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A Maharatna Company
Ashwini K Sinha
AGM (NETRA)
ashwiniksinha@ntpceoc.co.in, ashwiniksinha@gmail.com
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
The UN estimates that by 2050, half the World’s population will live in nations
that are short of Water. Water is needed throughout the energy sector at each
step-energy for extraction & production, refining & processing, transportation &
storage and electric power generation it self. It is estimated that water
consumption to generate electricity will more than double over the next 40 Years
Water footprint of an individual - sum of his or her direct and indirect freshwater
use. The direct water use is the water used at home, while the indirect water
use relates to the total volume of freshwater that is used to produce the goods
and services consumed.
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
The per capita availability of water at national level has been reduced from
about 5177 cubic meters in 1951 to the estimated level of 1,820 cubic
meters in 2001 with variation in water availability in different river basins.
Given the projected increase in population by the year 2025, the per capita
availability is likely to drop to below 1,000 cubic metres, which could be
labeled as a situation of water scarcity
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
10
By 2032, NTPC targets a capacity of 128 GW NETRA
A Maharatna Company with 28% capacity from non-fossil sources
2032
~128 GW
2017
~75 GW
2010
~32GW
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
Cleaning of Reservoirs
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
11. High pressure Steam Turbine 12. Deaerator 13. Feed Water Heater
20. Forced draught (draft) fan 21. Reheater 22. Combustion air intake
26. Induced draught (draft) fan hopper 27. Flue Gas Stack
Typical Thermal Power Plant NETRA
A Maharatna Company
17
Typical Scheme for Water Usage NETRA
A Maharatna Company
Typical Scheme for Clarification NETRA
A Maharatna Company
Typical Scheme for Demineralization NETRA
A Maharatna Company
Typical Scheme for CPU NETRA
A Maharatna Company
Typical Scheme for Two Stage RO NETRA
A Maharatna Company
Typical Scheme for RO Treatment NETRA
A Maharatna Company
Typical Scheme for RO and Mixed bed NETRA
A Maharatna Company
Presentation Outline NETRA
A Maharatna Company
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
27
COST OF CORROSION NETRA
A Maharatna Company
28
Costs of Corrosion Problems NETRA
A Maharatna Company Affecting Fossil Steam Plants
Corrosion Problem O&M Non- Fuel Depreciation Total Corrosion
Related Corrosion Cost Cost
Corrosion Cost US $ US $
US $
All Corrosion Problems in 3,43,50,00,000 1,14,20,00,000 4,57,70,00,000
Fossil Steam Plants
Waterside/Steam side 91,60,00,000 22,84,00,000 1,14,44,00,000
Corrosion of Boiler Tubes
Turbine CF & SCC 45,80,00,000 14,27,50,000 60,07,50,000
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
34
Flow rate
S.No. Description GPM M3/Hr
1 Boiler Feedwater 7645 1736.18
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
• RIVER
• SEA
• PONDS
• LAKES
• IRRIGATION CANALS
• BOREWELLS
• RECYCLED WATER
• RESORVOIRS
• RECYCLED EFFLUENTS
CHARACTERISTICS OF WATER & SOURCES NETRA
A Maharatna Company
OF IMPURITIES
IMPURITIES IN WATER:
• COOLING OF CONDENSATE
• AUXILIARY COOLING
• BOILER WATER
• ASH HANDLING WATER
• COAL DUST SUPPRESSION WATER
• WASHING
• DRINKING
• SANITATION
• FIRE WATER
• SERVICE WATER
• HVAC SYSTEM
DM Water Quality requirements NETRA
A Maharatna Company
Boiler Class
Feed-water
Ammonia (NH3) <— < 500 when copper alloys present —>
< 1000 when copper alloy absent
i.e. when SS or Titanium are present
pH (at 25oC) <— 8.8 - 9.2 (or 8.8 - 9.4 when copper —>
alloys absent)
Total Metals <20 <20 <20 <20
Spray Water 10 10 5 5
Sodium (Na) (without RH) (without RH) (without RH)
(without RH)
46
Summary of Primary and Secondary Targets for Drum-type
Boilers under Steady State Operation (expressed as ug/kg
NETRA
A Maharatna Company
unless otherwise stated)
Boiler-water
1. Non-volatile Phosphate Treatment
Chloride (NaCl) as < 3000 < 2000 < 1000 < 500
Chloride
Silica (SiO2) < 5000 < 1500 < 300 < 200
(at pH - 9)
Sulphate (SO4) <-local decision to achieve primary target in boiler water->
Disodium/ Trisodium 2000 2000 1000 1000
Phosphate To To To To
6000 4000 2000 2000
Saturated Steam
48
EPRI Guidelines for Cooling Waters NETRA
A Maharatna Company
PSI >6
Mn Mg/l < 0.5
Desirable: BOD < 5 ppm, Turbidity < 2 NTU, Sulphide < 0.1 ppm (for Cu based systems), Chloride <
200 ppm for SS 304 (upto 500 ppm short duration & < 500 ppm for SS 316 (3000 ppm short duration)
Presentation Outline NETRA
A Maharatna Company
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
S.No. Chemical Rate Rs. Annual Cost of Chemical per 1000 m3/hr make up (Rs.)
(Per Kg/L) 1 ppm 2 ppm 3 ppm 4 ppm 5 ppm
1 HEDP 50% 50 438000 876000 1314000 1752000 2190000
2 PBTC 50 % 180 1576800 3153600 4730400 6307200 7884000
3 Polyacrylate 100 876000 1752000 2628000 3504000 4380000
4 Polymaleic 150 1314000 2628000 3942000 5256000 6570000
5 Zinc sulphate 25 219000 438000 657000 876000 1095000
6 BTA 450 3942000 7884000 11826000 15768000 19710000
7 HEDP 60 % 60 525600 1051200 1576800 2102400 2628000
8 ATMP 50 438000 876000 1314000 1752000 2190000
9 Carboxylate/ 150 1314000 2628000 3942000 5256000 6570000
Sulphonate
10 Carboxylate/ 200 1752000 3504000 5256000 7008000 8760000
Sulphonate/
nonionic
11 Si & Mg 400 3504000 7008000 10512000 14016000 17520000
inhibitor
12 SHMP 35 306600 613200 919800 1226400 1533000
13 Molybdate 250 2190000 4380000 6570000 8760000 10950000
14 silicate 180 1576800 3153600 4730400 6307200 7884000
Presentation Outline NETRA
A Maharatna Company
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
Corrosion
Particle Entrapment
Deposition Growth Sites Biofouling
Optimizing COC NETRA
A Maharatna Company
Table 1
Thermal conductivity comparison of deposit-forming compounds
and bio-film
Thermal Conductivity
Substance
(W m-1K-1)
CaCO3 2.6
CaSO4 2.3
Fe2 O3 2.9
Analcite 1.3
Bio-film 0.6
Optimizing COC NETRA
A Maharatna Company
Table 2 - Effect of CaCO3 scale (of varying thickness) on overall heat transfer coefficient
Scale Thickness, Overall heat transfer coefficient, BTU per Percent loss in BTU per sq ft
Inches sq ft per deg F per deg F
0.000 92.77 0
0.012 73.68 20.58
0.024 61012 34.12
0.036 52.20 43.73
0.048 45.60 55.85
0.060 40.46 56.39
0.0625 (1/16 in.) 39.52 57.40
Optimizing COC NETRA
A Maharatna Company
Table 3 - Effect of CaSO4 scale (of varying thickness) on overall heat transfer coefficient
Overall heat transfer scale Coefficient, BTU per sq ft Percent loss in BTU per sq ft
thickness, inches per deg F per deg F
0.000 92.77 0
0.012 63.10 31.98
0.024 47.81 48.46
0.036 38.49 58.51
0.048 32.20 62.00
0.060 27.69 70.00
0.0625 (1/16 in.) 26.89 71.00
Optimizing COC NETRA
A Maharatna Company
• According to the U.S. DOE, pumps consume about 20% of all generated
electricity
• Unlike motors, the efficiency of pumps is highly influenced by the system
they are supplying
• In a typical surface water treatment and distribution system approx. 70-
90% of energies used are for pumping
• Over an expected life span of 20 years, only 2.5 – 3% of the cost of pump
operation related to the purchase of the equipment. Further 2 – 2.5% relates
to maintenance costs. 95% is towards the cost of electricity to run the unit
•In any pumping system, over the years, the hydraulic passages of
casings & impeller vane shape gets damaged due to wear, tear &
corrosion, also the clearance in wear rings increases substantially. All
these damages lead to head and flow losses & ultimately deteriorate
hydraulic performance. Due to this deterioration of performance the
power consumption increases putting pressure on energy demand due
to inefficient operation of pump.
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
Effects of Corrosion, Erosion-Corrosion, NETRA
A Maharatna Company
Cavitations on the Performance of Pumps
Major Friction Loss – This is the friction of inside surface of pipeline to the
flow of water. For large diameter and long lines this loss consumes large
power and therefore energy.
• Value of C would depend upon the roughness only and for any given
roughness C would be a constant.
Thickness of linings –
Pump designed for 630 m3/hr was delivering 450 m3/hr due to
Severe fouling. Corrosion products
Biofouling & MIC NETRA
A Maharatna Company
Severe Corrosion of CW System NETRA
A Maharatna Company
Control Measures NETRA
A Maharatna Company
Severe Fouling of PVC Fills NETRA
A Maharatna Company
Loss of around Rs. 1.2 Crore per 500 MW unit per year
Restoration of Heat Transfer NETRA
A Maharatna Company
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
PSI 5.39 4.46 3.81 3.30 2.88 2.53 2.23 1.96 1.72 1.50 1.30 1.12 0.95 0.79 0.65
- - - -
RSI 6.03 3.66 2.56 2.02 1.57 1.20 0.87 0.59 0.33 0.10 0.11 0.31 0.49 0.66 -0.81
Problems due to Organic Matter, Microbiolgy NETRA
A Maharatna Company Case 1
HIGH ORGANIC MATTER LOADING (UNTREATED SEWAGE) IN RAW WATER:
• Acute problem of obtaining required quality of DM water throughout the year
• Problem more severe in summers
• Due to high untreated sewage – proper clarification is very difficult
• Chlorine demand is very high (100 – 200 ppm)
• DM water conductivity goes as high as 0.8 us/cm (4 us/cm in DM tanks)
• pH of Boiler water drops to 7.5 – requires caustic dosing
• High Conductivity water causes deviations in Boiler & Stator water Chemistry
REMEDIAL MEASURES:
• Aeration of the make up water to remove BOD/COD
• Installation of Sewage Treatment Plant prior to clarifiers & Chlorine Dioxide
99
• Installation of Ultrafilteration system/RO water system prior to DM Plant
• Alternate source of raw water – borewell for DM plant
Problems due to Organic Matter, Microbiolgy NETRA
A Maharatna Company Case 2
Analysis of Water Sample
Water Extract ( 1gm plant fruit in 500 ml)
In the presence of high Organic matter, clarification of water is not effective even with
Alum/Polyelectolytes(cationic or anionic)
% Reduction
Water Extract ( 1000 ppm solution of plant fruit) 120
Water Extract ( 400 ppm solution of plant fruit)
64
Water Extract ( 400 ppm solution of plant fruit)+2
ppm KMnO4 56 12.5
Water Extract ( 400 ppm solution of plant
fruit)+Aeration 48 25
100
Problems due to Organic Matter, Microbiolgy NETRA
A Maharatna Company Case 3
Concentration in ppm
60
50 BOD
40 COD
30
20 TOC 1
10 TOC 2
0
CIRCULATING
RESERVOIR
RESERVOIR
CLARIFIED
LIVE RESERVOIR
WATER
INTAKE
DEAD
WATER
Nature of water
101
Presentation Outline NETRA
A Maharatna Company
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
3000 --
Makeup
2000 --
1000 --
Blowdown
0
1 2 3 4 5 6 7 8
Cycles of Concentration
COC Optimization NETRA
A Maharatna Company
2 2.0 32000 160 576 576 1312 157 315 5196 10391
3 2.5 32000 160 576 384 1120 134 269 4435 8870
4 3.0 32000 160 576 288 1024 123 246 4055 8110
5 3.5 32000 160 576 230 966 116 232 3827 7654
6 4.0 32000 160 576 192 928 111 223 3675 7350
7 4.5 32000 160 576 165 901 108 216 3566 7133
8 5.0 32000 160 576 144 880 106 211 3485 6970
Waste Water Recycling NETRA
A Maharatna Company
Evaporation+drift
40000 M3/hr
CW 700 M3/Hr
Pumps Induced
CONDENSER draft
COOLING BLOW DOWN
TOWER
AUX 240 M3/Hr (Design)
190 M3/Hr
COC = 4-5
Discharge to 9 Km
STP Effluent
MakeUp
distance
1100 M3/Hr (Design) 200 M3/day
800-900 M3/Hr C
(Actual) Drinking
water
M
Clariflocculators
B
Narmada River
One Standby
RESERVOIR
tank
unlined
DMP Effluent
Clarifier Gravity DM Plant
Raw Water Pumps for DM Filter 250 M3/day
Plant 275 M3/Hr
2x275 M3/hr
Water Balance
Waste Water Recycling NETRA
A Maharatna Company
CT BLOW DOWN
5760 M3/Day (Design)
4500 M3/Day
Softening Plant
Regeneration Waste
C Discharge
3 M3/day M
B
DMP Effluent
250 M3/day
STP Effluent
200 M3/day
Proposed
UF+RO
Effluents system
D/G pumps
PAC+Chlorine 4*125 m3/hr
D/G tank
FeCl3+lime+Dolomite 3*55 m3/hr
Reactor FW pumps
Clarifier 4*125 m3/hr
275
M3/hr FWST
2*150 m3/hr
4 Makeup water to boiler Improvement in the makeup water 25000 Approx. 3,00,000.00
quality will subsequently have less
blowdown rate in boiler.
5 Regeneration chemicals Rs 5.5/- per M3 5,94,000.00 71,28,000.00
6 life of resins Resin cost savings 5,00,000
7 Pretreatment chemicals Rs 0.25 per M3 27,000.00 3,24,000.00
Alum/lime/PAC
8 Brine treatment cost Rs 0.10 per M3 14,400.00 1,72,800.00
TOTAL 2,60,04,000.00
Waste Water Recycling NETRA
A Maharatna Company
Ash Water Recycling
The Ash Slurry is collected in Ash Dykes and the decanted water disposed off
Schemes have been developed to recycle the decanted Ash water with suitable
Treatment programs and only limited make up is provided to meet the requirements
Presentation Outline NETRA
A Maharatna Company
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
Emphasis on dry ash collection & disposal for ash utilization purposes
120
Presentation Outline NETRA
A Maharatna Company
1.0 Introduction
Water Availability & Utilization
Power Scenario with possible Water Foot Prints
Improving sewage treatment plants for better output & quality of water for
reuse
12
3