COOLING WATER – CHEMICAL DOSING SYSTEM

IN THERMAL POWER PLANT

Cooling water chemical dosing system supplied to Bellary 500 MW Unit

is described in this write up.

The cooling water circuit has been designed to operate at optimum

cycles of concentration in order to limit fresh water consumption and
minimize blow down. The main problems encountered in CW cycle are
scaling, corrosion, microbial fouling. Scaling is the precipitation of
adherent material on heat exchange surfaces and it occurs when
solubilities are exceeded because of high concentration or increased
temperature. Corrosion occurs due to dissimilar metals and non ferrous
metallurgy. Microbial fouling occurs due to turbidity and higher cycle
concentration.

The following chemical dosing systems are supplied to mitigate the

problems referred above by maintaining suitable chemical regime in CW
system.

1. Anti Scalant /corrosion inhibitor system to avoid scaling and

corrosion in cooling water cycle.

2. Bio dispersant dosing system to avoid coagulation of organic

materials.
 3. Biocide dosing system for prevention/control of fouling and
organic growth in CW system.

4. Sulphuric acid dosing system to maintain the required pH and

alkalinity to have effective control on scaling.

5. Chlorination system to destroy the organic growth in cooling

water circuit.

I. Anti Scalent/ Corrosion inhibitor system:

It consists of the following accessories

(i) Two numbers of solution preparation cum metering tank of

2000 liters capacity.
(ii) Two numbers of dosing pumps of 150 liters/hr capacity
with variable stroke adjustment facility.

II. Bio dispersant dosing system:

The skid consists of

(i) one number solution preparation cum metering tank of 150
liters capacity with accessories like stirrer, level indicators
etc.
(ii) Two numbers of dosing pumps of each 20 liters/hr capacity.

III. Biocide dosing system

It has been provided with only a preparation tank of 1.5

liters capacity. The chemical is dosed directly in fore bay since it
is dosed only once in 15 days.
IV. Sulphuric Acid (98% concentration) dosing system

It consists of

a) Two (2) numbers acid unloading pumps of each 10 cu m/hr

capacity and a head of 15 mlc
b) Two (2) numbers bulk acid storage tank of 15 cu m capacity
each
c) Two (2) numbers dosing tank of 2.5 cu m capacity each
d) Two (2) numbers dozing pumps of each 600 1/hr capacity and
head of 3 Kg/sq.cm (g)

Chemical dozing:

. Cooling water treatment chemicals are speciality and proprietary

chemicals and the treatment methodology is vendor specific.
The type of chemicals and dosing rate are as per the
recommendation of the O&M contractor for CW treatment. M/s
ANCO/Chennai was engaged by BHEL /PEM for cooling water
treatment from Unit commissioning up to handing over the unit.

The details of the chemicals dozed by M/s ANCO are as follows:

AA Anti Scalant/Corrosion inhibitor:

M/s ANCO supplied their proprietary chemical ANCOOL 3539 K

as anti scalant.

Ancool 3539K is a zinc based liquid formulation designed to protect

ferrous metal against corrosion. The low levels of zinc present in
it offer a good protection to carbon and mild steel components.
The product contains an excellent inhibitor which prevents
 precipitation of zinc salts at higher pH and alkalinity. Ancool
3539K contains an effective antiscalent for prevention of calcium
phosphate, sulphate and carbonate scales. The Azole in the
product adsorbs on the exposed metal surfaces protecting the
copper in the Alloy. The scale inhibitors ensure that the calcium
balance in the system so that the possibility of scaling is avoided.
The powerful dispersant blended in the product prevents fouling
due to silt and suspended matter.

This chemical is dozed continuously at the rate of 10 to 15 ppm

(to be calculated based on blow down) to have a P04 level not to
exceed 8 to 10 ppm.

BB Bio dispersant : M/s ANCO supplied ANCOSPERSE 3825 as bio

dispersant.

ANCOSPERSE 3825 is a blend of low foaming cationic and non-

ionic surfactant designed specifically to disperse micro-biological
growth, oil and sludge in cooling water. Ancosperse 3825 helps to
remove organic deposits and bio-films embedded on the metal
surface. It enhances the performance of oxidizing biocides and
non oxidizing biocides by dispersing the bio-films and hence
improving the penetration. The use of Ancopserse 3825 has
resulted in a better control on Anaerobic and Aerobic bacteria and
hence a control on the Microbiologically induced corrosion.

This chemical is dozed once in a day at the rate of 3 to 5 pp,

based blow down quantity.
CC: Biocide: M/s ANCO supplied ANCOCIDE 4070 as biocide.

Ancocide 4070 is highly effective against a broad spectrum of

bacteria. It is non-oxidising in nature and very useful to achieve
good bio-control in cooling water systems. Being biodegradable in
nature, it is ideal for use in any cooling water system as it is
environmentally safe.

It is dozed once in 15 days at the rate of 30 to 50 ppm based

blow down quantity.

DD: Sulphuric Acid ( H2 SO4 at 98% concentration).

This being a generic chemical, it was procured separately in acid

tankers and unloaded in the two bulk storage tanks.

Sulphuric acid is dosed such as to maintain the cooling water pH

of 8.2 to 8.5 to have better results of the treatment.

Sulphuric acid is dozed continuously based on the blow down

quantity and raw water chemical composition.

EE : Chlorination system:

Chlorine gas is dozed in fore bay to control the organic growth in

cooling water. This system consists of

(a) One number ejector, chlorinator, motive water booster pump

diffuser
(b) Eight numbers of Ton Container housed in chlorine Tonner room.
(c) 3 x 50% booster pumps
 (d) One number portable residual chlorine analyzer
(e) Two numbers chlorine leakage detectors
(f) Chlorine leakage absorption system
(g) One number electrically operated hoist to handle chlorine
tonner

Chlorine gas is available in Ton Containers. Each Ton Container

consists of (approximately) one (1) Tone of chlorine Liquid & Gas.
Liquid chlorine withdrawal rate from the chlorine ton containers
shall be more and hence evaporators shall be used for conversion
of liquid chlorine to chlorine gas from the tonners. After the
evaporators, chlorine gas filters are located, to filter the gas.
The chlorinator consists of pressure regulating valve and injector
device.
The pressure of chlorine is reduced in the pressure regulator and
metered quantity of chlorine gas and water are mixed in the
injector assembly. Chlorine solution is dosed in CW forebay.

There are three (3) streams each of capacity 150 kg/hr. two (2)
operating, and one (1) No. standby in CW chlorination system,
each stream consists of ejector, chlorinator, evaporator etc

Dosing Frequency:

Shock Dosing = 5 PPM for 30 minutes, once in 8 hours.

(Residual chlorine of min.0.5 ppm is to be ensured throughout, as
per the system requirement).

Remarks:
Since there was delay in commissioning of the chlorine dosing system,
as a contingency measure, sodium hypo chloride liquid was dosed directly
in forebay to maintain the residual chlorine level of 0.5 ppm in CW.