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g
/
l
)
1 14 4
Figure 3
Feed-water and Steam
Action Levels for Acid Conductivity
0,01
0,1
1
10
0 5 10 15 20 25 30
Pressure (MPa)
1 15 5
Figure 4
Feed-water and Steam
Action Levels for Sodium
0,1
1
10
100
1000
0 5 10 15 20 25 30
Pressure (MPa)
1 16 6
Fig. 5
Boiler Water - Solid Alkaliser
Action Levels for pH
0,01
0,1
1
10
100
1000
7,00 7,50 8,00 8,50 9,00 9,50 10,00 10,50 11,00 11,50
pH
1 17 7
Figure 6
Boiler Water treated with NaOH
Action Levels for Acid Conductivity
1
10
100
1000
0 2 4 6 8 10 12 14 16 18 20
Pressure (MPa)
1 18 8
Figure 7
Boiler Water - AVT
Action Levels for Acid Conductivity
0,1
1
10
100
0 2 4 6 8 10 12 14 16 18 20
Pressure (MPa)
1 19 9
Figure 8
Boiled Water
Action Levels for silica
0,01
0,1
1
10
100
0 2 4 6 8 10 12 14 16 18 20
Pressure (MPa)
2 20 0
Figure 9
Boiler Water treated with phosphate
Action Levels for Mineral Acids
0,1
1
10
0 2 4 6 8 10 12 14 16 18 20
Pressure (MPa)
2 21 1
Appendix 1
Comparison of significant parameters for control of water/steam cycle in UNIPEDE countries
2 22 2
A 1 - TABLE I. Comparison of Significant Parameters for Feed Water of Drum and Once Through Boilers (AVT)
Country BE DE DK ES FI FR GB IE IL IT NL PL PT SE
Acid Conduc-
tivity
(S/ cm)
N
1
2
3
<0,2 0,1
>0,2
<0,1
>0,15
<0,2 <0,2 0,1
>0,2
<0,1 <0,09
>0,12
>0,18
>0,30
0,1
>0,2
<0,15
>0,2
<0,2 0,1
<0,2
<0,2
>0,2
>0,35
>0,65
>2
<0,2
pH N
1
2
3
9,2-9,5 9 - 10 9,2-9,4 9-10 9,0-9,2 9,1-9,3
9 -9,4
8,8-9,2 9,2-9,6
<9,2
<8,7
<8,0
8,8-9,4 9,1-9,2
9,0-9,3
9,0-9,2 9,1-9,3 9,0-9,3 8,5-9,2
O2
(g/ kg)
N
1
2
3
<10 <100 <10 <7
<10
<10 <5
<10
<5 <7
>7
>15
>50
2 - 5 <5 <5 <20 <7
>7
>10
>20
<10
N2H4
(g/ kg)
N
1
2
3
>20 >20 10-200 15-80 30-50 20
100
2 23 3
A1 - TABLE II. Comparison of Significant Parameters for Feed Water at OT of Once Through Boilers
Country BE DE DK ES FI FR GB IE IL IT NL PL PT SE
Acid
Conduc-
tivity
(S/ cm)
N
1
2
3
0,1
>0,2
<0,1
>0,15
<0,2 <0,1 <0,1
>0,2
<0,2 0,1
>0,2
pH N
1
2
3
8 - 9 8,3-9,0 8-9 9,0-9,2 8,3-8,5*
8,0-8,8*
8 - 8,5 7-8
O2
(g/ kg)
N
1
2
3
30-150 30-150 30-150 10-20 80-120
60-150
50-100 >50
N2H4
(g/ kg)
N
1
2
3
* 8,6-8,8 resp. 8,5-9 for units with copper alloys
2 24 4
A 1 - TABLE III. Comparison of Significant Parameters for Boiler Water of Drum Boilers on Solid Alkalizer (16 MPa)
Country BE DE DK ES FI FR GB IE IL IT NL PL PT SE FI
Alkal. agent Ph-NaOH NaOH Ph Ph NaOH NaOH Ph NaOH Ph Ph Ph
(mg/ kg) <3 - 1 - 4 2 - 6 1,5.NaCl 0,5-1,5 3 - 5 1 - 6 2 - 6 2-6
Acid Conduc-
tivity
(S/ cm)
N
1
2
3
<50 <15
<100
150* <15* < 3
<10
<20
>20
15-23 * <60* <132 * <150 *
pH N
1
2
3
9,3-9,7 9,5 9,5-10,5 8,8-9,4 9,3-9,8
8,5-10,5
8,0-11
<8 V >11
9,2-9,8 9-9,5* 8,5-9,6 9,5-10,5
SiO2
(g/ kg)
N
1
2
3
<200 <250 350 <200 <200
<400
<800
>800
20-100
<400
<400 <350
Cl
-
(g/ kg)
N
1
2
3
<2000
**
<100
<500
<1000
>1000
20-200
<1000
* Calculated ** <500 g/ / L for Oil Fired Boilers
2 25 5
A 1 - TABLE IV. Comparison of Significant Parameters for Boiler Water of Drum Boilers on AVT (16 MPa)
Country BE DE DK ES FI FR GB IE IL IT NL PL PT SE
Acid Conduc-
tivity
(S/ cm)
N
1
2
3
<3 (5) <3 <2
3
0,3-1
3
<5 1
>5
pH N
1
2
3
7 - 9 >8,5 8,9-9,1 8,5 9-9,2
<8,8
8,5-9,5 9,0-9,3
8,8-9,6
8-10,6
7,5-10,6
7,5-12
SiO2
(g/ kg)
N
1
2
3
<200 <200
>200
20-50
>200
<200
<250
<300
>300
Cl
-
(g/ kg)
N
1
2
3
2 26 6
A 1 - TABLE V. Comparison of Significant Parameters for Steam
Country BE DE DK ES FI FR GB IE IL IT NL PL PT SE
Acid Conduc-
tivity
(S/ cm)
N
1
2
3
<0,2 0,1
0,2
<0,1
0,15
>0,5
<0,2 <0,2
>0,5
0,1
<0,2
<0,1
0,15
0,20
0,30
0,1
<0,2
<0,15
>0,20
<0,2 <0,25 <0,2
>0,2
>0,3
>0,5
<0,2
SiO2
(g/ kg)
N
1
2
3
<15 5
<20
<20 <10 <20 <20 <20 <5
<10
<20
>20
<10 <20 <20 <20 <20
Na
+
(g/ kg)
N
1
2
3
<5 2
<10
<3 <10 <2
(<5)
<2
<5
<10
>10
<5 <3 <1 <10 <10
Cl
-
(g/ kg)
N
1
2
3
<3 <1
<4
<8
>8
<3 <3
Cu
(g/ kg)
<2 1
<3
<1 <3
2 27 7
Appendix 2
Examples of Action Level Limits for pH of boiler water at different pressures
2 28 8
A2 Figure 1
0.5 MPa - Boiler Water treated with solid alkaliser
Action Levels for pH
0,1
1
10
100
1000
7,00 7,50 8,00 8,50 9,00 9,50 10,00 10,50 11,00 11,50
pH
A
c
i
d
C
o
n
d
u
t
i
v
i
t
y
(
S
/
c
m
)
2 29 9
A2 Figure 2
2 MPa - Boiler Water treated with solid alkaliser
Action Levels for pH
0,1
1
10
100
1000
7,00 7,50 8,00 8,50 9,00 9,50 10,00 10,50 11,00 11,50
pH
3 30 0
A2 Figure 3
8 MPa - Boiler Water treated with solid alkaliser
Action Levels for pH
0,1
1
10
100
1000
7,00 7,50 8,00 8,50 9,00 9,50 10,00 10,50 11,00 11,50
pH
A
c
i
d
C
o
n
d
u
c
t
i
v
i
t
y
(
S
/
c
m
)
3 31 1
A2 Figure 4
16 MPa - Boiler Water treated with solid alkaliser
Action Levels for pH
0,1
1
10
100
7,00 7,50 8,00 8,50 9,00 9,50 10,00 10,50 11,00
pH
3 32 2
Appendix 3
Assessment of water/steam chemistry by quality indices
The quality index I for any control parameter p is in general terms defined as a ratio of lifetime consumption
(T
P
) of a component effected by the control parameter at the actual operating value and the lifetime
consumption (T
L1p
) of this component operating at the reference conditions, which means at the limit between
target and action level 1 (L
1p
).
I
p
= dT
P
/ dT
L1p
The index expresses the relative rate of lifetime consumption and will then be 1 at the operation at the limit for
Action level 1, which is considered as conditions with reference lifetime consumption:
At P = L
1p
I
p
= I
0
= dT
L1p
/dT
L1p
= 1
The lifetime consumption at actual conditions T
p
of a particular component during any operation period t is
then calculated from the formula:
T I dt
P
P
t
=
*
0
Operating at action level 1 (P > L
L1p
and P < L
L2p
) the index will have value above 1 and operating below the
action level 1 limit (target area), the index will have value less then 1. Thus the lifetime consumption will be
faster or slower comparing to the operation at reference conditions.
It is extremely difficult to establish a scientifically or statistically based model for the lifetime consumption
deviations from reference conditions. A pragmatic way was chosen , based on the following concept:
- The lifetime consumption should be evaluated separately for each main component of water/steam
circuit using parameters significant for the componen t in question.
- The rate of lifetime consumption (Index I) is an exponential function of the relevent parameter
- The exponential function is normalized for action level limits defining:
at P = L
1p
I = 1
at P = L
2p
I = 10
at P = L
3p
I = 100
at P = 3*L
3p
I = 1000
The justification of these values is based on some experience from units operating with good chemical practice
and also from units where less attention is paid to chemistry, however, the data basis is limited.
The index is mathematically related to action levels by the following equations:
I
P
P L
L L
=
10
1
2 1
for L
1
< P L
2
I
P
P L
L L
=
+
10
2
3 2
1
for L
2
< P < L
3
3 33 3
I
P
P L
L
=
+
10
3
3
2
2
*
for P > L
3
where I
P
is the index for parameter p
P is the monitored value of parameter p
L
1
is the threshold for action level 1
L
2
is the threshold for action level 2
L
3
is the threshold for action level 3
The index can be used for relative evaluation of the chemical performance with respect to the lifetime
consumption of components for which the parameter p is the key parameter. It has to be emphasized, that it is
an evaluation relative to reference conditions and if more than one key parameter is relevant for the component
in question, a combination of indices described on page 33 should be used.
As examples of key parameters for some components are:
1. Acid conductivity of feed-water for the evaporator of once through boiler with respect to the operation time
between acid cleanings.
2. Acid conductivity and pH of boiler water for the evaporator of a drum boiler on caustic treatment with
respect to the operation time between acid cleanings.
3. Acid conductivity of boiler water and pH of feed-water for the evaporator of a drum boiler on AVT with
respect to the operation time between acid cleanings.
4. Acid conductivity of steam for the turbine blades.
5. Conductivity of the effluent from condensate polishing plant (CPP) as a key parameter for performance of
CPP. In this case there is no direct connection to lifetime of any particular component.
Some examples are illustrated in more details .
For a typical cold start-up a good practice is to reach L1 (coming from L3) for acid conductivity in feed-water
within 24 hours. The calculation shows, that the mean value of the index I is about 30. This indicates, that the
chemical load on the evaporator during this day of start-up is similar to the load of 30 (720 h) days of operation
at L1. For a unit, which is not performing very well, the purification period during the start-up can easily take 2
days, which makes the life consumption for the whole period 2*30=60 days (1440 h).
Similarly it can be calculated, that a hot start-up of a good unit taking 16 hours will be equivalent to roughly
200 h lifetime consumption, while unattended unit will use 400 h equivalent operation at reference condition.
These values are used in examples below.
Table A 3.1 shows some examples of units with different operation mode (1. base load, 2. cycling load, 3. peak
load) and different quality of chemical control (A. Ideal purity, B.Good practice, C. Unattended control). In
the following the layout and calculation procedure are explaned:
At the top of the table the limits L
1
, L
2
, L
3
are given.
Column 1 defines the unit operation mode and the purity standard according to the code specified above. As
reference a unit operating 7000 hours/year at L
1
, having 1 cold and 5 warm starts-up/year is taken.
Columns 2 and 3 specify the number of cold (n
1
) and warm (n
2
) starts-up/year.
Columns 4 - 6 specify operating hours at different levels of acid conductivity (key parameter). For simplicity
there are 3 groups only: 0,07 S/cm characterise excellent chemical conditions; 0,1 S/cm characterize
reference conditions and 0,15 characterise operation in action level 1. In the first row values of indeks I
matching these three acid conductivities are calculated.
Column 7 shows the average value of Index for the whole year. Here the contribution from start-ups is not
included. The calculation for row 1B is as follows:
3 34 4
I
I t
t
i i
i
= =
+
+
=
* , * *
,
0 501 3000 1 4000
3000 4000
0 786
Column 8 show the calculated equivalent lifetime consumption T
c
including contributions from start-ups. The
calculation for row 1B is as follows:
T
c
= I * t
i
+ n
1
* 720 + n
2
* 200 = 0,786 * 7000 + 1 * 720 + 0 * 200 = 6222
The registered lifetime consumption is of course 7000 h, but chemically the evaporator has received more load
due to start-ups, but decreased load because of the excellent purity in part of the operation time. In calculation
of examples with purity standard C, a higher life time consumption is used for start-ups (1440, 400).
Columns 9 and 10 show a prognosis for acid cleanings if the same operating conditions would be maintained
all the time. This calculation is based on experience with units operating close to the conditions of the reference
unit. These units used to be acid cleaned after 100 000 operating hours.
Tables A 3.II - A 3.V show similar exercises for drum boilers on NaOH and AVT respectively. Two key
parameters are used for separate calculation in each case, and in the table A 3.VI a combined evaluation of
indices calculated from these two key parameters is shown. As the best combination of indices was found to be
their sum -1. Mathematically:
I
12
= I
1
+ I
2
- 1
More generaly:
I I i
i i
i
i
1
1
1 = +
=
On the basis of these combined indices the expected acid cleaning frequency is calculated.
It must be emphasised that the method is designed for evaluation of operational lifetime consumption. The
impact of the off-load damage on lifetime must be evaluated separately. It may be possible to use the same
concept, but a careful consideration should then be given to reference condition, key parameters and action
levels.
3 35 5
Table A 3.I Examples of Lifetime Evaluation of Evaporator Protective Layer
Once Trough boiler - Acid conductivity of Feedwater
L1 L2 L3 3*L3
0,1 0,2 0,5 1,5
No. of Operation time (h) Average Used eq. Acid cleaning
Start-ups at acid conductivity (S/cm) Index lifetime frequency
Cold Warm 0,07 0,1 0,15 I (h/year) (years) (h)
I 0,501187 1 3,1622777
Ref. 1 5 7000 1 8720 11,5 100000
1A 1 0 7000 0,50 4228 23,7 165551
1B 1 0 3000 4000 0,79 6224 16,1 112476
1C 1 0 1000 3000 4000 2,02 17590 5,7 45480
2A 1 5 4000 1000 0,60 4725 21,2 105826
2B 1 5 2000 3000 0,80 5722 17,5 87376
2C 1 5 2000 3000 2,30 14927 6,7 33497
3A 3 50 1000 2000 0,83 14661 6,8 20462
3B 3 50 2000 1000 1,72 17322 5,8 17319
3C 3 50 3000 3,16 33807 3,0 8874
3 36 6
Table A 3.II Examples of Lifetime Evaluation of Evaporator Protective Layer
Drum boiler - Acid conductivity of Boiler water - NaOH treated
Limits L1 L2 L3 3*L3
S/cm 5 15,8 50 150
No. of Operation time (h) Average Used eq. Acid cleaning
Starts-up at acid conductivity (S/cm) Index lifetime frequency
Cold Warm 3 5 10 I (h/year) (years) (h)
I 0,65285 1 2,90378
Ref. 1 5 7000 1 8720 11,5 100000
1A 1 0 7000 0,65 5290 18,9 132326
1B 1 0 3000 4000 0,85 6679 15,0 104813
1C 1 0 1000 3000 4000 1,91 16708 6,0 47881
2A 1 5 4000 1000 0,72 5331 18,8 93784
2B 1 5 2000 3000 0,86 6026 16,6 82978
2C 1 5 2000 3000 2,14 14151 7,1 35332
3A 3 50 1000 2000 0,88 14813 6,8 20253
3B 3 50 2000 1000 1,63 17064 5,9 17581
3C 3 50 3000 2,90 33031 3,0 9082
3 37 7
Table A 3.III Examples of Lifetime Evaluation of Evaporator Protective Layer
Drum boiler - pH of Boiler water - NaOH treat.
Limits L1 L2 L3 3*L3
9,4 9,1 8,6 7
10,4 10,6 10,8 11,8
No. of Operation time (h) Average Used eq. Acid cleaning
Start-ups pH Indeks lifetime frequency
Cold Warm 9,4 9,2 8,8 I (h/year) (years) (h)
I 1 4,64159 39,8107
Ref. 1 5 7000 1 8720 11,5 100000
0
1A 1 0 6990 10 1,005202 7756 12,9 90248
1B 1 0 6500 500 1,260113 9541 10,5 73369
1C 1 0 6000 900 100 2,022643 14879 6,7 47048
0
2A 1 5 6990 10 1,005202 8756 11,4 79941
2B 1 5 6500 500 1,260113 10541 9,5 66409
2C 1 5 6000 900 100 2,022643 15879 6,3 44085
3A 3 50 6990 10 1,005202 19196 5,2 36465
3B 3 50 6500 500 1,260113 20981 4,8 33364
3C 3 50 6000 900 100 2,022643 26319 3,8 26597
3 38 8
Table A 3.IV Examples of Lifetime Evaluation of Evaporator Protective Layer
Drum boiler 16 MPa - Acid conductivity of Boiler water - AVT treat.
Limits L1 L2 L3 3*L3
S/cm 1 2,29 5,23 150
No. of Operation time (h) Average Used eq. Acid cleaning
Start-ups at acid conductivity (S/cm) Index lifetime frequency
Cold Warm 0,8 1 2 I (h/year) (years) (h)
I 0,69978 1 5,95928
Ref. 1 5 7000 1 8720 11,5 100000
1A 1 0 7000 0,70 5618 17,8 124589
1B 1 0 3000 4000 0,87 6819 14,7 102649
1C 1 0 1000 3000 4000 3,44 28977 3,5 27608
2A 1 5 4000 1000 0,76 5519 18,1 90594
2B 1 5 2000 3000 0,88 6120 16,3 81705
2C 1 5 2000 3000 3,98 23318 4,3 21443
3A 3 50 1000 2000 0,90 14860 6,7 20189
3B 3 50 2000 1000 2,65 20119 5,0 14911
3C 3 50 3000 5,96 42198 2,4 7109
3 39 9
Table A 3.V Examples of Lifetime Evaluation of Evaporator Protective Layer
Drum boiler 16 MPa - pH of feed-water - AVT treat.
Limits L1 L2 L3 3 * L3
9 8 7 6
No. of Operation time (h) Average Used eq. Acid cleaning
Start-ups pH Index lifetime frequency
Cold Warm 9 8,5 7,5 I (h/year) (years) (h)
I 1 3,16228 31,6228
Ref. 1 5 7000 1 8720 11,5 100000
1A 1 0 6990 10 1,003 7742 12,9 90420
1B 1 0 6500 500 1,15 8801 11,4 79535
1C 1 0 6000 900 100 1,72 13448 7,4 52051
2A 1 5 6990 10 1,00 8742 11,4 80077
2B 1 5 6500 500 1,15 9801 10,2 71420
2C 1 5 6000 900 100 1,72 15448 6,5 45312
3A 3 50 6990 10 1,00 17061 5,9 41028
3B 3 50 6500 500 1,15 17209 5,8 40677
3C 3 50 6000 900 100 1,72 30015 3,3 23322
4 40 0
Table A 3.VI Evaluation of drum boiler lifetime consumption on basis of combined Index
Treatment NaOH AVT
Purity pH Combined Used eq. Purity pH Combined Used eq.
Index Index Index lifetime Index Index Index lifetime
I 1 I 2 I12 (h) I 1 I 2 I12 (h)
Ref. 1 1 1 7000 1 1 1 7000
1A 0,65 1,01 0,66 4606 0,70 1,00 0,70 4920
1B 0,85 1,26 1,11 7779 0,87 1,15 1,03 7180
1C 1,91 2,02 2,93 20518 3,44 1,72 4,16 29103
2A 0,72 1,01 0,73 5092 0,76 1,00 0,76 5340
2B 0,86 1,26 1,12 7849 0,88 1,15 1,03 7241
2C 2,14 2,02 3,16 22154 3,98 1,72 4,69 32837
3A 0,88 1,01 0,89 6226 0,90 1,00 0,90 6321
3B 1,63 1,26 1,89 13263 2,65 1,15 2,81 19653
3C 2,90 2,02 3,93 27485 5,96 1,72 6,67 46723
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