Water Systems: Larsen & Toubro Limited Epc Power Training Manual

LARSEN & TOUBRO LIMITED TRAINING MANUAL 388.5 MW Combined Cycle Power Plant DOC No.
Water Systems Page No.
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IBDC/ L&T/ VCCPP/ 07 Page 1 of 43
Water systems
Introduction: Today, large power plants are usually designed as forced-circulation steam generators. In this type of steam generators, the water is evaporated and superheated in direct circulation. Two measures are taken today to minimize the quantity of corrosion products and precipitation of salts when the steam-solubility is exceeded: Demineralization systems are used for treatment of make-up water to compensate for losses in the water/steam cycle. Condensate polishing plants are used to continuously remove salts and corrosion products from the water/steam cycle. Apart from water for internal heat transfer within the power plant, also cooling water is required for temperature reduction to condense the steam in the turbine condenser. Depending on the power plant site, open-circuit cooling or closed-circuit cooling systems with or without evaporation are possible. Which cooling water treatment methods are applied depends on the chosen type of cooling system. Another important aspect is preventive maintenance work to be carried out on the water side in order to ensure economically efficient operation and to eliminate chemical influences on components, operation and availability of a power plant as far as possible. The schematic diagram in the Figure below illustrates the integration of the water treatment systems into a large power plant process.
Arrangement of water treatment systems in the power plant
LARSEN & TOUBRO LIMITED TRAINING MANUAL 388.5 MW Combined Cycle Power Plant DOC No. Water Systems Page No.
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Natural water: In the course of its natural circulation process, water absorbs various substances. Without undergoing special treatment it can thus be used in power plants only for once-through cooling. If used for other purposes, the substances contained in the water may cause damage to components and systems. Thus it is absolutely necessary that the water is subjected to suitable treatment. Classification of the natural types of water The water occurring in nature is classified according to its origin. For use in power plants, however, only water is significant that is available at the respective power plant site in large quantities: 1. Water from precipitation of any type, e.g. rain, snow. 2. Groundwater, natural spring water, well water. 3. Surface water Surface water includes all surface water bodies, in distinction to subterraneous water bodies. This includes: flowing water: rivers, creeks, canals, stagnant water: lakes, ponds; cooling, treatment and storage facilities, seawater. Water Systems at Power Plant Water is used at many places in the power plant for different purposes. Use of water in the power plant includes: supply of the water/steam cycle with feed water via the demineralization plant, supply of the turbine condenser with cooling water (open-circuit cooling) or of the closed cooling water circuit with make-up water, supply of the service cooling water system with make-up water, fire-fighting water, service water for general technical use, and potable water for consumption by the staff, for staff facilities etc.
Procurement and cleaning of water

Figure below shows schematically the arrangement of the water procurement, treatment and distribution system.
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water filtering plant
storage basins
Water treatment and supply system (diagrammatic illustration) Cleaning of the raw water between the water source and the storage basin is carried out by mechanical filtering. Figure below shows the system of a mechanical filtering plant. It consists mainly of the coarse and fine screens and sieve belts or sieve drums, the cooling water pumps and the concrete structure.
coarse screen
bulkhead
Mechanical filtering plant A cleaning device is used to clean the bar screens of impurities. Downstream of the bar screens, the automatically operated sieve belts or sieve drums with a mesh size of < 1mm are arranged. Velocity of the water flow in the intake construction is 0.5 to 1.5 m/sec. Cooling water pumps are employed to transport the water to the condenser. During the necessary inspections and repair measures, the individual plant parts can be shut off by bulkheads.
road
electrical systems
fine screen
belt sieve
bulkhead
bulkhead
pumps
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River Water System at Vemagiri
The source of raw water for the Vemagiri Plant is the river Godavari at about 8 km. from the plant site. The function of river water intake system is to draw water from the river and supply river water to plant raw water reservoir by intake pumps. The river water intake system consists of two x 100% vertical river water intake pumps (one working + one standby), about 8km long transfer piping and one raw water storage reservoir in two compartments. The raw water storage reservoir is of 2 Lakh m3 capacity (equivalent to 15 days storage), located inside the plant boundary. The river water intake pumps are housed in the river water pump house, which is located at the river water intake point. The river water pumps are installed in separate chambers, with coarse screens/trash racks and stop-logs which is located outside the pump house. Provision is made for isolation of individual river water pumps for maintenance. River water pumps are of the vertical turbine type provided with expansion joints, motorized butterfly valves, and necessary fittings on individual pump discharge lines. Capacity of the River water intake is equal to 110% of plant water requirement. The river water pump set is capable of permitting back flow of water from the other running pump in the event of tripping of the pump for a short duration of time (about 5 minutes). System Control: (i) Each pump will be provided with start / stop facility and start/stop and trip indication on the PLC based control panel at River Water Intake Pump House. (ii) Auto changeover of river water intake pumps when running pump trips and discharge header pressure is low. (iii) Each pump drive will be provided with one stop push button (PB) at field (near to drive), which will be lockable in stop position. This PB will be treated as Emergency Stop and will trip the drive whenever this PB is activated. In addition to above, the following interlocks & protections have been provided: Low level signal in the well will be provided in the PLC for alarm & start permissive of pumps. Low Low level signal will be provided in the PLC for tripping of pumps.
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Low Pressure switch at the common discharge header of pumps for alarm indication at PLC. Further, following instruments have been provided for indication purpose: One discharge pressure indicator for each pump Level transmitter for river water intake well for indication of level at the PLC Flow orifice with flow transmitter, flow totalizer on the river water intake pump discharge header for flow measurement and indication in PLC. Motor winding temperature detector and dial type bearing temperature indicators with alarm contacts, where the drive motors of the pumps are HT motors. River water intake system will be interfaced with the plant DCS through serial link.
Substances contained in water

Depending on its origin, water contains various substances, which - depending on the intended use - must be removed by a suitable water treatment plant. During its natural circulation process - evaporation, clouds, precipitation, groundwater, rivers, sea and again evaporation - water is impured by a variety of foreign matter, both dissolved and undissolved substances. From the air, rain water absorbs the gases nitrogen, oxygen, carbon dioxide and other gaseous, liquid and solid impurities (e.g. dust). When getting into contact with the ground surface, rainwater absorbs solid and dissolved substances. Particularly salts are dissolved by water as it penetrates the soil and rock layers. Undissolved visible substances These are coarse or fine disperse substances (disperse - solid matter that is dispersed in water). The undissolved solid substances can either be organic or inorganic. Inorganic impurities are e.g. dust or sand, organic impurities e.g. leaves, branches etc. Undissolved solid particles have a size of more than 10-5 cm in diameter. Undissolved solids are categorized into three groups: 1. floating matter: density lower than the density of water, 2. suspended matter: density approximately equal to the density of water, 3. settling matter: density higher than the density of water. Undissolved invisible substances These are colloid-dispersed substances. Substances with particle sizes ranging from 10-5 to 10-7 cm are referred to as colloidal particles. In natural water, humic acids and silicic acid occur as colloid-dispersed matter. Silicic acid, for instance, is constituted of finest particles of quartz sand that are colloidally dispersed in water. Examples of undissolved, invisible substances are microorganisms, phosphates, humic acids (frequently in marsh areas). Dissolved invisible substances Genuinely dissolved particles occur in particle sizes below 10-7 cm. The raw water at the power plant water intake structure contains a number of chemical compounds in dissolved state, which can be categorized into certain groups: a) hardening constituents e.g. Ca(HCO3)2, CaSO4), b) neutral salts (Na2SO4, NaCl)
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PROJECT DOC. TITLE c)
silicic acid (SiO2)
The water that occurs naturally is referred to as untreated water; after having undergone conditioning for human consumption it is called potable water. Water treatment technology deals mainly with the following dissolved constituents. Untreated water cations: calcium (Ca2+), magnesium (Mg2+), sodium (Na+), potassium (K+), etc. anions: gases: chloride ( Cl-), sulfate (SO42-), nitrate (NO3-), hydrocarbonate (HCO3-), silicic acid SiO2-) oxygen (O2), carbon dioxide (CO2)
Hardness of water A special group of dissolved minerals are the salts of the alkaline earths calcium, magnesium, barium and strontium, which are referred to as hardening constituents. In most types of natural water, however, only the salts of calcium and magnesium do occur. According to the International System of Units (SI), the hardening constituent content of water is no longer expressed in dH but in mmol/l, as sum of the calcium and magnesium ions 1dH corresponds to 10 mg CaO/l 1 mmol/l corresponds to 40 mg Ca++/l or 23.3 mg Mg++/l If a certain water contains a lot of hardening constituents, it is called hard water; if the opposite is true, viz the calcium and magnesium content is low, it is called soft water. A distinction is made between carbonate hardness which is also referred to as temporary hardness and the non-carbonate hardness which is also referred to as permanent hardness. Carbonate hardness Carbonate hardness is caused by carbonates and hydrocarbonates of Ca++ and Mg++. Carbonate hardness is caused by naturally occurring limestone, marble and chalk, all of which consist of calcium carbonate, and are dissolved in carbonic-acid containing water. Carbonic-acid containing water results from the balance that is achieved in the reaction of dissolution of carbon dioxide contained in the air in water: In this reaction the calcium carbonate which is almost insoluble in pure water is dissolved, thus producing calcium hydrocarbonate: However, in order to keep the carbonate hardness in dissolution, a certain surplus of carbonic acid is necessary. When the carbonic acid is removed, e.g. by heating, carbonate hardness can no longer be maintained in a dissolved state and calcium carbonate precipitates:
H2 O + CO2 H2 CO3
CaCO3 + H2 CO3 Ca ( HCO3 ) 2
Ca ( HCO3 ) 2 CaCO3 + H2 O + CO2

When this process occurs in a boiler or at hot heat exchanger surfaces, deposits of boiler scale occur, viz deposits with poor thermal conductivity. By this, a part of the hardness is removed from the water. On this process also the designation "temporary hardness" is based. In power plant operation it is thus necessary to remove carbonate hardness to a large extent or even completely from the water by implementing suitable decarbonization methods. Figure below illustrates the concept: total hardness = carbonate hardness + noncarbonate hardness.
>50C
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Types of hardness of untreated water Non-carbonate hardness Non-carbonate hardness includes all salts of Ca++ and Mg++ except for carbonates and hydrocarbonates, like, chlorides [CaCl2, MgCl2] sulfates nitrates [CaSO4, MgSO4] [Ca(NO3)2, Mg(NO3)2]
This permanent hardness cannot be removed by boiling the water. Salts, acids and conductivity High-purity water practically does not conduct electricity. Only when it contains dissolved salts is water capable of conducting electricity which can be proven by conductivity measurement. Substances which provide water with the capacity to conduct electricity are referred to as "electrolytes". Acids, bases and salts are electrolytes. Electrolytical dissociation and formation of ions In aqueous solution, acids, bases and salts tend to dissociate into electrically charged particles, one of which shows an excess of electrons (negative charge) and the other a shortage of electrons. Inversely charged particles emerge which are referred to as ions. The solution as a whole continues to be electrically neutral towards the outside. When direct current is put on the solution, the ions carrying a negative charge move to the positive anode, that is why they are called anions. The positively charged ions, the so-called cations, move to the negative cathode. The charge of the ion positive or negative - and the number of charges are stated by plus or minus signs.
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PROJECT DOC. TITLE Examples: 1. Acid: 2. Base: 3. Salt:
hydrochloric acid calcium hydroxide sodium chloride
HCL H + + CL
Ca 2+ ( OH ) 2 Ca 2+ + 2 OH NaCl Na + + Cl
Acids The oxides of nonmetals disolved in water form acids. A part of the nonmetals is gaseous. Nonmetals are, for instance, the elements carbon, sulfur, nitrogen, chlorine, phosphorous. When a nonmetal bonds with oxygen, a nonmetal oxide is created. C + O2 2 S + 3 O2 2 N2 + 5 O2 CO2 (carbon dioxide) 2 SO3 (sulfur trioxide) 2 N2O5 (nitrogen pentoxide)
Nonmetal oxides react with water and form acids. For this reason, nonmetal oxides are referred to as acid anhydrites. "Anhydrite" means "without water". CO2 + SO3 + N2O5 + H2O H 2O H2 O H2CO3 (carbonic acid) H2SO4 (sulfuric acid) 2 HNO3 (nitric acid)
The acid solutions conduct electricity because the acid has dissociated into ions. In aqeuous solution it dissociates into positive hydrogen ions and the negative acid part associated with the acid. Acid H2CO3 H2SO4 HNO3 Positive hydrogen ion (cation) 2 H+ 2 H+ H+ Negative acid part (anion) + CO3- + SO4- + NO3-
Apart from the already mentioned "oxygen acids", viz such acids that contain oxygen in the anion, there is another type of acids. It occurs by direct bonding between certain elements and hydrogen and releases also hydrogen ions in aqueous solution H2 + Cl2 H2 + S 2 HCl ( hydrochloric acid) H2S (hydrogen sulfide)
Dissociation of the acid: Acid HCL H2 S Positive hydrogen ion (cation) H+ 2 H+ Negative acid part (anion) + Cl+ S- -
According to the characteristic feature of releasing hydrogen ions, an acid is defined as those compounds that give rise to hydrogen ions in aqueous solution.
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Alkaline solutions (alkalis, bases) The oxides of metals, dissolved in water, form bases. Metals are, for instance, the elements sodium, potassium, calcium, magnesium. When a metal unites with oxygen, a metal oxide is created. 2 Na2O sodium oxide 4 Na + O2 4 K + O2 2 K2O potassium oxide 2 CaO calcium oxide 2 Ca + O2 Because of their ability to react with water and form bases, metal oxides are referred to as base anhydrites. Reaction of metal oxides with water: 2 NaOH sodium hydroxide caustic soda lye) Na2O + H2O K2 O + H 2 O 2 KOH potassium hydroxide (caustic potash sol.) CaO + H2O Ca(OH)2 calcium hydroxide (lime hydrate) Aqueous solutions of bases conduct electricity because the base has dissociated into ions. In aqueous solution it has dissociated into the positive metal ion and the negative hydroxide ion OH-. NaOH KOH Ca(OH)2 Na+ K+ Ca++ + + + OHOH2 OH-
In analogy to the acids, there is another type of alkaline solutions. It is formed by dissolution of various chemical compounds, e.g. ammonia (NH3) or hydrazine (N2H4) in water, and releases also hydroxide ions. NH3 + H2O N2H4 + H2O Dissociation of the base: NH4OH N2H5OH NH4+ + N2H5+ + OHOHNH4OH N2H5OH ammonium hydroxide hydrazine hydroxide
According to the characteristic feature of hydroxide ion release, a base is defined as those compounds that give rise to hydroxide ions in aqueous solutions: Neutralization When an acid reacts with a base in aqueous solution, the hydrogen ions of the acid react with the hydroxide ions of the base to produce water which is dissociated only to an extraordinarily small extent. The reaction between the anion of the acid and the cation of the base gives rise to a salt. Since the acid constituents of the acid (hydrogen ions) and the alkaline constituents of the base (hydroxide ions) neutralize their effect mutually, the solution is neutral when equivalent (chemically equivalent) quantities of acid and base are available in the solution. + OH H2O H+ + H Cl + Na+OH H2O + Na+Cl+ Ca++(OH)2 2 H2O + Ca++SO4-H2+SO4Salts Salts are the third group of electrolytes. Salts consist of a cation and an acid part as anion. In principle, it is thus necessary in any case that an acid is involved in the formation of salts. The cation may either be contributed by a base or directly by a metal.
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When a metal is being dissolved directly in acid, hydrogen is released during the process of formation of salts. The designation of the salts is based on the name of the acid part. Acid HCl H2SO4 HNO3 H2CO3 Designation of the salts chlorides sulfates nitrates carbonates
Some examples for the formation of salts are: Acid Base or metal Salt HCl + NaOH NaCl + H2O 2 HCl + Ca(OH)2 CaCl2 + 2 H2O 2 HCl + Fe FeCl2 + H2 H2SO4 + 2 NaOH Na2SO4 + 2 H2O H2SO4 + Mg MgSO4 + H2 HNO3 + KOH KNO3 + H2O H2CO3 + Ca(OH)2 CaCO3 + 2 H2O
Designation sodium chloride calcium chloride ferrous chloride sodium sulfate magnesium sulfate potassium nitrate calcium carbonate
When salts are dissolved in water, the water conducts electricity because the salts are dissociated in positive ions (cations) and negative acid parts (anions). Salt NaCl CaCl2 Na2SO4 MgSO4 KNO3 CaCO3 pH-value The degree of alkalinity or acidity of a solution depends on the concentration of hydrogen ions (CH+) or hydroxide ions (COH-). Ion concentrations are expressed in mol/l. This interrelation is also referred to as ion product of water. A solution is neutral if equal quantities of hydrogen ions and hydroxide ions occur in a solution. Considering the interdependence of hydrogen ion and hydroxide ion concentrations, the product of which is constant, the hydroxide ion concentration is also given by stating the hydrogen ion concentration. The strength of an acid or base can be expressed by the H+ or OH- concentration. For practical reasons, the hydrogen ion concentration is stated not in negative decimal power mode or decimal figures but as hydrogen ion exponent. This value is referred to as "pH". Measurement of pH is almost exclusively made by methods with electrical pH measuring instruments. The following examples are to give a general idea measurement in the power plant: determination of the pH in neutralization of waste condensate polishing and FGD waste water; control of lime/limestone proportioning in the flue the pH; monitoring of cooling water for pH; monitoring of waste water for pH. means of physical/chemical of the significance of pH water from demineralization, gas desulfurization plant via Cation Na+ Ca++ 2 Na++ Mg++ K+ Ca++ + + + + + + Anion Cl2 ClSO4SO4NO3CO3--
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pH indicators pH indicators are organic compounds which show a different color, depending on the pH, i.e. the hydrogen ion concentration. The change of color occurs in a narrow pH range. Color may change from colorless to color (or vice versa) or from one color to another color. The most common indicators used in the power plant include phenolphtalein and the composite indicator Cooper. Another indicator is litmus. By means of litmus it is quite easy to determine whether we are dealing with an acid or with a base. Litmus is colored red by acids and blue by bases. Indicator Phenolphthalein Cooper indicator pH of change 8.2 4.3 acid solution colorless red color in alkaline solution red blue-green
For precise pH measurement, however, electrical instruments of suitable design are required. Measurement of conductivity For determination of the salt content of liquids, the method of conductivity measurement is used. It is a reliable method that is easy to handle to get an overview of the salt concentration. The applicability of industrial conductivity measurement is mainly limited to lowconcentration solutions of salts, acids or bases. In such solutions there is a linear interrelation between conductivity and concentration. Unambiguous results are obtained in the power plant where determination of salt content in boiler feedwater, condensate and steam is important. For operation of a steam power plant with condensation it is important to know whether undesired ingress of salts, acids or bases occurs which may cause damage to the steam boiler or form deposits on the turbine blades. Here, the total of ions is of interest which may result in an increase of conductivity in the steam/condensate cycle, no matter which type of ions are present. A List of impurities found in water, their effect and method of removal is tabulated below. Sr. Impurities Effect Method of removal No. 1 Turbidity or S.S. clog pipelines & equipment, Coagulation, Settling & can choke ion exchange filtrations. resin 2 Color Indication of organic Coagulation, Settling & by activated carbon filter. 3 Organic matter Can foul the ion exchange Coagulation, Settling, filtrations resin & super chlorination. 4 Iron Corrosion deposits Coagulation, Settling & filtrations. 5 pH High & low both pH can Ion exchange, addition of acid induce corrosion or alkali. 6 Hardness Scaling Ion exchange, lime soda. 7 Sodium High concentration Ion exchange through cation increases corrosion rate 8 Bicarbonates , Corrosion, foaming, Ion exchange, degasification. carbonate , & carryover. Hydroxide
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9 9 10 11 12 13
alkalinity Sulphate Chloride Nitrate Silica Carbon dioxide Oxygen
Scaling if associates with calcium Corrosion Normally not found in raw water Scaling & deposition Corrosion Corrosion
Ion exchange, Reverse osmosis. Ion exchange, Reverse osmosis. Ion exchange, Reverse osmosis. Ion exchange. Degasification, deaeration. deaeration chemicals , addition of
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Water Purification:
Mechanical methods of purification Removal of coarse-disperse substances (undissolved, visible particles) Treatment of raw water for cooling water purposes aims at removing coarse-disperse impurities and can be effected by mechanical purification methods. Removal of coarse impurities, which include floating, suspended and settling matter, is carried out in screen, strainer, settling and filter systems. For removal of very coarse floating or suspended matter (driftwood, branches, plants), which is exclusively contained in surface waters, coarse or fine screens or strainer systems (cage, belt, drum-type strainer systems) are used. For finer impurities, in general filter plants are used. The suspended particles are retained by the filter. Usually quartz rubble is used as filter material in water treatment technology. In the course of time every kind of filter clogs, and this the more rapidly, the heavier the filter bed is polluted with retained matter. When clogging, which is manifested by an increase of head loss, reaches an upper limit, the filter must be backwashed. As a criteria for backwashing, often a head loss of 0.5 bar is established. Backwashing is carried out in two stages: a) combined air-water flushing, with air and water at the same time, b) rinsing with clear water, until the backwashing water is clear. Backwashing is carried out from the bottom to the top. Sampling establishes whether part of the rubble is as well removed or not. Removal of colloid-disperse substances (undissolved, invisible particles) Not all constituents can be removed by filtering in rubble filters, e.g. the salts genuinely dissolved in water. Between the substances that can be filtered and the dissolved salts, there is another group of chemical compounds called colloids. Decisive for the designation of the constituents is their respective degree of dissolution in water, viz the diameter of the particles. By means of flocculation it is possible to transform the colloidal matter that can only be filtered with difficulty, into filterable matter. The essence of the flocculation process is that flocculating chemicals are added to the water, which cause the colloidal matter to agglomerate and thus to become filterable. The overall process of flocculation can be broken down into three partial processes which occur consecutively: 1. Neutralization of similar electrical charges of the particles. The similarity of charges causes repulsion forces between the particles which prevent agglomeration of the particles. By neutralizing the similarity, the repulsion forces are reduced. 2. Formation of microflakes. 3. Formation of macroflakes by agglomeration of the microflakes. The flocculation method is used for removal of colloidal particles, phosphate and biological impurities from the water. Ferric chloride and aluminum sulfate are used as flocculating agents, e.g. The hydrochloric acid arising from this process is neutralized by the carbonate hardness. In the most simple form of the process, ferric chloride is added in the water-bearing pipe. The flow of water ensures a good mixture with the water. After a
FeCl3 + 3 H2 O Fe( OH ) 3 + 3 HCl
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reaction section, the arising flakes are separated from the water by means of rubble filters. Removal of disperse undissolved substances Mechanical filter methods are also used in the field of condensate treatment. Since the particles to be removed are much smaller than in case of raw water treatment, apart from pressure filters with activated carbon or hydroanthracite as filter bed, also cartridge filter with or without precoating are used. As is the case with rubble filters, also cartridge filters can be backwashed; however, in case of the cartridge filters backwashing is carried out only by means of water washing. Figure below gives a schematic diagram of an alluvial filter system.
Schematic diagram of an alluvial filter system Upon backwashing, the actual filter layer, i.e. the precoating, is applied on the filter elements. The precoating, prepared in an open tank as a 3% suspension of the filter aid, must be applied in an equal thickness all over the filter elements. By means of a recirculation pump, the flow rate of which is adjusted to the filter capacity, this suspension is recirculated through the filter until the water is clear. Then the filter operation is started without interrupting the flow. The medium to be treated enters the tank in the center, flows through the filter element and leaves the filter through a collecting line. Magnetic filters are a special type of filters, which remove magnetite (Fe3O4) from
the condensate by means of an electromagnet. The medium to be purified flows through the filter from the bottom to the top. The magnetic field of the outer coils magnetizes the spherical elements accommodated by the inner filter vessel which thus are able to retain the iron particles dissolved in the medium flowing through the filter vessel. With the electromagnet switched off, the magnetite can be removed from the filter by means of backwashing.
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Chemical methods (removal of genuinely dissolved matter <10-7 cm) These water treatment methods are mainly based on chemical reactions. From these reactions solids arise which must then be separated from the water by means of a mechanical purification method. Flocculation, for instance, is the combination of a chemical reaction with a mechanical purification method. Also decarbonization by means of calcium hydroxide requires mechanical separation of the reaction products. The decarbonization processes using acid or ion exchangers and the demineralization of water rank among the group of water treatment methods which do only include chemical reactions and which do not require mechanical separation, or in case of which mechanical separation is not possible. Decarbonization Decarbonization is a chemical process, in the course of which the HCO3 ions are partially or totally removed from the water. The types of water in question contain mainly the chemical compounds Ca(HCO3)2 and Mg(HCO3)2, which together are also referred to as carbonate hardness. In power plant operation, decarbonization is practiced for conditioning of cooling tower make-up water and in some cases as preliminary stage to demineralization. It is necessary in order to prevent the formation of deposits at hot heat exchanger surfaces, e.g. in the condenser. Decarbonization by means of calcium hydroxide Carbonate hardness and free carbonic acid are removed by adding calcium hydroxide to the water. In proportion to the precipitated carbonate hardness, the mineral content of the decarbonized water is reduced. Decarbonization by means of lime is thus a partial demineralization.
Ca ( HCO3 ) 2 + Ca ( OH ) 2 2 CaCO3 + 2 H2 O
solid
Mg ( HCO3 ) 2 + 2 Ca ( OH ) 2 2 CaCO3 + Mg ( OH ) 2 + 2 H2 O
solid
CO2 + Ca ( OH ) 2 CaCO3 + H2 O
solid The CaCO3 arising from the chemical reaction is a hardly soluble substance which precipitates as a solid. Depending on the separation of the solid from the water, a distinction is made between fast decarbonization methods and slow decarbonization methods. Fast decarbonization The precipitated calcium carbonate is very easily crystallizing. Use is made of this property in the operation of fast reactors by carrying out the chemical reaction within a fluidized sand layer. In this case, the insoluble product (CaCO3) arising from the reaction between carbonate hardness and calcium hydroxide crystallizes at the sand particles. The water flows from the bottom to the top through the decarbonization reactor which is filled with sand. Here, it is necessary that the upward flow velocity of the water is sufficiently high as to keep the sand in suspension. Depending on the design type a distinction is made between cone-shaped and cylinder-shaped reactors. The outlet cross-section must be dimensioned such that no sand can be removed from the reactor together with the water. For a good mixture of lime milk - this is a
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slurry of solid Ca(OH)2 - with the water to be decarbonized, a whirl chamber is arranged at the inlet of the reactors, which is entered by the water in tangential direction. Upon completion of the chemical reaction, the water leaves the reactor more or less clear and is led through rubble filters for a possibly required secondary purification . Slow decarbonization In case of the slow decarbonization, the CaCO3 arises as sludge. This method is frequently used in combination with flocculation as indicated by the figure below. This process is thus also referred to as flocculation-precipitation method. The chemical reaction and the clarification of the water are carried out in suspended matter contact system, the design of which may vary widely. Reaction and retention time of the water to be treated are of high importance for the efficiency of such a system.
Schematic representation of a flocculation decarbonization system The advantages of the fast decarbonization method, such as small reactor, reaction products arising in solid form, low water loss during removal of the reactor mass cannot be counted on in case of all waters, since waters with a high suspended matter content, exceedingly high magnesium hardness or high phosphate content exert a negative influence on the separation process in the reactor.
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Raw Water System at Vemagiri

The source of the raw water for the plant is river Godavari. The Raw water analysis is as below. Sr. Parameter Unit as CaCO3 Analysis result No. 1 Calcium mg/lit as CaCO3 78 2 Magnesium mg/lit as CaCO3 72 3 Sodium mg/lit as CaCO3 80 4 Potassium mg/lit as CaCO3 0 5 Total Cat ion mg/lit as CaCO3 230 6 Bicarbonate mg/lit as CaCO3 132 7 Carbonate mg/lit as CaCO3 24 8 Chloride mg/lit as CaCO3 60 9 Sulphate mg/lit as CaCO3 14 10 Nitrate mg/lit as CaCO3 0 11 Total anion mg/lit as CaCO3 212 12 Silica mg/lit as SiO2 25 13 Iron mg/lit as Fe 0.8 14 pH 8.5 to 9.0 15 T.D.S. Mg/lit as CaCO3 250 16 Turbidity NTU 1 to 200 17 Conductivity uS/cm Raw Water Pre-treatment:
Raw Water Clarification system at Vemagiri The function of the raw water pre-treatment system is to treat raw water available from river water intake system and supply the clarified water for various plant consumptive uses like makeup to the cooling water system, fire protection system, service water system (air-conditioning & ventilation system and miscellaneous
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services) and to supply the clarified water to the water treatment (DM) plant which in turn will meet the filtered water and DM water requirements of the plant. The pre-treatment plant consist of two clariflocculators one for producing clarified water to be used for CW make-up, fire protection, service water system (air conditioning & ventilation system and miscellaneous services) requirement and the other for producing clarified water to be fed to Water treatment Plant for producing DM water as power cycle make up. The other components of the system are separate clarified water storage tanks, chemical dosing system for individual clariflocculators, common sludge handling system with sludge thickener, centrifuge etc.
Raw water from raw water reservoir is pumped to the individual stilling chambers of the raw water clariflocculator and DM Plant clariflocculator by common 3 x 50% (2W+1S) raw water supply pumps for breaking the turbulence of the water. The raw water then flows by gravity into the flash mixers of the individual clariflocculators through Parshall flume of the respective system, for measurement of flow. Alum and lime are dosed in the flash mixers and/ or flocculation zone from where the water flows by gravity into the respective clariflocculators for removal of suspended impurities. Both the clariflocculators are of reactivated solid contact type and polyelectrolyte is dosed in the flocculating zone of the clariflocculator to augment the flocculation process. Clarified water from the raw water clariflocculator is stored in an above ground, clarified water storage tank the capacity of which is adequate to store six hours requirement of the system and also fire protection system water requirement as per Tariff Advisory Committee. The tank is divided into two compartments to facilitate cleaning and maintenance. Clarified water from the DM plant clariflocculator is stored in a separate, above ground, DM plant clarified water storage tank, adjoining the above clarified water storage tank. The capacity of this tank is adequate to store six hours requirement of system. Separate alum, lime and polyelectrolyte dosing systems are provided for respective clarification systems. Chlorine solution is dosed in the common discharge header of the raw water supply pumps for destroying microbiological contaminants if any. Dosing rate of coagulant, polyelectrolyte and chlorine is to be set manually as per the requirement. Make-up water for the circulating water system is supplied from the clarified water storage tank to the cooling tower basin by gravity through pipes. Motor operated
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make-up control valves are provided in the make up water line, which are controlled by the level controllers in the cooling tower basin. There are 2x100% service water pumps for supplying clarified water to service water overhead tank, HVAC make-up, and misc. services. Influent water to water treatment (DM) plant is supplied from the DM plant clarified water storage tank by two (1W + 1S) water treatment plant supply pumps. The service water pumps, water treatment plant supply pumps, and fire protection system pumps are located in a common clarified water pump house adjoining the clarified water storage tanks. The sludge from the raw water and DM water clariflocculators are collected in a common sludge pit and pumped by two (1W + 1S) sludge transfer pumps to the sludge treatment plant which includes one thickener and two (1W + 1S) centrifuges. Poly dosing arrangement is provided at the inlet of centrifuge for proper sludge dehydration. Suitable arrangement for disposal of sludge into a truck has to be made. The pre-treatment plant consists of following principal components: Three (3x50%) Raw water supply pumps Two stilling chambers (one each for raw water clariflocculator and DM Plant clariflocculator). Two flash Mixers with motor driven agitator (one each for Raw water clariflocculator and DM Plant clariflocculator) One reactivator solid contact type clariflocculator for Raw water clarification One reactivator solid contact type clariflocculator for DM Plant clarification One above ground clarified water storage tank in two compartments One above ground DM Plant clarified water storage tank Chlorine dosing system consisting two (2x50%) vacuum solution feed tonner mounted type chlorinators and two (2x100%) capacity booster pumps for dosing at the discharge header of the raw water supply pumps. Provision for dosing the liquid chlorine solution at the reservoir inlet has also been made. Alum dosing system consisting of two alum solution preparation cum dosing tanks and two (2x100%) dosing pumps each both for Raw water and DM water clariflocculator. Lime dosing system consisting of two solution preparation cum dosing tanks and two (2x100%) dosing pumps each both for Raw water and DM water clariflocculator. Polyelectrolyte solution dosing system consisting of one Polyelectrolyte solution dosing tanks and two (2x100%) dosing pumps each both for raw water and DM water clariflocculator. One common sludge pit Two (1W + 1S) sludge transfer pumps One thickener Two (1W + 1S) centrifuges Poly dosing system consisting of one dosing tanks and two (2x100%) dosing pumps for dosing at the inlet of centrifuge for proper sludge dehydration. Piping and valves, control and instrumentation and electrical items and accessories Pre-treatment system The Pre-treatment system has been designed based on raw water quality at Vemagiri plant and turbidity of treated water at the outlet of clariflocculator not exceeding 20 NTU. Stilling chamber is sized for two minutes retention time while flash mixers for oneminute retention of inlet raw water flow. For design purpose following indicative dosage rates has been used:
LARSEN & TOUBRO LIMITED TRAINING MANUAL 388.5 MW Combined Cycle Power Plant DOC No. Water Systems Page No. Dosage Rates 50 ppm 15 ppm 0.5 ppm 5 ppm
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Chemicals Alum Lime Polyelectrolyte Chlorine Solution
Hydraulic circuit is designed in such a way that the water from stilling chamber will flow to clariflocculator by gravity and clarified water will also flow by gravity to clarified water storage tank.
Demineralization
In steam power plant operation, the significance of feedwater treatment increases the higher the superheated steam temperature and the pressure of the steam generator are. In the high-pressure range, i.e. at pressures above 64 bar, steam generators must be operated with demineralized water. In case of once-through steam generators, all the water fed into the steam generator is transformed into steam. Salts still occurring in the water would form deposits at the tube walls and would thus cause a heat build-up. Types of ion exchangers Ion exchangers are insoluble resins which are used in the form of spherical particles. These are capable of taking up ions from solutions and giving off other ions to the solution in turn. The exchange can only be carried out between ions with charges of the same kind. Cation exchangers thus exchange only cations, anion exchangers only anions. This process takes place in a very short time during the contact of a solution with the ion exchanger material. A given volume of exchanger has a defined capacity. If this capacity is exhausted, a regeneration is carried out in order to return the exchanger into the desired state of being capable of performing the ion exchange. In practice, the ion exchange process is carried out in such a way that an aqueous solution is allowed to flow through the filter which is filled with the ion exchanger material, either from top to bottom or from bottom to top. In this process the ions of the solution are exchanged against the ions of the exchanger carrying the same electrical charge. This process is referred to as "loading" of the exchanger. In flow direction of the water, initially in any case the cation exchange is carried out:
Na + Cl + H + R Na + R + H + Cl
Na+ H+ R ion to be exchanged ion at the exchanger, being capable of performing the exchange resin
In the anion exchange stage, the acid arising from this process (HCl) is converted into water. Clion to be exchanged ion at the exchanger, capable of performing the exchange OHR resin The exchanger is loaded with the ions until the content of residual ions in the outflowing filtrate exceeds the still admissible value. This is called "inrush" in which case we say that the ion exchanger is exhausted. In order to return it to an operative state, it is to be activated again. This process is called regeneration.
H + Cl + OH R Cl R + H2 O
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As there are two types of ions, i.e. cations and anions, also a distinction is made between two types of exchangers: the cation exchanger and the anion exchanger. Depending on the tasks that an exchanger is designed to perform, in case of the cation exchanger we differentiate between weak-acid cation exchangers and strong-acid cation exchangers, and in case of the anion exchangers, between weak-base anion exchangers and strong-base anion exchangers. The difference between weak-acid and strong-acid or weak-base and strong-base exchangers is their respective active group which makes the exchange process possible. This results in different fields of applications of the exchanger types: weak-acid cation: strong-acid cation: weak-base anion: strong-base anion: only cations which are combined with HCO3 or CO3 ; all types of cations; only anions of the mineral acids (HCl, H2SO4, HNO3); all anions, CO2, SiO2.
2
exchange the calcium, magnesium and sodium ions combined with hydrocarbonate and carbonate against H+ ions. This process is a decarbonization by means of ion exchanger. The outflowing water thus still contains all minerals except the cations of the hydrocarbonates. Examples of weak-acid cation exchanger reactions:
H Ca ( HCO3 ) 2 + H R Ca = R + 2 H 2 O + 2CO2 H Mg( HCO3 ) 2 + H R Mg = R + 2 H 2 O + 2CO2
Weak-acid cation exchanger The weak-acid cation exchanger is usually regenerated by means of hydrochloric acid (HCl). The exchangeable ion is the H+ ion. The weak-acid cation exchanger is able to
R = Resin Since the mineral content of the treated water is reduced by the cations from the hydrocarbonates, this process step is also called partial demineralization. This process releases carbon dioxide which must be removed in order to avoid corrosion. For its regeneration, the weak-acid cation exchanger requires a quantity of acid, the effect of which is theoretically exactly equivalent to the amount of absorbed ions. The actual regenerant demand is given in percent of the theoretically required quantity. In case of the weak-acid cation exchanger, 100% to 110% of the theoretical quantity of HCl are required for regeneration. Strong-acid cation exchanger The strong-acid cation exchanger is regenerated by means of hydrochloric acid (HCl). The exchangeable ion is the H+ ion. The strong-acid cation exchanger is able to
exchange all cations against H+ ions, thus forming the free acids of the respective anion. Examples of strong-acid cation exchanger reactions:
KCl + H R K R + H 2 O
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MgCl 2 + Na 2 SO4 +
R K R + H2O Na R Na R + H 2 SO4 H Ca ( HCO3 ) 2 + H R Ca = R + 2 H 2 O + 2CO2

H H H H
R=Resin The regenerant demand for the regeneration process is 150% to 250% of the theoretical quantity of HCl (in case of parallel flow regeneration), i.e. about 1.5 to 2.5 times the theoretically required quantity. The lower consumption of regenerant is possible only by means of a combined regeneration process, i.e. the excess quantity of the regenerant of the strong-acid cation exchanger is used for regeneration of the weak-acid cation exchanger. Weak-base anion exchanger The weak-alkaline anion exchanger is regenerated by means of sodium hydroxide (NaOH). The exchangeable ion is the OH- ion. The weak-alkaline anion exchanger is only capable of exchanging free mineral acids, HCl, H2SO4, HNO3 , forming H2O. In other words: This process is the neutralization of an acid (as a result of the cation exchange stage!) by means of an alkaline solution (exchangeable OH- combined with
the resin). This process produces salt (anion remains absorbed by the exchanger) and water. Examples of weak-alkaline anion exchanger reactions:
HCl + OH R Cl R + H 2 O HNO3 + OH R NO3 R + H 2 O OH H 2 SO4 + OH R SO4 = R + 2 H 2 O

R = Resin The actual regenerant demand is 125% to 150% of the theoretically required quantity of NaOH. Strong-base anion exchanger The strong-alkaline anion exchanger is regenerated by means of sodium hydroxide (NaOH). The exchangeable ion is the OH- ion. The strong-alkaline anion exchanger is
capable of exchanging free mineral acids, salts, carbon dioxide and silicic acid against OH- ions. Examples of strong-alkaline anion exchanger reactions:
HCl + OH R Cl R + H 2 O NaCl + OH R Cl R + NaOH CO2 + OH R HCO3 R SiO2 + OH R HSiO3 R

R = Resin The actual regenerant demand is 250% to 400% of the theoretically required quantity of NaOH (in case of parallel flow regeneration). Also in this case it is possible to reduce the regenerant consumption by means of using a combined regeneration.
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Mixed bed exchangers A mixed bed exchanger contains a mixture of strong-acid cation and strong-alkaline anion exchanger material, which is present in a mixed state during the exchange process. The adjacent cation and anion exchanger resin particles act like a very long chain of cation and anion exchangers connected in series. This is the basis of the good demineralization effect of the mixed bed exchanger. The main field of application of the mixed bed exchanger is its use as safety filter, which is arranged as the final filter stage in a demineralization plant. It is to absorb the very small amounts of cations, anions and silicic acid which still emerge from the strong-alkaline exchanger. By using a mixed bed filter, the conductivity of the demineralized water is reduced to values below 0.1 S/cm (0.01 mS/m). The residual content of silicic acid (SiO2) is below 0.01 mg/l. Reverse osmosis (RO) For untreated water with higher salt content a preliminary desalination may be made by means of reverse osmosis. Residual demineralization to reach boiler feedwater quality is made by means of ion exchangers. Osmosis is the separation of substances by means of semipermeable diaphragms which allow the molecules of the solvent to pass through, while retaining molecules or ions of the dissolved substances to a large extent. The pressure at which equilibrium is reached is referred to as osmotic pressure. When a pressure is put on the higher concentration side, which exceeds the osmotic pressure, the transition of the solvent occurs in reverse direction. This process is referred to as "reverse osmosis". Compared to conventional demineralization methods, viz ion exchange and electrodialysis, reverse osmosis offers the advantage that more than 90 percent of salts can be removed in a one-step process. Figure below shows a comparison of the waste water salt load of different demineralization systems, in relation to one cubic meter of clean water. A disadvantage of the reverse osmosis method is the required preliminary treatment of the untreated water to ensure that the diaphragms are not being blocked by interfering substances. This includes a good separation of solid matter, including colloidal impurities, prevention of fouling by chlorination and of scaling by proportioning of acid. Waste water salt load obtained by different demineralization systems
a Parallel-flow ion exchanger b Counter-flow ion exchanger c Reverse Osmosis and continuous ion exchanger
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Configuration of demineralization plants Figure below shows some examples of possible configurations of DM plants.
Examples of the combination of exchanger stages When a strong-acid cation exchanger is regenerated by means of sodium chloride (NaCl), it will, during the exchange process, work as a softening filter.
Demineralization Plant at Vemagiri

The function of the DM Plant is to provide the demineralised water for the plant DM water requirement. The treatment will be done in two stages filtration and demineralization. The filtered water serves as an influent to the DM Plant and also used as plant potable water. The demineralized water from DM Plant is stored in DM water storage tank and used for HRSG feed cycle make-up in the condenser, make-up in gas turbine compressor water wash skids, CCW make-up; initial filling of HRSG and boiler feed chemical solution preparation. It is also used in hydrotesting, chemical cleaning; displacement flushes after cleaning and wet storage of HRSG during commissioning. The system boundary for Demineralization (DM) plant starts from DM Plant clarified water storage tank and ends at the DM water storage tank (inlet) including all plant and equipment, acid /alkali storage tank and neutralization pit outside the building.
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Filtration System
The clarified water from the DM Plant clarified water storage tank is pumped by 2 x 100% (1W+1S) capacity WTP supply pumps to 2 x 100% Pressure Sand Filters (PSF). Sodium hypochlorite solution is dosed in the DM Plant clarified water storage tank to destroy organic and microbiological contaminants if any. Alum solution is also dosed at the WTP supply pump discharge for online coagulation and subsequent removal of suspended particulate matter in the PSF. Sodium hypochlorite dosing system consists of a storage-cum-dosing tank, 2x100% dosing pumps and 2 x 100% sodium hypochlorite unloading pumps with the associated piping and accessories. Alum dosing system consists of 2x100% dosing tank and 2x100% dosing pumps with the associated piping and accessories. The filtered water from the PSF is used as an influent to the DM Plant. A part of the filtered water tapped from the outlet line of PSF is used for back washing of PSF and stored in the overhead filter backwash water storage tank. Another part of the filtered water is used as potable water and stored in the overhead potable water storage tank. Both the tanks are located on the top of water treatment Plant building. 2 x 100% capacity air blowers are provided for air scouring of pressure sand filters. DM System The DM plant consists of 2x50% streams. Each stream will consists of Activated Carbon Filter, Strong Acid Cation exchanger, Degasser system common to both streams (with one degassed water storage tank, 2x100% degasser blowers and 3x50% (2W+1S) degasser pumps), Strong Base Anion exchanger, Mixed Bed exchanger.
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The filtered water passes through 2 x 50% Activated Carbon filters (ACF) for the removal of organic impurities and traces of chlorine, if present. The water is then led through 2 x 50% Strong Acid Cation (SAC) for removal of cations. The decationised water is then passed through 1 x 100% degasser tower provided with 2 x 100% degasser air blowers for the removal of carbon di-oxide and the degassed water is stored in 1 x 100% degassed water storage tank. The degasser tower, blowers and storage tank are common for both the streams. The degassed water is then pumped by three 3 x 50% (2W+1S) degassed water pumps (common to both the streams) through two 2 x 50% Strong Base Anion column (SBA) for the removal of anions and subsequently SBA outlet water is passed through 2 x 50% capacity Mixed Bed (MB) exchangers for final polishing of DM water and the polished demineralised water is then led to 2 x 50% DM water storage tank. 2 x 100% capacity air blowers are provided for air scouring of ACF. Similarly 2 x 100% capacity air blowers are provided for resin remixing in MB Exchanger. Two 2 x 100% regeneration water pumps supply DM water from DM water storage tank to acid/alkali ejectors for regeneration of SBA & MB exchanger units. Degassed water from the degassed water pump outlet will be used for regeneration of cation bed. 30% HCL and 48% NaOH will be used as regenerants. The regeneration facilities consist of 2 Nos. bulk acid storage tanks, 2 Nos. bulk alkali storage tank, acid and alkali measuring tanks, unloading hose arrangements and 2 x100% unloading pumps for acid & alkali, ejectors for acid & alkali injection etc. Regeneration effluent from all the units, waste water from DM Plant and filters are to be led to a common neutralization pit. The plant is designed in such a way that the regenerant effluent from cation, anion and mixed bed units neutralise each other. Facilities for addition of acid/alkali to neutralize the effluent are also provided. The neutralizing pit has two compartments and the active volume of each pit is at least 120% of the total waste arising from the regeneration of one complete DM Plant stream and filter back wash water. The neutralized effluent then is to be pumped to the guard pond by means of 2 x 100% neutralized effluent disposal pumps. Morpholine is dosed by 2x100% Morpholine dosing pumps at the discharge header of DM water transfer pumps and HRSG fill pump to correct the pH of the DM water.
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The design of each stream of DM Plant is such that in the event of one of the streams not working / out for maintenance, the other stream shall be capable of catering to twice the load with two regenerations per day. The DM plant will consists of the following components: Two (2x100%) horizontal centrifugal type water treatment plant supply pumps One Sodium hypochlorite storage tank Two (2x100%) sodium hypochlorite dosing pumps Two (2x100%) sodium hypochlorite unloading pumps Two (2x100%) alum dosing tanks with agitator Two (2x100%) alum dosing pumps Two (2x100%) Pressure sand filters (PSF) One O/H filter backwash water storage tank One O/H potable water storage tank Two (2x100%) Pressure sand filter air blowers Two (2x50%) Activated Carbon filters (ACF) Two (2x50%) Strong Acid Cation exchanger (SAC) One Degasser tower Two (2x 100%) Degasser air blowers One Degassed water tank Three (3x 50%) Degassed water pumps (2W+1S) Two (2x50%) Strong Base Anion exchanger (SBA) Two (2x50%) Mixed Bed exchanger (MB) Two (2x100%) Mixed Bed exchanger air blower Two (2x100%) air blower for ACF Two (2x50%) DM water storage tank One Morpholine dosing skid comprising one tank and 2 x100% Morpholine dosing pumps Two (2x100%) regeneration water pumps Two (2x100%) acid unloading pumps Two (2x100%) alkali unloading pumps Two bulk acid storage tanks Two bulk alkali storage tanks Two acid measuring tanks (one for cation and one for mixed bed) Two alkali measuring tanks (one for anion and one for mixed bed) One alkali measuring tank for neutralization One acid measuring tank for neutralization Two (2x100%) Neutralized effluent disposal pumps One Neutralization pit (with two compartments) Piping and valves, Control and instrumentation, Electrical items and accessories The net capacity of DM Plant has been designed based on 3% of HRSG MCR as make up, DM water required for evaporative cooling make up plus 5% margin and DM water required for CCW system make up, dilution water for preparation of chemical and chemical dosing and requirement of regeneration water for ion exchange beds per manufacturer recommendation. Treated water quality at Vemagiri: At the outlet of Mixed Bed, the treated water quality would be as under: Conductivity pH Sodium Not greater than 0.1 Micro -mho / Cm at 25oC. 7.0 +_0.2 at 25oC. Shall not be greater than 0.05 ppm
LARSEN & TOUBRO LIMITED TRAINING MANUAL 388.5 MW Combined Cycle Power Plant DOC No. Water Systems Page No. Nil Not detectable as per ASTM methods Not detectable as per ASTM methods Not detectable as per ASTM method
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Total Organics Iron as Fe Free CO2 ppm as CO2 Total Hardness Total solids at outlet
Shall not be greater than 0.15 ppm in which silica shall not exceed 0.02 ppm
Operation & Control Philosophy The control philosophy of DM plant is such that the operation of the plant can be monitored and controlled through a microprocessor based programmable logic controller (PLC). The PLC is provided with a PC based programmer station for performing software changes. Taking the equipment into service and initiation of back washing of filters and regeneration of all the exchangers will be done manually from the control panel and balance operation will be carried out sequentially by the PLC. However, manual override facility for all operations has been provided. Once a filter/exchanger has been backwashed/ regenerated, it will not be put back into service automatically, but operator will have to do manually through a selector switch. On exhaustion of unit, the particular filter/exchanger will be completely isolated from the system automatically and an alarm status is displayed on the CRT screen. Complete stream will be automatically isolated from the service in case any of the following takes place and an alarm displayed on the CRT. On reaching high differential conductivity of effluent or on exceeding the totalized flow of de-cationised water through cation exchanger, whichever occurs first. On reaching higher conductivity of effluent at outlet of anion exchanger or on exceeding the totalised flow of de-anionised water through anion exchanger, whichever occurs first. On reaching higher conductivity of effluent at outlet of mixed bed exchanger or on exceeding the totalised flow of deionised water through MB unit or on reaching high silica content of effluent at MB outlet, whichever occurs first. Pressure sand filter and Activated Carbon Filter will be back washed at the time of regeneration of a stream or after every 24-hrs interval. The operator should initiate operation of regeneration/rinsing of each exchanger unit and after that the change from one step of the sequence to the next will be automatic. Auto-Manual operation is possible for degassed water pumps, degasser blowers, MB blowers and regeneration pumps. Auto/ Manual, selection can be done from the PLC Workstation. Each pumps/blowers are provided with one stop push button (PB) at field (near to drive), which is lockable in stop position. This PB will be treated as Emergency Stop and will trip the drive whenever pressed. Local start for each pump is directed through PLC. Although the basic operation of DM plant is semi-automatic in nature, some of the operations like unloading & transfer of acid and alkali are manual while the transfer of acid & alkali from the measuring tanks to the each exchanger units is automatic. The neutralization and transfer of regeneration effluent will be done manually. Following plant instrumentation have been provided:
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Inlet and outlet pressure indicators for vessels and discharge pressure indicators for various pumps. Inlet (rate of) flow indicators and outlet flow totalizers for exchanger units. Flow switches at filter outlet. Conductivity comparator at cation outlet. Individual outlet pH recorder-indicators, conductivity recorder-indicators for anion & MB units. Outlet silica analyser cum recorder common for both streams and common for both anion and MB units with multipoint recorder. Density indicators for regenerant chemical solutions. Level indicators and level switches with protection interlocks for filtered water storage tank, degassed water storage tank and DM water storage tank and associated pumps.
Annunciation for abnormal conditions like conductivity, pH and silica levels, high flow through filters and ion exchange units, high and low levels in the chemical tanks, filtered water tank, degassed water tank, DM water storage tanks and neutralization pit are provided in the control panel. The critical parameters such as pH at MB outlet, conductivity at MB outlet, Silica at MB outlet, DM tank level can be monitored in the main plant DCS CRT through serial interface with PLC. Each DM water storage tank has one number on/off type inlet valve, this valve closes when the level in the DM storage tank reaches high high and opens when the level reaches low. The DM water storage tank has also been provided with necessary redundant very low level (low-low) interlocks for DM water pumps.
Water distribution
The water is distributed within the power plant site by the service water system. The service water system includes the necessary pumps, valves and piping to deliver the water from the storage basin to the water demineralization plant, the fire-fighting piping system, the cooling water systems and all other water consumers in the plant.
Potable water and Service water system at Vemagiri Plant

Potable Water System: The function of Potable water system is to supply drinking water (of filtered water quality) to various facilities and buildings of the plant to cater to the need of the operating personnel. The Potable water system at Vemagiri consists of 2x100% horizontal potable water supply pumps taking suction from a dedicated filtered water storage tank (located atop the water treatment plant building). The potable water supply pumps convey the potable water to the potable water storage tanks located on suitable elevated structures on the respective buildings. From these overhead tanks potable water is circulated to individual Potable water distribution network within plant. At each drinking water point, a treatment unit such as aqua guard (or equivalent) and a water cooler have been provided.
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The plant potable water pumps are located in the water treatment plant building and derive power from the WT Plant MCC. The potable water system is sized based on the total number of personnel required for the plant and considering 45 litres of water per person per day. Potable Water Pumps: The potable water pumps can be started or stopped from the DCS. Auto-Manual operation is possible for each pump. Auto/ Manual, selection can be done from the DCS. Manual start/stop operation of each pump is possible from DCS. Each drive is provided with one stop push button (PB) at field (near to drive), which is lockable in stop position. This PB would be treated as Emergency Stop and will trip the drive whenever this PB is activated. The pump is to be operated by the operator for a pre defined period in a day. In addition to above, following interlocks & protections have been provided: Filtered water storage tank level not low will be used as start permissive for the potable water pumps. Filtered water storage tank outlet isolation valve locked open condition Low level signal from operating filtered water storage tank Auto start of pumps from low level switch in the potable water over head tank or low potable water discharge header pressure. Further, one discharge pressure indicator for each pump has been provided for indication purpose Service Water System: The function of the service water system is to supply the service water to the different consumption points in the plant building, including makeup to the airconditioning & ventilation system and other miscellaneous services.
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The Service water system at Vemagiri consisting of 2x100% horizontal service water pumps taking suction from clarified water storage tank and the service water is pumped to the service water overhead tank, of eight (8) hours storage capacity. The tank is located at a suitable elevation. The distribution of water to all the consumption points is by gravity, which also caters to the make up for air conditioning and ventilation requirements. The service water pumps are housed in the clarified water pump house. Hose points are provided as required for cleaning floors of various buildings. For cleaning purpose, quantity of water required at each hose point has been considered as 10 gal/min (2.27 m3 /hr). The service water pump capacity has been calculated considering 3 hoses in operation simultaneously at a given point of time the and make up water requirement for the Air Conditioning and ventilation system. Service Water Pumps The service water pumps can be started or stopped from the DCS. Auto-Manual operation is possible for each pump. Auto/ Manual, selection can be done from the DCS. Manual start/stop operation of each pump is possible from DCS. Each drive is provided with one stop push button (PB) at field (near to drive), which is lockable in stop position. This PB would be treated as Emergency Stop and will trip the drive whenever this PB is activated. In addition to above, following interlocks & protections have been provided: Level transmitter signal in clarified water storage tank will be used for generation of alarm & start permissive of pumps in DCS. Low low level signal from clarified water storage tank for tripping of pumps. Auto start of standby pump on low level in the Service Water Overhead Tank. Further, one discharge pressure indicator for each pump has been provided for indication purpose: A main shut-off or isolation valve is provided within the building at the entry point of all potable and service water supply piping.
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Cooling Water System (CW)

There is a variety of power plant parts which need to be supplied with cooling water, e.g. bearings at different types of equipment and coolers for air and oil. The most extensive cooling requirements arise from condensation of the steam in the turbine condenser. The waste heat arising from condensation is to be removed by a coolant. There are different process types to achieve this goal. Atmospheric air is also used as coolant for the condensation process because the required large volumes of cooling water are not always available in unlimited quantities due to the size of the condensing turbines and due to the growing number of power plants in limited areas. Different types of cooling water systems are possible. We will discuss the two main types, direct cooling and indirect cooling. In case of the direct cooling water system, water is taken from the water source (normally a river), sent through the turbine condenser, and returned into the river as indicated in the figure below.
live steam
turbine generator
steam generator condenser cooling water
condensate river
Direct cooling system In the indirect cooling water system, the water itself is cooled in a cooling tower before being returned into the river as shown in the figure below. A bypass of the cooling tower is generally provided.
live steam cooling tower air
turbine generator
steam generator
air
condenser
cooling water
condensate river
Indirect cooling system
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Auxiliary cooling water system (ACW) The auxiliary cooling water system uses circulating water to transfer heat removed by various plant equipment heat exchangers into the main auxiliary cooling water heat exchanger where the collected heat is transferred to the main cooling system flow. Some examples of the various equipment giving off waste heat: electric drives, generators (ultra-pure water, hydrogen), hydraulic systems (oil coolers), sampling coolers, gland coolers, air-conditioning systems, and emergency diesel generators. Cooling Towers Function and types of cooling towers For closed-circuit cooling, wet-type cooling towers use cooling water as cooling agent. The cooling water is recirculated by means of cooling-water pumps in a circuit between condenser and cooling tower. In case of the dry-type cooling tower, air is used as cooling agent, which - instead of the cooling water - flows through the cooling tower. Wet-type cooling tower In the cooling-water circuit, evaporation loss and water discharge loss are to be compensated by make-up water. The wet-type cooling tower with natural draught includes a suitably high chimney to generate the draught. It is also referred to as natural draught cooling tower. Figure below shows a natural draught cooling tower.
water distributing pipes
drift eliminator
trickling trays spray nozzles
air inlet openings
water basin
Natural draught cooling tower Distribution and spraying of the supplied water is effected by a system of gutters or pipe manifolds. They are arranged in the lower part of the cooling tower chimney in
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such a way that the hot return-circuit water is distributed over the entire surface of the cooling tower. The close contact of the cold air with the hot water (convection) causes a heat exchange between water and air. The simultaneous evaporation of water cools down the trickling cooling water further by removing the evaporation heat. The efficiency of a cooling tower depends decisively on the prerequisite that the cooling water is equally distributed as a fine spray all over the entire cross-sectional area of the cooling tower. Moreover, it is necessary that the air is permitted to flow equally distributed over the entire surface area of the cooling tower from the bottom to the top. The supporting structure of the cooling towers is made of timber, steel or reinforced concrete. The shell of the chimney consists of timber or reinforced concrete; formerly also asbestos cement was used for construction. A chimney covered by reinforced concrete has a longer lifetime than a timbercovered one, also the maintenance costs are lower, but construction costs are considerably higher. In case of large, modern cooling towers, the cover is made of reinforced concrete with a hyperbolic and divergent shape. The cooling tower fill consists of timber or synthetic material. Timber has to be treated with a special impregnation to render it weather-resistant. The treatment has to be repeated from time to time. Dry-type cooling tower Dry cooling towers are gaining more and more importance with regard to the required make-up water in case of the wet-type cooling towers, and with regard to the limitations to heating of rivers in case of open-circuit cooling. In contrast to the wet cooling tower, the dry cooling tower neither entails any water loss nor produces any water vapors. Spray loss is also avoided, hence there are no harmful consequences, such as slipperiness of roads in winter. However, condenser pressure and thus vacuum are more unfavorable compared to the wet-type cooling tower. Whereas in case of the wet-type cooling tower cooling is effected by the air via the intermediate agent cooling water, in case of dry cooling the intermediate agent cooling water circulating in open circuit is omitted. The air is directly admitted to the steam cooling surfaces arranged in the area of the air intake. In this case, however, three to four times the volume of air is required, compared to the natural draught cooling tower. Hence, dry cooling towers are considerable larger than natural draught cooling towers. There are three variants of the dry cooling process. In case of the direct process as shown in the figure below, the exhaust steam of the condensing turbine (1) flows into an air-cooled condenser (2) adjoined to the turbine house, which is supplied with cooling air by means of fans. In order to keep the energy demand of the fan as low as possible, the cross-section of the pipes is designed in an elliptical shape, with the effect that the pressure loss at the tube bundles is low. In case of ambient air temperatures higher than 20C, the cooling air can be moistened additionally, prior to entering into the heat-exchanger elements. Thus, an additional evaporative cooling effect is achieved. In case of large power plant units, however, pipes with large cross-sections are necessary between the exhaust flange of the turbine and the air condenser.
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1 condensing turbine 2 dry cooling tower with pressing ventilator 3 condensate pump
Closed-circuit cooling with dry cooling tower (direct process) The indirect process again works with water as intermediate agent, which, however, does not evaporate. The water circulates within the cooling tower in a closed piping and cooling system and can not flow freely and irrigate as in case of the wet-type cooling tower. In the indirect process with direct-contact condenser as shown in the Figure below, the exhaust steam of the condensing turbine (1) is condensed in the direct-contact condenser (2).
1 condensing turbine 2 barometric condenser 3 condensate pump 4 cooling water pump 5 dry-type natural draught cooling tower
Closed-circuit cooling with dry-type cooling tower and direct-contact condenser (indirect process) Mechanical-draught cooling tower The quality of a cooling tower is judged by the attained cooling water temperature. The lower air temperature and humidity are, the lower is the attained cooling water temperature. Because of this a better cooling effect can be obtained with cold and dry air than with warm and damp air. In the mechanical-draught cooling tower, ventilation is carried out by means of ventilators. Therefore, in comparison with natural draught cooling towers, mechanical-draught cooling towers with a sucking ventilator have only a short, constricted chimney which acts as diffuser, as shown in Figure below.
1 ventilator 2 tower shell 3 shaft 4 drift eliminator
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5 water distribution 6 cooling tower fill 7 drive shaft, arranged vertically 8 dry motor hall 9 driving system with motor and variable-speed gear
Mechanical-draught cooling tower with a sucking ventilator There are also mechanical-draught cooling towers with pressing ventilators of a cellular design. Depending on weather and load conditions, the ventilators of the individual cells can be switched on or off. Thus it is possible to control the cooling water temperature. The advantage of mechanical draught coolers in comparison with natural draught cooling towers is the lower space requirement. Moreover, it is possible to achieve lower cooling water temperatures with the mechanical-draught cooling tower.
CW System at Vemagiri
The function of the circulating water (CW) system is to dissipate the thermal load of steam turbine by providing a continuous supply of cooling water to the main condenser, vacuum pump coolers, motive water requirement for chlorination system and for the ACW pumps to meet the requirement of ACW Heat exchanger open circuit. A re-circulating type of circulating cooling water system with one number Induced Draft Cooling Tower (IDCT) and three 60% (2W + 1S) circulating water pumps have
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been provided. The circulating water make-up will be by gravity flow of water from the clarified water storage tank. The CW system returns the hot circulating water to hot water return header, which goes to the cooling tower, where the heat absorbed by the circulating water is released to the atmosphere. A tap-off from the CW discharge header is taken to the side stream filters. 2 x 100% Side stream filter of dual media / pressure sand filter /auto valve less gravity filter type, are provided to control the circulating cooling water turbidity. The side stream filter is sized based on 1% CW system flow. The side stream filters have manual back washing facility with proper valves and back washing water supply and disposal arrangement. The outlet filtered water is discharged in the CW fore bay. The CW pumps are located indoor inside the CW pump house. Principal components of the CW system are: Three x 60% vertical circulating water pumps (2W + 1S) One mechanical Induced draft cooling tower Two x 100% Side stream filters with back washing facility. Two x 100% Blowdown Pumps Cooling Tower make-up system Associated piping, valves and instruments & controls required to circulate the water through the main condenser. Cooling Tower The cooling tower is of mechanical induced draft, counter-flow, multi-cell (11) construction type. The cooling tower is having reinforced concrete structure, high performance PVC film type fill and PVC drift eliminators. The area covered by the projected circle at 45o angle from the fan cylinder opening on the drift eliminator plan area is not less than 80% of the drift eliminator plan area. The re-cooled cooling water temperature at the outlet of the cooling tower basin will be 28.9C and a temperature rise across the condenser will be 8 C (approx.) at design reference conditions of the project. The cooling tower basin has a storage capacity of about six (6) hours (excluding free board) of make-up water flow. The basin is partitioned into two compartments complete with draining facilities, cold water outlet channel with screens and stop logs. Axial flow induced draft type single speed motor driven fans (FRP blades). The heat-duty of the cooling tower will be sum of condenser heat duty and the auxiliary circulating water (ACW) system heat duty. Circulating Water Pumps The circulating water pumps are of indoor vertical turbine, non pull out, mixed flow, wet pit type and motor driven with pump bowel and discharge elbow will be of CI to IS 210 FG 260, column pipes will be fabricated to IS 2062 with epoxy painting. Line shaft bearing are self lubricated type. Bearing above minimum water level shall be either suitable for starting the pump without pre lubrication or pre lubrication tank have been provided.
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CW ACW Pumps 1) The pump set is capable of reverse rotation due to back flow of water from the other running pump in the event of tripping of the pump for a short duration of time (about 5 minutes). 2) Each pump is been provided with Motor winding temperature detectors and dial type bearing temperature indicators with alarm contacts. 3) The pump shall be capable of operation under shut-off conditions for duration of 5 minutes 4) Total capacity of two pumps shall be equal to 120 % of cooling water system requirement. 5) The pumps are capable of operating from shut-off point to a maximum flow of 10% over the point of intersection between system resistance curve and pump HQ curve for single pump operation 6) Motor rating is suitable to support above operating condition at 50 Hz frequency Auxiliary & Closed cooling water system The auxiliary cooling water system uses circulating water to transfer heat removed by various plant equipment heat exchangers into the main auxiliary cooling water heat exchanger where the collected heat is transferred to the main cooling system flow. Some examples of the various equipment giving off waste heat: electric drives, generators (ultra-pure water, hydrogen), hydraulic systems (oil coolers), sampling coolers, gland coolers, air-conditioning systems, and emergency diesel generators.
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Auxiliary Cooling Water (ACW) & Closed Cooling Water (CCW) System at Vemagiri The auxiliary cooling water system takes cooling water from CW supply header to ACW / CCW heat exchanger where it picks up the heat released by CCW system and returns to CW hot return header which leads to the cooling tower return system. The closed cooling cycle system provides cooling of various heat loads such as GTG coolers STG coolers, lube oil coolers, sample coolers, HRSG and auxiliaries, HP/IP BFP coolers, air compressor coolers. The closed cooling water will be passivated DM water which is circulated through the primary side of ACW / CCW heat exchanger. DM water is used as a make up water to the system. The secondary side circulates auxiliary cooling water.
Three CCW pumps of 50% (2W+1S) capacity circulate the DM water in a closed loop system through plate type heat exchangers (ACW / CCW heat exchanger). Three ACW pumps of 50% (2W+1S) capacity are provided to circulate cooling water on the secondary side of the plate type heat exchangers. In the secondary loop the ACW pumps draw suction from tap-off from main circulating water pump discharge header and circulate the cooling water through the plate type heat exchangers back into the circulating water line downstream of the condenser. The CCW pumps, the ACW pumps and the plate type heat exchangers are located in the STG building. Make-up to the CCW system is through the CCW expansion tank located on the roof of the STG building. A minimum flow recirculation line for CCW pumps through an automatic recirculation cum non return valve or an automatic flow control valve controlled by a differential pressure switch on a flow element are provided in the common discharge line. In the ACW system a control valve is provided to maintain a constant pressure differential between the main supply and return headers. This bypasses flow to maintain a constant return header pressure to compensate for fluctuation in coolant flow to the plate heat exchangers. Principal components of the ACW/ CCW system are: Two 100% ACW / CCW plate type heat exchangers Three 50% CCW pumps (2W + 1S) Three 50% ACW pumps (2W + 1S)
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Chemical dosing system in the closed loop DM water circuit. 2x100% self cleaning type debris filter (1W + 1S) CCW expansion tank, Associated piping, valves and controls required to circulate cooling water through various heat exchangers. The CCW system is to be treated with suitable chemical dosing in the closed loop DM water circuit to control pH and the iron level. CCW System Recirculation Control CCW system recirculation is controlled by modulating the control valve 1WC004V. Total flow at the CCW pumps discharge header is measured by the flow transmitter 1FT-WC004V. Control Valve 1WC004V is modulated by the Controller 1FIC-WC004V. The control loop trips to manual on high differential between the set point (SP) & the measured signal (MV) and the control system fault. Circulating Water Chemical Feed System & Chlorination System at Vemagiri The function of Circulating Water (CW) Chemical feed system is to prevent microbiological fouling, scaling and corrosion of CW system by dosing chlorine and chemicals (scale/corrosion inhibitor/dispersant, organic biocide/ bio-dispersant and acid). The circulating water chemical feed system consists of following three subsystems: The chlorine dosing subsystem: prevents microbiological fouling by feeding chlorine to the cooling water on a continuous and/or shock dosage basis. Chemical dosing subsystem: prevents scale, corrosion as well as fouling in the circulating water system. The acid dosing subsystem: controls scaling by pH adjustment. Chlorine storage/chemical storage area is provided under a roof covered shed. A separate room is provided adjacent to CW pump house for housing chemical dosing and chlorination equipment. The system boundary for chlorination plant starts from chlorine tonners located in the chlorine tonner shed and ends at diffusers located in cooling tower forebay. The system boundary for chemical dosing sub system starts from dosing tank including all equipment located in the CW Chemical room and ends at diffusers located in cooling tower forebay. Similarly, the system boundary for acid dosing subsystem starts from the bulk acid storage tank and acid unloading pumps located outside and ends at diffusers located in cooling tower forebay including acid dosing tank and pump in the CW Chemical room. Chlorine dosing subsystem To prevent bio fouling in the condenser, cooling tower and other system components, a chlorination system for Circulating Water (CW) has been provided. The chlorination plant consists of 2x50% capacity vacuum solution feed free standing/ wall mounted type chlorinators, electrically heated constant temperature water bath type chlorine evaporators, chlorine gas filters, booster pumps and associated accessories. The motive water is tapped off from the CW pump discharge header and fed to the chlorinators through booster pump and chlorinated water is dosed into the CW forebay through diffusers.
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A chlorine leak absorption system is provided for absorption and neutralization of chlorine in case of leakage. Quick reaction chlorine detectors are provided to sense chlorine. The chlorine leak absorption system will be sized considering the entire chlorine leaked from one tonner will be absorbed in one hour. The blower and caustic recirculation pumps will start automatically based on the signal from the chlorine leak detectors. The principle of operation for absorption system is to pass the leaked chlorine along with ambient air to the neutralization tower with countercurrent flow of caustic solution for chlorine absorption. All the associated interlocks are provided such that the system starts automatically by a signal from leak detector. The Chlorine dosing subsystem consists of the following equipment: Required numbers of Chlorine Tonners suitable for 7 days storage. Two x 50% Evaporators Two x 50% Vacuum solution feed type Chlorinators Two x 100% booster pumps Diffusers Leaked chlorine absorption system consisting of one x 100% exhaust blower, one absorption tower, one caustic solution tank, two x 100% caustic solution recirculation pump and one FRP hood. One monorail electric hoist with a lifting beam and load indicator. One platform dial type-weighing machine (2-ton capacity). Piping and valves, Electrical items and accessories One set of safety and supervisory instruments with: Two leak detectors. Two gas masks along with breathing apparatus, with minimum 30 minutes capacity tank complete with full mask, full vision face pieces, airflow regulating valves and all accessories. Two canister type oxygen breathing equipment. Four ammonia bottles containing commercial grade ammonia solution. Two emergency kit for sealing off leaking container as per Chlorine Institute standard. Two mechanical type safety shower (both eye and body wash automatic) One weather cock. Two residual chlorine test kits. Two moisture absorbing breathing bottles.
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Chlorine dosing is carried out at the rate of 2 ppm continuously so as to control the microbiological growth in the circulating water and shock dosing at the rate of 5 ppm intermittently for 30 minutes in each of the 3 shifts to create sudden impact on the micro-organism. Free residual chlorine in the range of 0.3 to 0.5 ppm will be maintained in the system. The capacity of the chlorinators & evaporators are based on the maximum dosing rate i.e. 5.0 ppm in the Circulating Water flow. However, the number of tonners to be stored will be decided based on average dosing rate of 0.5 ppm. Chemical dosing subsystem The chemical to be used will be of non-toxic type, free from heavy metal based chemicals like chromate, and zinc etc. Organic polymer/organic phosphorus/organio phosphate based chemicals are used. The dosing is done in the CW forebay using two x 100% dosing tanks with two x100% dosing pumps for scale inhibitor, two x 100% dosing tanks with two x100% dosing pumps for corrosion inhibitor and two (2) x 100% dosing tanks with 2 x 100% dosing pumps for bio-dispersant. Also dosing is done up to Mixing tee of chlorine dosing line using two (2) x 100% dosing tanks with 2 x100% dosing pumps for Chlorine activator. The dosing pumps for Acid dosing is of positive displacement type and the material of construction is compatible with the chemical to be handled and the dosing pumps is electronically diaphragm operated for chemical dosing. Chemicals are stored in jerrycans as it is supplied by the chemical supplier for 15 days requirement. Chemicals are dosed in the forebay through diffusers.
The chemical dosing subsystem consists of: Two x 100% dosing tanks for scale inhibitor with two x 100% dosing pumps Two x 100% dosing tanks for corrosion inhibitor with two x 100% dosing pumps Two x 100% dosing tanks biocide/biodispersant with two x 100% dosing pumps. Two x 100% dosing tanks Chlorine Activator with two x 100% dosing pumps.
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Diffuser Piping and valves, Electrical items and accessories
Acid dosing subsystem The acid dosing subsystem controls the pH of circulating water by dosing acid in CW forebay. The subsystem consists of two (1w + 1s) acid unloading pumps of adequate capacity and head sufficient to unload and deliver acid from road tankers to bulk acid storage tank. Two bulk acid storage tanks, two metering tanks and two x 100% dosing pumps are provided. Acid is dosed in the forebay after dilution in a mixing tee through diffusers. Acid storage tanks are surrounded by a dyked wall of 600mm high. A neutralization pit filled with lime inside the dyked area is provided for neutralizing spilled acid if any. The Acid (H2SO4) dosing subsystem consists of: Two x100%) acid unloading pumps Two bulk acid storage tanks Two x100%) acid measuring tanks Two x100 %) acid dosing pumps Two mixing tees Diffuser

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LARSEN & TOUBRO LIMITED TRAINING MANUAL 388.5 MW Combined Cycle Power Plant DOC No.

Water Systems Page No.

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Arrangement of water treatment systems in the power plant

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Procurement and cleaning of water

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water filtering plant

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River Water System at Vemagiri

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Substances contained in water

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silicic acid (SiO2)

CaCO3 + H2 CO3 Ca ( HCO3 ) 2

Ca ( HCO3 ) 2 CaCO3 + H2 O + CO2

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hydrochloric acid calcium hydroxide sodium chloride

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alkalinity Sulphate Chloride Nitrate Silica Carbon dioxide Oxygen

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FeCl3 + 3 H2 O Fe( OH ) 3 + 3 HCl

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Raw Water System at Vemagiri

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Chemicals Alum Lime Polyelectrolyte Chlorine Solution

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R K R + H2O Na R Na R + H 2 SO4 H Ca ( HCO3 ) 2 + H R Ca = R + 2 H 2 O + 2CO2

HCl + OH R Cl R + H 2 O HNO3 + OH R NO3 R + H 2 O OH H 2 SO4 + OH R SO4 = R + 2 H 2 O

HCl + OH R Cl R + H 2 O NaCl + OH R Cl R + NaOH CO2 + OH R HCO3 R SiO2 + OH R HSiO3 R