Technochem Labs

TECHNICAL REPORT ON
STEAM PURITY TESTS CONDUCTED FOR SAP I & SAP II
TANFAC INDUSTRIES LIMITED
14, SIPCOT INDUSTRIAL COMPLEX , CUDDALORE

As per the email from M/s.TANFAC dated 26.12.2006 and Order No: POWO50725 dated 19.01.2006, a
detailed study was undertaken to estimate the purity of steam produced from both SAP I & SAP II on

C-56, “Balaji Bhavan”, Thillainagar, N.E.E; Tiruchirapalli-620 018

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30.12.2006 and 31.12.2006. The detailed procedure for the Steam-Purity Test was handed over to
M/s.TANFAC prior to tests on 30.12.2006 by our chemist Mr.S.Ganesh.

1.0 BRIEF OUTLINE OF THE PROCEDURE FOR STEAM-PURITY TESTS

Prior to collection of the samples, the boiler has to be stabilized at (i) Steady steam flow rate (ii) Drum
operating pressure (iii) Boiler water chemistry conditions and (iv) Steady drum level.

To facilitate steady boiler water chemistry conditions, the blow down has to be closed and no HP dosing
(Phosphate) to be done during this stabilization period.

The sampling lines are to be thoroughly flushed and kept bleeding to obtain representative samples.

The boiler has to be run under steady operating conditions for a period of three hours and during the
fourth hour four sets of boiler water, and Saturated and Superheated steam samples are to be collected.
Samples of Feed water and Condensate are also to be collected.

The feed water & boiler water chemistry conditions are maintained as per existing conditions and
practices. The following analyses are carried out in the samples collected.

Sl No Samples Parameters

pH, Specific electrical conductivity, Sodium, Total iron, Silica,

1 Feed water
and Hydrazine

pH, TDS, Specific electrical conductivity, Phosphate, Sodium,

2 Boiler water
Silica, P-Alkalinity, and M-Alkalinity

Saturated steam and pH, TDS,Specific electrical conductivity, Silica, Sodium, and
3
Superheated steam Total iron

pH, Specific electrical conductivity, Silica, Sodium and Total

4 Condensate
Iron.

All the above parameters are analysed as per ASTM procedures as stipulated in ASTM 10.1.0 (Water).

The TDS of Steam samples are to be calculated as per ASTM D-2186 using the following formula:

TDS of steam (ppm) = [TDS (ppm) of boiler water / Sodium (ppm) in boiler water] x Sodium (ppm) in
steam.

For safe turbine operation the following steam purity is recommended:

1. TDS (ppm), max : 0.10

2. Silica (as SiO2, ppm) max : 0.02

2.0 RESULTS AND DISCUSSIONS:

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The operational data collected during the tests for SAP I & SAP II are furnished in Tables 1 & 2
respectively. The analytical results for SAP I are furnished in Table 3 & Table 4. The analytical results for
SAP II are furnished in Table 5 and Table 6. Highest possible steam loading to drum internals was
permitted during the testing period to test their steam-moisture separating efficiency.

Both boilers are operated at 42 kg/cm2(g) drum operating pressures with 52 to 53% drum water levels.

The TDS levels in SAP I was between 753 to 789 ppm and SAP II 1014 to 1045 ppm.

The pH of boiler water in SAP I was 10.7 and in SAP II was 10.8 corresponding to a PO 4 level of 12.7
ppm in SAP I and 18.8 ppm in SAP II.

The silica levels in boiler water SAP I was 6.5 ppm and in SAP II was around 30.0 ppm.

The saturated steam of SAP I was found to have a TDS level of between 0.83 to 0.94 ppm against a
recommended value of 0.1 ppm. The saturated steam of SAP II was found to have a TDS level of
between 1.08 to 1.16 ppm against a recommended value of 0.1 ppm.

The silica levels in Saturated steam of both SAP I & SAP II are very much on the higher side viz. 0.25 and
0.05 ppm respectively.

Both boilers are found to have heavy carryover of salts perhaps more carryover was observed in
SAP II than in SAP I.

Surprisingly, both silica levels and TDS levels of SH Steam of both SAP I & SAP II are observed to be
within the recommended limits . This may be due to the probable deposition of the impurity constituents
on the surfaces of the SH steam pipe lines due to lower solubility of the same at the superheat.

Cause of carryover:

The most probable cause of the carryover of salts along with steam is the abnormally high level of
caustic alkalinity maintained in the boiler water of both SAP I & SAP II.

Boiler Caustic alkalinity (ppm as CaCO3)

(2P-M)

SAP I 84

SAP II 114

Higher levels of caustic alkalinity will create foam under boiler water conditions which may cause
carryover.

The presence of caustic in boiler water is further confirmed by the higher level of Sodium in boiler water
than permitted by the counter part Phosphate.

It was reported that the practice of dosing boiler water involves the usage of a proprietary compound.
We are not aware of the composition of the same to comment further on the excessive caustic presence
and imbalance in sodium content in boiler water.

3.0 RECOMMENDATIONS:
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1. It is recommended to avoid the presence of excessive caustic soda in boiler water. This is possible by

maintaining Co-ordinated PO4 –pH treatment by dosing a mixture of Tri-Sodium Phosphate & Disodium

Hydrogen phosphate so that the residual PO4 level in boiler water will be 5 to 10 ppm corresponding to

a pH range between 9.2 to 9.8.

Another method to avoid excessive caustic is to have a controlled dosing of TSP alone and avoiding

any direct addition of caustic soda.

2. It is recommended to control the addition of the boiler water dosing compound in such a way that

2P < M (where P is the P-Alkalinity and M is the M-Alkalinity) .

3. If the above conditions with the existing method of dosing are not possible, It is strongly recommended

to stop addition of any proprietary chemical formulation to boiler water.

In a way it is safer to use generic chemicals in place of any proprietary compounds for use in boiler &

feed water treatments, since (i) its quality could be controlled by employing a standard method of

testing (ii) hazards due to decomposition of the same under boiler water conditions could be avoided

and (iii) dosage could be easily monitored in boiler water.

4. It is recommended to exercise more care on external water treatment since the feed water silica is on

the higher side.

5. Since the make-up water is of DM quality, it is recommended to maintain lowest TDS (specific electrical

conductivity) in boiler water with minimum addition of dosing compounds like TSP. This will reduce

blowdown and subsequent loss of heat and recurring cost due to chemicals.

6. It is recommended to check the drum internals (spacings between the screen driers and any loose

fittings in drum internals during immediate shutdown of the boilers.

7. It is recommended to check the quality of the steam samples after correcting the boiler water regime as

recommended above, to confirm the improvement.

8. It is recommended to examine the steam pipe lines and tubine for any suspected presence of

deposition and to further clean the same with suitable non corrosive solvent.

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