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On-line Particle Counters in the Thermal Power Plant Joe Zimmerman Director of Power Industry Sales Chemtrac, Inc.
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Page 1: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

On-line Particle Counters

in the Thermal Power Plant

Joe Zimmerman

Director of Power Industry Sales

Chemtrac, Inc.

Page 2: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Introduction

Page 3: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

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

Page 4: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Introduction

Overview

I. Particle Detection Technology

II. Applications

III. Condensate Polisher Monitoring

IV. Conclusions

Page 5: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Particle Detection Technology

Page 6: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Particle Detection Technology

Traditional Turbidity Monitors utilize a “light

scattering” measurement

Particle Counters & Particle Monitors utilize a

“light blockage” measurement

Page 7: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Particle Detection Technology

Turbidity Monitor

Lamp

Photo Detector 0.00 NTU 0.30 NTU

Lens

Page 8: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Particle Detection Technology

Laser Diode

Or LED Photo Diode

Water Flow

Particles Light Beam

Page 9: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Particle Detection Technology

Particle Counter

Detect particles > 2 µm

Reports results in particles/ml for up to 8 size ranges

Page 10: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

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

Page 11: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Particle Detection Technology

Particle Counter, Particle Monitor, Turbidity Monitor

How Are Particles Detected?

INSTRUMENT COMPARISON USING AC FINE TEST DUST

0

50

100

150

200

250

300

350

400

450

500

PA

RT

ICL

E C

nts

/mL

- P

AR

TIC

LE

IN

DE

X

0

0.1

0.2

0.3

TU

RB

IDIT

Y (

NT

U)

Particle Counter

Particle Monitor

Turbidimeter

Particle Counter 21 48 75 106 200 300 390 440

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

Page 12: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

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

Page 13: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

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

Page 14: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Applications

Page 15: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Applications

Water Treatment Plant

Monitor filter performance

Assure proper removal of pathogen-size particles

(Cryptosporidium and Giardia)

Page 16: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Applications

Pre-Treatment

Monitor filter performance

Page 17: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Common Backwash Results

Page 18: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Backwash Based On

Effluent Quality

Page 19: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Applications

Pre-Treatment

Monitor SDI

Page 20: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

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

Page 21: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Applications

CPT MonitoringCPT MonitoringCPT MonitoringCPT Monitoring

EPRI diagram

Page 22: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Applications

Econ Inlet PI, BFW Flow, Load

760.19

188.85

ECONOMIZER INLET PARTICLE INDEX

MAIN STEAM PARTICLE INDEX

10/14/2010 5:07:34 AM10/13/2010 5:07:34 AM 24.00 hours

Particle Index

0

1000

1500

2000

3000

2CFXFEEDWTRF1

1244.0

KLB/HR

2CFXFEEDWTRF2

1232.1

KLB/HR

10/14/2010 5:07:49 AM10/13/2010 5:07:49 AM

FW Flow Transmitter

600

800

1000

1300

2GJ5NETMWATT

173.00

MW

10/14/2010 5:08:14 AM10/13/2010 5:08:14 AM

Unit Load

0

100

200

Page 23: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Applications

Volumetric ppb vs. Grab Sample Total Fe ppb

Condensate Monitoring -- Thermal Power Plant in Southeast US

0.00

5000.00

10000.00

15000.00

20000.00

25000.00

0.00

200.00

400.00

600.00

800.00

1000.00

1200.00

1400.00 11/2

5/2

013 …

11/2

5/2

013 …

11/2

5/2

013 …

11/2

5/2

013 …

11/2

5/2

013 …

11/2

5/2

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11/2

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11/2

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11/2

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Page 24: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Page 25: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Particle Counters Upstream and Downstream

See insoluble material reduction across the filter

Better identify resin leakage

Cond. Filter/Polisher Particle Counter

Condensate

Hotwell

Particle Counter

Page 26: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Upstream Polisher (Hotwell) Downstream Polisher

Decrease in insoluble ppb concentration across polisher.

Page 27: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Upstream Polisher (Hotwell) Downstream Polisher

Typical reduction in particle concentrations across polisher.

Page 28: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Example of Particle Counter results when a there is a

Condensate Polisher Problem

Page 29: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Upstream Polisher (Hotwell) Downstream Polisher

Increase in insoluble ppb concentration across polisher.

Page 30: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Upstream Polisher (Hotwell) Downstream Polisher

Addition of 30 um particles contributed significantly to total

ppb concentration.

Page 31: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Condensate Polisher Monitoring

Other available diagnostic screen views.

Particles per 100 ml ppb based on particle size

Page 32: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Conclusions

Page 33: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

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

Page 34: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

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

Page 35: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Chinese Quotation

Page 36: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

Chinese Quotation

欲穷千里目 更上一层楼 To enjoy a grander sight, climb to a greater height.

Page 37: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,
Page 38: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

"There's a way to do it better - find it."

-- Thomas Edison

Page 39: On-line Particle Counters in the Thermal Power · PDF fileOn-line Particle Counters in the Thermal Power Plant ... Particle Detection in the Thermal Power Plant For this presentation,

谢 谢


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