On-line Particle Counters in the Thermal Power Plant Joe Zimmerman Director of Power Industry Sales Chemtrac, Inc.
Introduction
Introduction High Purity Water is Essential in the Power Plant Steam Cycle Make-up water Pretreatment & Steam Cycle Chemistry Monitoring Grab samples Composite Sampling On-line Continuous Monitoring Particle Detection Steam Cycle Make up water
Introduction Overview I. Particle Detection Technology II. Applications III. Condensate Polisher Monitoring IV. Conclusions
Particle Detection Technology
Particle Detection Technology Traditional Turbidity Monitors utilize a “light scattering” measurement Particle Counters & Particle Monitors utilize a “light blockage” measurement
Particle Detection Technology Turbidity Monitor Lens Lamp 0.30 NTU 0.00 NTU Photo Detector
Particle Detection Technology Particles Light Beam Laser Diode Photo Diode Or LED Water Flow
Particle Detection Technology Particle Counter Detect particles > 2 µm Reports results in particles/ml for up to 8 size ranges
Particle Detection Technology Particle Monitor Single channel device, producing a “relative” measurement called a Particle Index (PI) The PI will increase with both an increase in particle size and concentration
Particle Detection Technology Particle Counter, Particle Monitor, Turbidity Monitor INSTRUMENT COMPARISON USING AC FINE TEST DUST 500 0.3 Particle Counter 450 Particle Monitor PARTICLE Cnts/mL - PARTICLE INDEX Turbidimeter 400 350 How Are Particles Detected? 0.2 TURBIDITY (NTU) 300 250 200 0.1 150 100 50 0 0 21 48 75 106 200 300 390 440 Particle Counter Particle Monitor 50 150 170 200 300 390 460 470 Turbidimeter 0.05 0.05 0.05 0.05 0.06 0.06 0.07 0.07
Particle Detection Technology On-line Continuous Particle Detection Allows for seeing extremely low levels of insoluble particle contamination Real-time results Complements other measurements (pH, conductivity, DO, sodium, etc.) Limitations - Cannot see particles <2 µm - Cannot differentiate between types of particles - Bubbles cause interference because they are detected as particles
Particle Detection Technology Particle Detection in the Thermal Power Plant For this presentation, focus on the particle counter New development: the ability to report volumetric concentration in ppb in addition to particles/ml
Applications
Applications Water Treatment Plant Monitor filter performance Assure proper removal of pathogen-size particles (Cryptosporidium and Giardia)
Applications Pre-Treatment Monitor filter performance
Common Backwash Results
Backwash Based On Effluent Quality
Applications Pre-Treatment Monitor SDI
Appications Steam Cycle Corrosion Product Monitoring EPRI corrosion monitoring research has confirmed that ~ 90%, or more, of Fe corrosion product transport is in the insoluble (particulate) form
Applications CPT Monitoring CPT Monitoring CPT Monitoring CPT Monitoring EPRI diagram
Applications Econ Inlet PI, BFW Flow, Load Particle Index 3000 760.19 188.85 2000 1500 1000 0 10/13/2010 5:07:34 AM 24.00 hours 10/14/2010 5:07:34 AM ECONOMIZE R INLE T PARTICLE INDEX MAIN STEAM PARTICLE INDE X FW Flow Transmitter 1300 2CFXFEEDWTRF1 1244.0 1000 KLB/HR 2CFXFEEDWTRF2 800 1232.1 600 KLB/HR 10/13/2010 5:07:49 AM 10/14/2010 5:07:49 AM Unit Load 200 2GJ5NETMWATT 173.00 MW 100 0 10/13/2010 5:08:14 AM 10/14/2010 5:08:14 AM
Volumetric ppb vs. Grab Sample Total Fe ppb Condensate Monitoring -- Thermal Power Plant in Southeast US 1000.00 1200.00 1400.00 200.00 400.00 600.00 800.00 Applications 0.00 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 … 11/25/2013 0.00 5000.00 10000.00 15000.00 20000.00 25000.00
Condensate Polisher Monitoring
Condensate Polisher Monitoring Condensate Hotwell Cond. Filter/Polisher Particle Counter Particle Counter Particle Counters Upstream and Downstream See insoluble material reduction across the filter Better identify resin leakage
Condensate Polisher Monitoring Upstream Polisher (Hotwell) Downstream Polisher Decrease in insoluble ppb concentration across polisher.
Condensate Polisher Monitoring Upstream Polisher (Hotwell) Downstream Polisher Typical reduction in particle concentrations across polisher.
Condensate Polisher Monitoring Example of Particle Counter results when a there is a Condensate Polisher Problem
Condensate Polisher Monitoring Upstream Polisher (Hotwell) Downstream Polisher Increase in insoluble ppb concentration across polisher.
Condensate Polisher Monitoring Upstream Polisher (Hotwell) Downstream Polisher Addition of 30 um particles contributed significantly to total ppb concentration.
Condensate Polisher Monitoring Other available diagnostic screen views. Particles per 100 ml ppb based on particle size
Conclusions
Conclusions On-line Particle Monitoring: provides real-time indication of insoluble CPT particulate loading allows for continuous data collection & trending Events or upsets can be detected very quickly Pretreatment filter performance can be significantly improved using the proper tools and techniques Savings can be realized in energy costs, membrane cleaning costs, and in cartridge filter replacement costs. Upstream and downstream monitoring across the condensate polishers would offer additional comparative data
References Comprehensive Cycle Chemistry Guidelines for Fossil Plants , EPRI Cycle Chemistry Guidelines for Combined Cycle/HRSGs , EPRI The Impact of Oxidizing Environment on Feedwater Corrosion and Metal Transport - New tools and Findings , Daniel C. Sampson Power Plant Particle Applications: Corrosion Product Monitor /Foreign Material / Water Treatment Control and Optimization (presentation), Mike Caravaggio A Method for Continuously Monitoring and Selectively Sampling Boiler Cycle Water for Metal Oxide Transport Analyses , Richard A. Breckenridge, L. Joseph Hancock, Robert L. Bryant, John W. Clark An Alternative to Silt Density Index (SDI)…Continuous Particle Counting , Robert L. Bryant Assessment and Development of Low-Pressure Membrane Integrity Monitoring Tools, AwwaRF
Chinese Quotation
Chinese Quotation 欲 穷千里目 更上一 层楼 To enjoy a grander sight, climb to a greater height.
"There's a way to do it better - find it." -- Thomas Edison
谢 谢
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