light weight. Long handle makes it easy to operate. Ball valve type design ensures full flow at open condition.

Hi-temp Isolation Valve

High temperature isolation has a simple light weight construction which is ideal for high temperature isolation application. It is hydro tested at 630

0Kg/Cm2(body) & 420 Kg/Cm2(seat) as per ANSI B 16.34, 1996 at 25 C 0and is applicable above 180 C.

Philosophy And Importance Of Monitoring Boiler Parameters

Water Chemistry

Nuclear cycle measurement

CONDENSATE POLISHING PLANT

WATER SUPPLYMAKE-UP

CONDENSOR

GENERATOR

LP TURBINES

RE-HEATER

HP TURBINES

DE-AERATOR

FEED PUMP

CONTAINMENT BUILDING

REACTOR COOLANT PUMP

WASTE GAS DECAY TANKS

RECTOR CORE

STEAM GENERATOR

PRESSURIZER

PRIMARYLOOP:PWR

SECONDARYLOOP:PWR

COOLINGTOWER

H2 O2

Cond pH CI

H2H2 O2

Cond

pHCI

H2 O2

O2H2

Cond SiO2 NH2 4 O2 pH PO4

O2

Cond +NaTOC O2

Cond +NaSiO2 pH

SiO2Cond +Na

TOC O2THAK

CondSiO2

+Na pH NH2 4

Cond +NapH

SiO2

SiO2

O2H2

TOC Cond+Na

Cond

Turb

TH O2

Thermal Power Plant Steam and Water in-line Analytics

COOLINGTOWER

CONDENSERPOLISHING PLANT

MAKE-UP

DE-AERATOR

FEED PUMP

FEED PUMP

HPHEATERSECONOMIZER

SUPERHEATERS

DRUM

RE-HEATER

GENERATOR

HP TURBINES

O2 H2 SiO2

SiO2

SiO2Cond

SiO2+Na

N H2 4Cond

O2 SiO2

PO4 pH

O2

O2

+NaCond

TOCO2

TOC+Na

Cond

T0CTH

AKCI2

pHCond

+Na

Cond+Na SiO2

pH+NaSiO2

Cond N H2 4

SiO2 Cond+NapH

DEMNERALIZATION PLANT

1) pH : The steam which goes to the turbines has to be ultra pure. The pH value of the feed water gives direct indication of alkalinity or acidity of this water. The ultra pure water has pH value of 7. In steam circuit it 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. Typically dedicated pH Analyzers are recommended at following locations in Steam circuit: High pressure heaters, DM Make-up Water, Condensate Extraction Pump Discharge

Dedicated pH analyzer in each line ensures that pH is getting maintained in specified band.

Two wire Aquamon 2000 plus model is simplest pH and ORP transmitter. These analyzers are directly loop powered by +24V DC supply from DCS and PLC.

Also direct 110-230 V AC powered Aquamon 4000 transmitter is available if Alarm contacts required along with 4-20 mA output. For pH measurement both low and high pH alarm contacts can be used to control dosing for chemicals. Separate PT-100 sensor input can be used for temperature compensation for pH measurement.

2) Conductivity : Conductivity is an important parameter for detecting any contamination of steam in the boiler circuit. Conductivity of pure water is almost zero (1-2 µ Siemens). Even addition of 1 ppm of salt may increase conductivity > 100 µ Siemens. Thus conductivity is an important parameter for the detection of leakages.

Typical points in the steam circuit where conductivity should be monitored are . Superheated steam, Drum water, High pressure heaters, Low pressure heaters, Condenser, Plant effluent, D.M. plant, Make-up water to D.M. plant.

Like pH Analyzer, Conductivity is also basic measurement. Both 24V DC loop powered and AC powered option available for this measurement.

These conductivity transmitters can be used with cells with different cell constant. PT-100 temperature sensor in conductivity cell helps to get a compensated reading for conductivity measurement.

3) 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 super heater and turbine sections.

The solubility of silica in stream increases with pressure. The presence of silica in the steam can lead to deposition in superheated tubes and on the turbine blades which may lead to loss of efficiency and turbine blade failure. For proper working of turbines, continuous monitoring of silica is highly recommended. The monitoring of anion and mixed bed ion exchanges safeguards and optimizes the operation of demineralization plant. Silica analysis is required at this stage also.

Thus the typical points in steam circuits where silica analysis is required are Low Level Silica Measurement in: High pressure and Low pressure turbines Steam, Drum (Saturated) steam, CEP discharge, Make-up water, D.M. makeup water & High Level Silica measurement: In Drum Water

Benefits to user:• To ensure safe operation Silica trend need to be monitored at a

multiple location in steam and water circuit. Our multi-channel silica analyzer with inbuilt sequencer is specially designed to take care of this need.

• Also Plant chemist is interested in getting graphical trend for each measurement. Silica analyzer is equipped with inbuilt data logger to take care of this need.

• We offer smallest cycle time (~9 min) that can help you to know your process better.

• We offer Micro-piston Pumping avoiding cross contamination between two different channels.

• Automatic two point calibration giving best accuracy. • Locally available reagents and minimum reagent consumption ensures

minimum cost of ownership for our analyzer.• There is no need of peristaltic pump tubes/ No need of instrument air.• Auto diagnostic features make our Silica analyzer easy for

maintenance.

4) Dissolved Oxygen : Within a temperature range of 200...250°C (feed water), dissolved oxygen causes corrosion which may cause puncturing and failures of piping and components respectively. Dissolved oxygen also promotes electrolytic action between dissimilar metals causing corrosion and leakage at joints and gaskets. To minimize 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 Deaerator Inlet and outlet

5) Hydrazine : Hydrazine is used as oxygen scavenger and for maintaining feed water alkalinity to prevent acidic corrosion. It prevents frothing in the boiler and minimizes deposits on metal surfaces. Hydrazine also helps in maintaining a protective magnetite layer over steel surfaces. The nominal dosage rate for hydrazine in feed water is about three times its oxygen level. Under dosing of hydrazine leads to increased corrosion; overdosing represents a costly waste. Therefore hydrazine monitoring is extremely important.The typical points in steam circuit where hydrazine monitoring is required are. Re-heaters, Economizer inlet and L.P. heaters.

As 4-20mA output from Hydrazine analyzer can be used for precise dosing control Hydrazine analyzer used in Forbes Marshall SWAS Package offers:

a) A response time lower than 60 seconds for a fast renewal of the diffusion layer.

b) Unlike traditional amperometric techniques, our analyzer uses three electrodes. Thus, voltage drift due to changes in the composition of the water is eliminated

c) A reference electrode with pre-pressurized gel electrolyte which facilitates maintenance.

d) All electrodes which are directly connected to the transmitter through a detachable cable for an easy removal for maintenance.

e) No moving parts such as pumps or valves that are used to force gases, making analyzer the most reliable one.

In Boiler & Power Plant dissolved oxygen is removed using deaeration methods. Thus we offer dissolved Oxygen analyzer which:

a) Measures in ppb Rangeb) Has better response time.c) Has temperature sensor with NTC for

temperature compensation.d) Has sensors that are directly connected to

the transmitter through a detachable cable for an easy removal for maintenance.

6) Sodium : The presence of sodium signals contamination with potentially corrosive anions, e.g. chlorides, sulfates etc. Underconditions of high pressure and temperature, neutral sodium salts exhibitconsiderable steam solubility. NaCl and NaOH, in particular, are known to be associated with “StressCorrosion Cracking” of boiler and superheater tubes.The ubiquitous character of sodium in the environment makes it a useful indication to reveal possible“Leak conditions” within the circuit, particularly in the condenser section where the measurement ofsodium detects cooling-water leaks with a much higher sensitivity than conductivity measurements.The typical points in steam circuit where sodium monitoring is required are. D.M. plant make up water, Condensate Pump Discharge, Condenser, Drum (Saturated) steam.

As Sodium Analyzer is being used for smallest leak detections and Slippages of ions, Sodium Analyzer used in Forbes Marshall make SWAS is with:

a) A measuring range of 0.01 to 10,000ppb freely programmable. (Very Accurate)

b) Use of Non Hazardous chemicals for automatic reactivation of electrodes.

c) Fast Response. Even in multichannel measurement Auto-adapted rinsing sequence to reach accuracy in a minimized cycle time (10 minutes possible).

d) A reproducibility <1.5% of reading or <±0.02 ppb, whichever is greater within 10°C ,

e) An accuracy <5% of the reading or <±0.1 ppb, whichever is greater.

f) User can go for freely programmable “FULLY AUTOMATIC CALIBRATION SEQUENCE” as a option

Chiller

Chiller Package

Chilled water is required when the cooling water available at site is incapable of cooling the sample to the temperature required by the analyzers. If cooling water temperature exceeds 40 Deg. C , the sample temperature exceeds 45 Deg. C , which is higher than the temperature required by the analyzers. To bring down the temperature of the sample chilled water is required. Chiller Package also required when sample is to be cool at 25 Deg. C. We manufacture these in our factory and are the only SWAS manufacturers having this capability

Forbes Marshall offer Lab Sampling module for laboratory analysis of steam in Process Boilers which is designed as per international standards. Its small & compact size and light weight design makes it suitable for on line analysis and also for continuous lab sample collection. It is easy to operate and fits easily on site. Wherever there is a boiler, lab sampling module is required.

Lab Sampling Module

Photo Gallery

Photo Gallery

Performance Certificates

3000/02/2004/3499

Forbes Marshall Pvt. Ltd.

A-34/35, MIDC, Industrial Estate, 'H' Block, Pimpri, Pune - 411 018. India.Tel.: 91(0)20 - 27442020 Fax: 91(0)20 - 27442040 E-mail: swasmktg@forbesmarshall.comDomestic:Ahmedabad Tel: 91-79-26851738, Alibag Tel: 91-2141-223795, Bangalore Tel: 91-80-25483047, Bhopal Tel: 91-734-2564237, Chandigarh Tel: 91-172-5080285, Chennai Tel: 91-44-26611238, Coimbatore Tel: 91-422-2303679, Delhi Tel: 91-11-22713485, Hyderabad Tel: 91-40-27152276, Jamshedpur Tel: 91-657-2437721, Kanpur Tel : 91-129-2226366, Kolkata Tel: 91-33-22407359, Lucknow Tel : 91-522-2393517, Madurai Tel : 91-452-4390967, Mumbai Tel: 91-22-22673821, Nagpur Tel: 91-712-2539386, Navi Mumbai Tel: 91-22-27666157, Pondicherry Tel : 91-413-2254454, Surat Tel: 91-261-2651448, Trichy Tel : 91-431-2730373, Vadodara Tel: 91-265-2343733, Visakhapatanam Tel: 91-891-2552538International Operations:exp@forbesmarshall.comBangladesh Tel: +88 028811501, Canada Tel: +905 361 2525, Egypt Tel: +202 3036935 Indonesia Tel: +6281519917178,Iran Tel: +9821- 423 8427, Kenya Tel: +254734763913, Malaysia Tel.: _60 32161 8260, Nepal Tel: +977-1-4278781/4282344, Sri Lanka Tel: +9411 - 2512997 & + 9411-4511127, Thailand Tel: +6619020690, U.A.E.(Instrumentation) Tel: + 9714 3350020 (Boilers) Tel.: +971 4 3350020, USA Tel: +1- 650 327-4227 Toll Free Tech Support #: 1 866 803-6224Website : www.forbesmarshall.com

Some of our esteemed customers

S. No Customer Job1 BHEL BANGALORE NTPC Kayamkulam, Simhadri, Faridabad, Ramagundam, Vindhyachal, Unchahar, Paricha,

Rihand, Sipat, Khaparkheda, APGENCO Kothagudam TPS, Rayalseema TPP, TNEB Ennore, MPEB Korba, GIPCL, DVB Pragati, STPP, NEEPCO AGBPP,

2 BHEL TRICHY IOCL Baruni, KMCL Dubari, Chambal Fertilizer, Aditya Cement, TNEB Kuttalam, TNEB Vallathur, PT IBR Indonesia, Bannari Aman Sugars, RIL Hazira/Patalganga/ Jamnagar, GAIL Pata, IFFCO Phulpur, IOCL Panipat, Shamnur Sugars, HPCL Vizag,

3 BHEL DELHI NTPC Dadri, TNEB North MDS, IPCL Gandhar, Jindal Steel & Power, Raigarh CPP, TATA Powers Jojobera.

4 BHEL HYDERABAD Aditya Cement, Chambal Fertilizer, IFFCO Phulpur, TNEB Kuttalam, HPCL Vizag, IOCL Panipat

5 THERMAX LTD Indo Gulf Dahej, Awarpur Cement, Konark Motcoke, HFCL Namrup, Balrampur Chini, Shakti Sugars, Sriram EPC, Bannari Aman sugars, Oman fertilizers, Chettinad Cement, Davangiri Sugars, TISCO, Nectec Russia, Bhurup Austrailia, Indo Rama Indonesia, Thai Toyo Thailand

6 ABB Jindal Steel & Power, IOCL Haldia, MRPL, PSEB Bhatinda7 SIEMENS DVC Mejia, Jindal Steel & Power, Essar Powers Bhander8 HONEYWELL PSEB, NTPC Talchar, CPCL, Indal Hirakud, HEG, ACC Wadi9 YOKOGAWA Vijayawada TPS, Raichur TPS, NTPC Talchar, Barh, BCCL, HSEB Panipat, MPEB SGTP, 10 L&T BOMBAY IPCL Gandhar, Awarpur Cement, HPCL Haldia, GACL Dahej, IGCARR11 L&T BARODA Ennore TPS, Kelanitiss Srilanka, Konaseema, Vemagiri12 CETHAR VESSELS NCPL, Adani Wilmar, Jubilant, Dalmia Cement, Indo Rama, Aryan Coal, Orient Cement13 IJT Mysore Sugars, Jaypee Cement14 IL KOTA MPEB Satpura, Amarkantak, Korba, Kota TPS15 THERMAL SYSTEMS Birla Cooper, Sriram energies, HIL Dahej, Vandana Global16 CHEEMA BOILERS Lalitha Enterprise17 DEUTSCHE BABCOCK Reliance Goa, /Jamnagar18 LINDE PROCESS TECH Reliance Petro Jamnagar19 FOSTER WHEELER PPN Power20 MITSUI BABCOCK Godavari Sugars21 KUTCH LIGNITE Kutch Lignite TPS22 HPCL HPCL Vizag23 GEB Dhuvaran