Descriptions-of-Past-Research-Boiler-and-Turbine-Steam-and-Cycle-Chemistry-Program

v PRODUCT DESCRIPTION This document contains summaries of many past Electric Power Research Institute EPRI Boiler and Turbine Steam and Cycle Chemistry Program research and development

Descriptions of Past Research

Boiler and Turbine Steam and Cycle Chemistry Program

3002004151

EPRI Project Manager

M Caravaggio

Descriptions of Past Research

Boiler and Turbine Steam and Cycle Chemistry Program

3002004151Technical Update, June 2014

DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES

THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC (EPRI) NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM:

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Electric Power Research Institute (EPRI)

This is an EPRI Technical Update report A Technical Update report is intended as an informal report of continuing research, a meeting, or a topical study It is not a final EPRI technical report

NOTE

For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or e-mail askepri@epri.com

ELECTRICITY are registered service marks of the Electric Power Research Institute, Inc

Copyright © 2014 Electric Power Research Institute, Inc All rights reserved

This publication is a corporate document that should be cited in the literature in the following manner:

Descriptions of Past Research: Boiler and Turbine Steam and Cycle Chemistry Program EPRI,

Palo Alto, CA: 2014 3002004151

iii

CITATIONS

This report was prepared by

Electric Power Research Institute (EPRI)

v

PRODUCT DESCRIPTION

This document contains summaries of many past Electric Power Research Institute (EPRI) Boiler and Turbine Steam and Cycle Chemistry Program research and development (R&D) efforts

Results and Findings

Although not all-inclusive, this document will assist utility personnel in quickly identifying related EPRI R&D products on www.epri.com

Challenges and Objectives

This document will assist plant personnel who are responsible for boiler and turbine

maintenance, operation, risk management, or troubleshooting in quickly locating the appropriate EPRI reports on www.epri.com

Applications, Value, and Use

This document is a useful reference resource for EPRI member organizations that are seeking past reports on specific topics of interest EPRI will update this document periodically to include new research reports and software produced in the Boiler and Turbine Steam and Cycle

Chemistry Program

EPRI Perspective

The R&D projects completed by the EPRI Boiler and Turbine Steam and Cycle Chemistry Program provide a comprehensive integration of the knowledge and guidance of disciplines within the program This document is a catalogue of the topical reports that will provide

assistance in locating and identifying information in research areas of interest With such a reference, chemistry, engineering, managerial, and plant personnel can quickly locate reports of interest, as well as related material and background research Such availability greatly enhances the transfer of research technology to EPRI members

Approach

A compilation of well over 100 product summaries describing EPRI research performed over the previous 30 years is contained in this document The summaries are arranged in the following categories:

• Cycle chemistry

• Copper

• Flow-accelerated corrosion (FAC)

• Turbine steam chemistry

• Condenser

• Value and cost

• Reliability and productivity

vii

ABSTRACT

A compilation of over 100 product summaries describing EPRI research performed over the previous 30 years is contained in this document The summaries are arranged in the categories of cycle chemistry, copper, flow-accelerated corrosion (FAC), turbine steam chemistry, corrosion, boiler corrosion, deposition, instrumentation, ChemExpert, condensate polishing and filtration, turbine corrosion, stator cooling, condenser, value and cost, reliability and productivity, and proceedings

Each product summary contains an abstract; a description of the report’s objective, approach, and results; optionally, the report’s application, value, and use; an EPRI perspective; and

keywords This document is a useful reference resource for EPRI member organizations who are seeking past reports on specific topics of interest EPRI will update this document periodically to include new research reports and software

ix

CONTENTS BY SUBJECT

1 CYCLE CHEMISTRY GUIDELINES 1-1

2 DAMAGE: THEORY AND PRACTICE 2-1

15 VALUE AND COST 15-1

16 RELIABILITY AND PRODUCTIVITY 16-1

17 PROCEEDINGS 17-1

xi

TABLE OF CONTENTS

1 CYCLE CHEMISTRY GUIDELINES 1-1

Boiler Chemical Cleaning Waste Management Manual 1-2 Influence of Cycling and Low-Load Operation on Cycle Chemistry Control and

Requirements 1-4 Closed Cooling Water Chemistry Guideline: Revision 2 1-6 Open Cooling Water Chemistry Guideline 1-8 Primer on Flexible Operations in Fossil Plants 1-10 Comprehensive Cycle Chemistry Guidelines for Combined Cycle/Heat Recovery

Steam Generators (HRSGs) 1-11 Comprehensive Cycle Chemistry Guidelines for Fossil Plants 1-13 Compilation of EPRI Fossil Plant Cycle Chemistry Guidelines 1-15 Cycle Chemistry Guidelines for Fossil Plants: Oxygenated Treatment 1-17 Cycle Chemistry Guidelines for Fossil Plants: Oxygenated Treatment 1-19 Cycle Chemistry Guidelines for Fossil Plants: Phosphate Continuum and Caustic

Treatment 1-21 Chemistry Guidelines for Fossil Plants: All-Volatile Treatment: Revision 1 1-23 Selection and Optimization of Boiler Water and Feedwater Treatments for Fossil

Plants 1-25 Assessment of Amines for Fossil Plant Applications 1-27 Interim Guidance—Amine Treatments in Fossil Power Plants 1-29 Thermal Degradation of Amines in Supercritical Water 1-31 Cycling, Startup, Shutdown, and Layup Fossil Plant Cycle Chemistry Guidelines for Operators and Chemists 1-33 Cycling, Startup, Shutdown, and Layup Fossil Plant Cycle Chemistry Guidelines for Operators and Chemists 1-35 Shutdown Protection of Steam Turbines Using Dehumidified Air 1-37 Integrated Boiler Tube Failure Reduction/Cycle Chemistry Improvement Program 1-39 Cycle Chemistry Improvement Program 1-41 Cycle Chemistry Corrosion and Deposition: Correction, Prevention, and Control 1-43 Guidelines for Chemical Cleaning of Conventional Fossil Plant Equipment 1-45 Interim Guidance on Chemical Cleaning of Supercritical Units 1-47 Guidelines for Makeup Water Treatment 1-49 Revised Guidelines for Makeup Water Treatment 1-51 Guidelines for Turbine Deposit Collection and Analysis 1-53

2 DAMAGE: THEORY AND PRACTICE 2-1

Turbine Steam Path Damage: Theory and Practice 2-2 Plant Turbine Steam Path Damage: Theory and Practice— Volume 1: Turbine

Fundamentals Volume 2: Damage Mechanisms 2-4 Field Guide: Turbine Steam Path Damage 2-6 Revision of EPRI's Boiler Tube Failure Books 2-8 Boiler and Heat Recovery Steam Generator Tube Failures— Volume 1:

Fundamentals Volume 2: Water-Touched Tubes Volume 3: Steam-Touched Tubes 2-10 Field Guide: Boiler Tube Failure 2-12 Field Guide: Heat Recovery Steam Generator Tube Failure 2-14 Feedwater Heater Tube Failure Manual 2-16 Condenser Tube Failures: Theory and Practice 2-18

3 COPPER 3-1

Guidelines for Copper in Fossil Plants 3-2 State-of-Knowledge of Copper in Fossil Plant Cycles 3-4 Influence of Water Chemistry on Copper Alloy Corrosion in High Purity Feedwater 3-6 Influence of Water Chemistry on Copper Alloy Corrosion in High Purity Feedwater 3-8 Copper Alloy Corrosion in High Purity Feedwater 3-10 Copper Alloy Corrosion in High Purity Feedwater: Admiralty Brass, Aluminum Brass, and 90/10 Copper/Nickel at 95 °C (203 °F) 3-12 Corrosion of Cu-Ni-Zn Alloys in Water-Ammonia Power Plant: Development of

High Temperature Potential-pH (Pourbaix) Diagrams 3-14 Behavior of Aqueous Electrolytes in Steam Cycles: The Final Report on the

Solubility and Volatility of Copper (I) and Copper (II) Oxides 3-16 Behavior of Aqueous Electrolytes in Steam Cycles: The Solubility and Volatility of

Copper (I) and Copper (II) Oxides 3-18 Behavior of Aqueous Electrolytes in Steam Cycles: The Solubility and Volatility of

Cupric Oxide 3-20

4 FLOW-ACCELERATED CORROSION (FAC) 4-1

Guidelines for Controlling Flow-Accelerated Corrosion in Fossil and Combined

Cycle Plants 4-2 Flow-Associated Corrosion in Power Plants 4-4 Flow-Accelerated Corrosion (FAC) Fossil and Combined Cycle Self-Assessment

Guideline 4-6 Investigation of Critical Parameters in Flow-Accelerated Corrosion Under Two-

Phase Flow Conditions 4-8 Investigation of Flow-Accelerated Corrosion Under Two-Phase Flow Conditions 4-10 Investigation of Flow-Accelerated Corrosion Under Two-Phase Flow Conditions 4-12 Development of an In Situ System for Monitoring or Indicating Flow-Accelerated

Corrosion in Fossil Plant Feedwater 4-14

xiii

Development of In Situ System for Monitoring or Indicating Flow-Accelerated

Corrosion in Fossil Plant Feedwater 4-18 Fossil FAC Advisor (FFA) Flow-Accelerated Corrosion Version 1.0 4-20 CHECUPweb 1.1 - CHECUPweb, Version 1.1 4-21 FAC Wear Rate Assessment Through Insulation 4-22 New and Emerging Inspection Technologies for Flow-Accelerated Corrosion in

Fossil Power Plants 4-23

5 STEAM CHEMISTRY 5-1

Vapor-Liquid Partitioning of Phosphoric Acid and Sodium Phosphates 5-2 The Volatility of Impurities in Water/Steam Cycles 5-4 Volatility of Aqueous Sodium Hydroxide, Bisulfate and Sulfate 5-6 Volatility of Aqueous Sodium Hydroxide, Bisulfate and Sulfate 5-8 Volatility of Aqueous Acetic Acid, Formic Acid, and Sodium Acetate 5-10 Computer Code for Prediction of Corrosion Fatigue: Life of Steam Turbine Blades and Disks 5-12 Improved Efficiency and Availability of Steam Turbines from Electrostatic

Interactions Within the Steam Flowpath 5-14 Electrostatic Effects in Nucleating Flows of Steam 5-16 Investigation of Enhanced Heat Transfer Coefficient with an Electrostatic Grid 5-18 Electrostatic Charge and Its Influence on the Condensation of Steam in a Turbine 5-20 Turbine Steam Chemistry and Corrosion: Electrochemistry in LP Turbines 5-22 Turbine Steam, Chemistry and Corrosion Generation of Early Liquid Films in

Turbines 5-24 Investigation of Electrophysical Effects in the Turbine Exhaust upon Steam Flow

and Power Output 5-26

6 CORROSION 6-1

Low-Temperature Corrosion Problems in Fossil Power Plants: State of Knowledge Report 6-2 Priorities for Corrosion Research and Development for the Electric Power Industry 6-4 Characterization of Surface Film Growth During the Corrosion Process 6-6 Effect of Oxygen Concentration on Corrosion Product Transport at South Texas

Project Unit 1 6-8 Sodium Phosphate Hideout Mechanisms: Data and Models for the Solubility and

Redox Behavior of Iron (II) and Iron (III) Sodium-Phosphate Hideout Reaction

Products 6-10 Initiation of Intergranular Stress Corrosion Cracking in Type 304 Stainless Steel

and Alloy 600 6-12 On-Line Corrosion Monitoring Using Electrochemical Frequency Modulation (EFM) 6-14 Corrosion Fatigue Boiler Tube Failures in Waterwalls and Economizers—

Volume 5: Application of Guidelines at Hazelwood Power Station 6-16 Erosion-Corrosion of Metals and Alloys at High Temperatures 6-18

7 BOILER CORROSION 7-1

Heat Flux Electrochemical Studies of Underdeposit Boiler Tube Corrosion 7-2

Evaluation of Waterwall Corrosion Fatigue, Volume 1: Roadmap for Addressing

Corrosion Fatigue of Boiler Waterwall Tubes 7-4 Evaluation of Waterwall Corrosion Fatigue, Volume 2: Roadmap Case Study:

Evaluation of AEP's Big Sandy Unit 1 7-6 Evaluation of Circumferential Cracking on Supercritical Boiler Waterwalls— Volume 1: Evaluation and Root Cause of Thermal Fatigue Cracking in Supercritical Boilers;

Volume 2: PP&L Brunner Island Power Station (Unit 3) Furnace Wall Scanner

1015314 7-8 Growth Characteristics in Waterwall Tubes of Supercritical Units 7-10 Oxide Scale Growth Characteristics in Waterwalls of Supercritical Steam Boilers 7-12 Evaluation of Solvent Processes for Chemical Cleaning of Supercritical Waterwalls and Removal of Duplex Oxides Formed by High Temperature, In-situ Oxidation of

Ferritic Steels 7-14 Program on Technology Innovation: Oxide Growth and Exfoliation on Alloys

Exposed to Steam 7-16 Program on Technology Innovation: Development of a Conductivity/Corrosion Probe for Use in Boiler Water at Temperatures Up to 360 °C 7-18 Root Causes of Circumferential Cracking in Waterwalls of Supercritical Units:

State-of-Knowledge 7-20 Simulated Boiler Corrosion Studies Using Electrochemical Techniques: AVT(R)

Contaminant Limits 7-22 Simulated Boiler Corrosion Studies Using Electrochemical Techniques: AVT(O)

Contaminant Limits 7-24 Simulated Boiler Corrosion Studies Using Electrochemical Techniques 7-26 Simulated Boiler Corrosion Studies Using Electrochemical Techniques 7-28 Assessment of Probes to Measure Waterwall Wastage at American Electric

Power's Gavin Unit 1 7-30 Status Review of Initiation of Environmentally Assisted Cracking and Short Crack

Growth 7-31 Remaining Life Assessment of Austenitic Stainless Steel Superheater and

Reheater Tubes 7-33 Interfacial Crack Propagation During Compressive Failure of Thin Protective Oxides and the Fracture of Iron Oxide Scales—Appendix: EPRI/NPL Database on the

Mechanical Properties of Oxide Scales (MPOS) 7-35 Corrosion Fatigue Boiler Tube Failures in Waterwalls and Economizers—

Volume 5: Application of Guidelines at Hazelwood Power Station 7-37 Corrosion Fatigue Crack Initiation of Boiler Tubes: Effect of Phosphate in Boiler

Water 7-39

8 DEPOSITION 8-1

Boiler Water Deposition Model for Fossil-Fueled Power Plants: Engineering

Sourcebook for Risk Mitigation 8-2 Boiler Water Deposition Model for Fossil-Fueled Power Plants 8-4

xv

Boiler Water Deposition Model for Fossil-Fueled Power Plants: Progress on

Enhancement of a Deterministic Model and Development of Risk-Based

Assessment – Part 2 8-6 Boiler Water Deposition Model for Fossil-Fueled Power Plants 8-8 Program on Technology Innovation: Influence of Bubble Dynamics on Surface

Deposition Under Sub-Cooled Boiling Conditions 8-10 Boiler Water Deposition Model for Fossil-Fueled Power Plants 8-12 Boiler Water Deposition Model for Fossil-Fueled Power Plants 8-14 Deposition on Drum Boiler Tube Surfaces 8-16 Deposition on Drum Boiler Tube Surfaces 8-18 Boiler Water Deposition Model— Part 1: Feasibility Study 8-20 State-of-Knowledge on Deposition— Part 2: Assessment of Deposition Activity in

Fossil Plant Units 8-22 Deposition in Boilers: Review of Soviet and Russian Literature 8-24 State-of-Knowledge on Deposition Part 1: Parameters Influencing Deposition in

Fossil Units 8-26

9 INSTRUMENTATION 9-1

Enhanced Chloride Monitoring for Steam Condensate Samples 9-2 Cycle Chemistry Instrumentation Validation 9-3 Instrumentation Validation Manual: Supplemental Report 9-5 Fossil Plant Cycle Chemistry Instrumentation and Control—State-of-Knowledge

Assessment 9-7 Continuous Fossil Plant Corrosion Product Monitoring and Corrosion Control

Optimization 9-9 Corrosion Product Transport Monitoring: Continuous On-Line Monitoring

Evaluations for Electric Power Generating Stations 9-12 On-Line Corrosion Monitoring Using Electrochemical Frequency Modulation (EFM) 9-14 Optical pH Sensors for High Temperature Environments 9-16 Development of Steam-Phase Sensors III 9-18 Development of Steam-Phase Sensors II 9-20 Development of Steam Phase Sensors 9-22 Program on Technology Innovation: Development of Steam Phase Sensors 9-24 Reference Manual for On-Line Monitoring of Water Chemistry and Corrosion:

1998 Update 9-26 Development of a Steam Sampling System 9-28 Guideline Manual on Instrumentation and Control for Fossil Plant Cycle Chemistry 9-30

11 CONDENSATE POLISHING AND FILTRATION 11-1

Impact of Film-Forming Amines on Condensate Polishing Ion-Exchange Resins 11-2 Condensate Polishing Guidelines for Fossil Plants 11-3 Condensate Polishing Guidelines 11-5 Condensate Polishing State of Knowledge Assessment 11-7 Condensate Polishing Training Manual 11-9 Condensate Polishing Guidelines: Ammonium Form Operation 11-11 Guideline for Off-Site Regeneration of Condensate Polishing Resins 11-13 Condensate Polishing Performance Assessment: Use of Separate Bed Single

Vessel Designs 11-15

On Demand Condensate Polishing: An Innovative Approach to Maintaining

Condensate Purity 11-17 Development of a Radial Flow Condensate Polisher Pilot Scale Test Vessel

Design Specification 11-19 Radial Flow Condensate Polishing: Radial Ion Exchange Physical Model

Experiments 11-21 Radial Flow Condensate Polishing: Radial Ion Exchange Simulation Studies 11-23 Field Demonstration of the EPRI Resin Tester: Prototype Development and Initial

Field Usage 11-25 EPRI Resin Tester: A Simple Tool for Monitoring Resin Kinetics 11-27 Deoxygenation in Cycling Fossil Plants 11-29 Condensate Filtration Technologies for Electric Power Generating Stations 11-31 Program on Technology Innovation: Assessment of Advanced Feedwater Filtration for Electric Power Generating Stations 11-33

12 TURBINE CORROSION 12-1

Inhibition of Pitting and Crevice Corrosion by Filming Amines and Vapor Phase

Corrosion Inhibitors 12-2 Inhibition of Pitting and Crevice Corrosion in Turbine Steels 12-4 Development of Steam Phase Sensors 12-5 Development of Model to Predict Stress Corrosion Cracking and Corrosion Fatigue

of Low Pressure Turbine Components 12-7 Development of Code to Predict Stress Corrosion Cracking and Corrosion Fatigue

of Low Pressure Turbine Components Electrochemical and Corrosion Properties of Turbine Steels 12-9 Development of Code to Predict Stress Corrosion Cracking and Corrosion Fatigue

of Low-Pressure Turbine Components 12-11 Development of Code to Predict Stress Corrosion Cracking and Corrosion Fatigue

of Low Pressure Turbine Components 12-13 Steam Turbine Efficiency and Corrosion: Effects of Surface Finish, Deposits, and

Moisture 12-15 Corrosion of Low Pressure Steam Turbine Components 12-17

xvii

13 STATOR COOLING 13-1

Prevention of Flow Restrictions in Generator Stator Water Cooling Circuits 13-2 Generator Cooling System Operating Guidelines: Cooling System Maintenance and Performance Guidelines During Start-Up, Operation, and Shutdown 13-5 Conversion to Deaerated Stator Cooling Water in Generators Previously Cooled

with Aerated Water: Interim Guidelines 13-7 Preventing Leakage in Water-Cooled Stator Windings (Phase 2) 13-9

14 CONDENSER 14-1

Interim Guidelines for Control of Steamside Corrosion in Air-Cooled Condensers of Fossil Units 14-2 Update Report on Condenser Air In-Leakage Monitoring 14-4 Air In-Leakage and Intrusion Prevention Guidelines 14-6 Condenser Tube Failures: Theory and Practice 14-8 Control of Biofouling Using Natural Furanones to Eliminate Biofilms 14-10

15 VALUE AND COST 15-1

Cycle Chemistry Upsets During Operation: Cost and Benefit Considerations 15-2 Real-Time Cycle Chemistry Excursions: An Approach to Valuation and Decision

Guidance 15-4 Valuing Cycle Chemistry in Fossil Power Plants 15-6 Justifying Cycle Chemistry Upgrades to Improve Availability, Performance and

Profitability 15-8

16 RELIABILITY AND PRODUCTIVITY 16-1

Productivity Improvement for Fossil Steam Power Plants, 2007 16-2 Guidelines for New High Reliability Fossil Plants 16-4 Productivity Improvement for Fossil Steam Power Plants, 2006 16-6 Productivity Improvement for Fossil Steam Power Plants 2005: One Hundred

Case Studies 16-8 Repairs of Deaerators 16-10 Productivity Improvement for Fossil Steam Power Plants Industry Case Studies 16-11 Productivity Improvement Handbook for Fossil Steam Power Plants: Third Edition 16-13 Productivity Improvement Handbook for Fossil Steam Power Plants: Second

Edition: Chapters 1–6 16-15 Damage to Power Plants Due to Cycling 16-17 Impact of Operating Factors on Boiler Availability 16-19 Productivity Improvement Handbook for Fossil Steam Power Plants 16-21 Retrofits for Improved Heat Rate and Availability: Circulating Water Heat

Recovery Retrofits 16-23

17 PROCEEDINGS 17-1

Cycle Chemistry Conferences 17-2 Ninth International Conference on Cycle Chemistry in Fossil and Combined Cycle Plants with Heat Recovery Steam Generators 17-2 Proceedings: Eighth International Conference on Cycle Chemistry in Fossil and

Combined Cycle Plants with Heat Recovery Steam Generators - June 20–22, 2006, Calgary, Alberta Canada 17-4 Proceedings: 7th International Conference on Cycle Chemistry in Fossil Plants 17-6 Proceedings: Sixth International Conference on Fossil Plant Cycle Chemistry 17-8 Proceedings: Fifth International Conference on Fossil Plant Cycle Chemistry 17-10 Proceedings: Second Fossil Plant Cycle Chemistry Conference 17-12 Boiler & HRSG Tube Failure Conferences 17-14 Proceedings: International Conference on Boiler Tube and HRSG Tube Failures

and Inspections November 2–5, 2004 17-14 Proceedings: International Conference on Boiler Tube Failures and Heat

Recovery Steam Generator (HRSG) Tube Failures and Inspections 17-16 Failures and Inspections of Fossil-Fired Boiler Tubes: 1983 Conference and

Workshop 17-18 Turbine Steam Chemistry & Corrosion Conferences 17-20 Steam Chemistry: Interaction of Chemical Species with Water, Steam, and

Materials During Evaporation, Superheating and Condensation; June 22–25,

1999, Frieburg, Germany 17-20 Proceedings: Workshop on Corrosion of Steam Turbine Blading and Disks in the

Phase Transition Zone 17-22 Condenser Conferences 17-24 Condenser Technology Conference 17-24 Condensate Polishing Conferences 17-26 Proceedings: 2003 EPRI Workshop on Condensate Polishing 17-26 Interactions of Materials, Water, and Steam (Including Organics) Conferences 17-28 Proceedings: Second International Conference on the Interaction of Organics and

Organic Cycle Treatment Chemicals with Water, Steam and Materials 17-28 Proceedings: International Conference on the Interaction of Organics and Organic Cycle Treatment Chemicals with Water, Steam, and Materials 17-30 Steam Chemistry: Interaction of Chemical Species with Water, Steam and

Materials During Evaporation, Superheating and Condensation: June 22-25, 1999, Frieburg, Germany 17-32 The Interaction of Non Iron-Based Materials with Water and Steam 17-34

1-1

1

CYCLE CHEMISTRY GUIDELINES

Boiler Chemical Cleaning Waste Management Manual

addition to rinse and passivation solutions An earlier manual,Boiler Chemical Cleaning Wastes Management Manual (EPRI Report TR-101095) provided guidance on managing chemical

cleaning wastes; however, there have been significant changes in environmental regulations pertaining to disposal of chemical cleaning wastes In addition, the types of oxide for

supercritical units have changed with the longer intervals between chemical cleanings, there is more use of organic-based solvents, inhibitor formulations are different, and operation of HRSGs

is more prevalent

Results and Findings

The manual provides a review of the various solvents that may be used to perform chemical cleanings and characterization of the waste solutions (solvent, rinse, and passivation) The

regulations promulgated by the EPA Various treatment and disposal options are discussed including those that have been successfully used for cleaning wastes and others that may provide alternatives if existing techniques are no longer viable based on changes to environmental

regulations The manual presents a set of roadmaps to assist plant personnel in the planning process to evaluate and select the method for disposal of waste solutions generated during the chemical cleaning process The results of the utility survey are presented in the Appendix

Challenges and Objectives

The manual was developed to assist power plant personnel in evaluating the options to properly manage and dispose of wastes associated with chemical cleaning of boilers and HRSGs

Chemical cleaning of plant equipment is a costly and time-consuming process, most often

performed at the end of unit outages, which may delay the return of the unit to service In many cases, chemical cleanings are postponed, and the when ultimately performed, the waste volume may be greater due to the need for increased solvent use or the multiple solvent stages

Furthermore, higher chromium content could result in the waste solution being characterized as hazardous waste Recent changes to environmental regulations may limit the ability to dispose of

1-3

Applications, Value, and Use

Information in this manual can be used to determine the anticipated waste solution for various chemical cleaning solvents and techniques for proper handling and disposal The detailed

environmental regulations pertaining to air, water, and coal ash combustion by-products will allow plant staff to determine appropriate disposal options and to use roadmaps to assist in the planning process for a chemical cleaning Various alternative handling options are presented that could be evaluated for waste minimization, treatment, beneficial reuse/recycling, and disposal

Approach

The Electric Power Research Institute held an interest group meeting to discuss chemical

cleaning techniques, environmental regulations, and concerns associated with the process,

handling, and disposal of chemical cleaning wastes After the meeting, a survey questionnaire was developed and submitted to program members and nonmember utilities to ascertain

information on cleaning solvents, waste characterization, and disposal techniques and to identify outstanding environmental issues The previous manual, information from the survey, and the interest group meeting were used to formulate the basis for the waste management manual Members of the boiler chemical waste management interest team and the Boiler and Turbine Steam and Cycle Chemistry Program reviewed the draft sections and appendices to provide feedback

Influence of Cycling and Low-Load Operation on Cycle Chemistry Control and Requirements

The chemistry-related influences of the major systems’ conventional recirculating drum-type boilers and combined-cycle heat recovery steam generator evaporators individually exhibit unique reactions to changes in the operating regimes Assessment of resulting thermodynamic and physiochemical changes of operating fluid (water/steam) using technologically and

scientifically based information provides a clear representation of expected conditions

Changes in pressure, temperature, and water/steam flow alter the efficiency and effectiveness of major systems’ components Condenser and deaerator air-removal capability declines with lower heat loads and results in higher levels of condensate/feedwater dissolved oxygen Feedwater components operate at lower temperatures, which alter the location of corrosion mechanisms, particularly flow-accelerated corrosion (FAC) in both the hydraulic sections and steam-touched portions of feedwater heater systems Boiler and evaporator pressure changes impact the pH conditioning of ammonia and phosphate treatments, exacerbating corrosion and deposition during low-load and shutdown conditions

The more frequent and longer duration (both as single events and cumulative events) of unit shutdowns and layups increases the risk of off-line damage and increases the requirement for

Closed Cooling Water Chemistry Guideline: Revision 2

This Closed Cooling Water Chemistry Guideline addresses the use of chemicals and monitoring

methods to mitigate corrosion, fouling, and microbiological growth in the closed cooling-water (CCW) systems of nuclear and fossil-fueled power plants The chemical additives used for these purposes depend on plant-design characteristics, water quality, operating parameters, and the specifications of the Nuclear Steam Supply System (NSSS) suppliers The list of chemicals is not

as extensive as that for open cooling-water systems, but it can be confusing to utility CCW system engineers and chemists Both generic chemicals and proprietary blends are used in CCW systems Acquiring chemicals with sufficiently low levels of contaminants (for example, halides and metals) to meet NSSS suppliers’ original specifications is an issue in some nuclear plants This concern relates particularly to many of the microbiological control agents The use of

chemicals in CCW systems may not resolve problems originating from poor design or

operating/maintenance practices that result in excessive system leaks Excessive leakage makes consistent chemical control very difficult, and it offsets the ability of the chemicals to provide adequate protection

Background

This second revision of the Closed Cooling Water Chemistry Guideline has been endorsed by the

utility chemistry community and represents another step in developing a more proactive

chemistry program to limit or control closed cooling system degradation with increased

consideration of corporate resources and plant-specific design and operating concerns Each utility should examine its plant-specific situation to determine which recommendations should be implemented These guidelines were developed using laboratory data, operating experience, and input from organizations and utilities within and outside of the United States of America It is the intent of the Revision Committee that these guidelines are applicable to all nuclear and fossil-fueled generating stations around the world

Objectives

This second revision of the Closed Cooling Water Chemistry Guideline is intended to provide

recommendations for chemistry control of closed cooling systems of all manufactures and

designs

1-7

Approach

A committee of industry experts—including utility specialists, Institute of Nuclear Power

Operations representatives, water-treatment service-company representatives, consultants, a primary contractor, and EPRI staff—collaborated in reviewing available data on closed cooling-water system corrosion and microbiological issues From these data, the committee generated water-chemistry guidelines that should be used at all nuclear and fossil-fueled plants

Recognizing that each plant owner has a unique set of design, operating, and corporate concerns, the Guidelines Committee developed a methodology for plant-specific optimization

Applications, Value, and Use

This guideline will be of value to power plant chemical personnel, engineering personnel with closed cooling system responsibility, maintenance personnel, and management personnel It will assist station management in endorsing a chemistry program to optimize equipment life, reduce chronic operating problems, and provide assistance with issues regarding regulatory

requirements and plant-life extension Because of the wide range of operating conditions for closed cooling-water systems and the differences in materials of construction and chemical-treatment regimes, each station must develop its own site-specific chemistry program

Open Cooling Water Chemistry Guideline

State-of-the-art chemistry programs help to ensure the continued operation of open cooling water

systems while mitigating corrosion and fouling mechanisms This document, Open Cooling Water Chemistry Guideline, prepared by a committee of industry experts, reflects field and

laboratory data on corrosion and fouling issues of open cooling systems

Background

Service Water System Chemical Addition Guideline (Electric Power Research Institute [EPRI]

report TR-106229) was published in 1996 This guideline targeted service water systems in nuclear power plants and provided guidance for the use of chemicals to treat macrobiological growth, microbiological growth, corrosion, suspended solids fouling, and scaling within these systems A panel of industry experts made the determination that this guideline should be revised and the scope broadened to include all open cooling systems, at both nuclear and fossil

generating stations

Objective

• To update the Service Water System Chemical Addition Guideline, published in 1996, and

ensure that the updated guideline addresses concerns related to all open cooling systems at nuclear and fossil generating stations

EPRI Perspective

The Open Cooling Water Chemistry Guideline represents a significant step toward the use of

proactive chemistry programs to mitigate the damage and lost electrical generation that can result from corrosion and fouling mechanisms common within open cooling systems The Guideline also represents the advantages of combined resources and experience of the nuclear and fossil generating industries This joint effort has produced a document that contains more robust and comprehensive experiences; a fruitful demonstration of the benefits possible when all related knowledge and experience can be combined With a focus on the optimization of individual plant open cooling chemistry programs, the Guideline will aid the plants in developing and optimizing chemistry control to mitigate corrosion and fouling within these systems

Newer Version Of

TR-106229-Service Water System Chemical Addition Guideline

Microbiologically influenced corrosion

Open cooling water

Service water

Total suspended solids

Primer on Flexible Operations in Fossil Plants

The primer reviews the different types of duty cycles, the stresses that the changes in plant operation put on plant equipment, the potential damage to equipment due to cycling, other effects

of cycling, and the mitigation strategies that plant operators are putting into place

The purity of water and steam is central to ensuring combined cycle/heat recovery steam

generator (HRSG) plant component availability and reliability These guidelines for combined cycle/HRSG plants provide information on the application of all-volatile treatment (AVT), oxygenated treatment (OT), phosphate treatment (PT), caustic treatment (CT), and amine

treatment The guidelines will help operators reduce corrosion and deposition and thereby

achieve significant operation and maintenance cost reductions and greater unit availability

document was drafted, and team members were assigned tasks to address the identified needs Subcommittees were struck to write and review chapters and appendices of the guidelines A series of conference calls and webcasts was used to consolidate feedback of the team into the final draft of these guidelines

Objectives

These guidelines have been developed to address the serious corrosion and deposition problems that have been experienced in the steam/water cycle of combined cycle power plants These problems include chemistry-influenced heater tube failures, turbine corrosion, deposition, and flow-accelerated corrosion Compounding these problems is the wide variety in designs and configurations in combined cycle plants, which can significantly affect the damage mechanisms

• OT, which adds oxygen and ammonia to the feedwater

These guidelines include the following evaporator/drum water treatment chemistry control practices for subcritical drum combined cycle/HRSG power plants:

• AVT, which covers all feedwater treatments in which no chemical addition to the evaporator drum is made during normal operation (that is, AVT[O] and OT)

• CT, in which caustic NaOH is added to the evaporator/drum to provide solid alkali-based pH

• PT, in which trisodium (Na3PO4) is added to the evaporator/drum to provide solid based pH; small additions of caustic NaOH are also used in this treatment

alkali-These guidelines also introduce the potential use of amine treatments, using both neutralizing and filming amines, within the combined cycle/HRSG plant

Applications, Value, and Use

The chemistries in these guidelines can be applied to all combined cycle/HRSG plants to achieve optimal reliability and performance of the plant Guidance is provided for the following:

• Selecting the most effective treatment for individual units based on the unit configuration and level of contaminants in the cycle

• Optimizing applied feedwater and evaporator/drum water treatments

• Applying treatments and customizing the suite of instrumentation used for the applied

treatment depending on unit-specific factors

• Identifying and taking corrective action for chemistry upset conditions, including identifying the potential consequences of inaction

Heat recovery steam generator (HRSG)

Power plant availability

1004925 & TR-102285Cycle Chemistry Guidelines for Fossil Plants: Oxygenated Treatment

Objective

These guidelines have been developed to address the serious corrosion and deposition problems that have been experienced in fossil power plants These problems include chemistry-influenced boiler tube failures, turbine corrosion, and deposition and flow-accelerated corrosion

Approach

EPRI developed an initial skeleton of the comprehensive guidelines to include all pertinent research results and areas for improvement from the previous revisions of the guidelines This was used as the basis for a meeting of the EPRI Comprehensive Guidelines Team Following this meeting, a comprehensive needs assessment document was drafted, and team members were assigned tasks to address the identified needs Subcommittees were struck to write and review chapters and appendices of the guidelines A series of conference calls and webcasts was used to consolidate feedback of the team into the final draft of these guidelines

Results

These guidelines include the following feedwater chemistry control philosophies for subcritical, supercritical, drum, and once-through fossil power plants:

• Reducing AVT (AVT[R]) uses ammonia (or an amine of lower volatility than ammonia) and

a reducing agent (usually hydrazine or carbohydrazide)

• Oxidizing AVT (AVT[O]), which applies only ammonia (or an amine of lower volatility than ammonia), does not use a reducing agent and allows a sufficient oxygen residual to ensure an oxidizing condition

• OT adds oxygen and ammonia to the feedwater (An amine of lower volatility than ammonia has very limited application.)

These guidelines include the following boiler drum water chemistry control philosophies for subcritical drum fossil power plants:

• AVT covers all feedwater treatments in which no chemical addition to the boiler drum is made during normal operation (that is, AVT(R), AVT(O), and OT)

• CT, in which caustic NaOH is added to the boiler drum to provide solid alkali-based pH

• PT, in which trisodium (Na3PO4) is added to the boiler drum to provide solid alkali-based pH; small additions of caustic NaOH are also used in this treatment

Application, Value, and Use

The chemistries in these guidelines can be applied to all conventional fossil power plants to achieve optimal reliability and performance of the plant Guidance is provided for the following:

• Selecting the most effective treatment for individual units based on the unit metallurgy, configuration, and level of contaminants in the cycle

• Optimizing applied feedwater and boiler drum water treatments

• Applying treatments and customizing the suite of instrumentation used for the applied

treatment depending on unit-specific factors

• Identifying and responding to chemistry control upset conditions, including identifying potential consequences of inaction

maintain significant operation and maintenance cost reductions and greater unit availability

Objective

This suite of guidelines addresses the critical aspects of fossil plant cycle chemistry and

encompasses five (5) boiler chemistry treatments, three (3) feedwater treatments,

shutdown/startup/layup, condensate polishing, makeup, instrumentation and control, chemical cleaning, copper, and FAC These guidelines identify important factors involved in the local assessment and decision process, define treatment operating parameters, provide cost-benefit evaluation methodologies, and detail methods for customizing application of these guidelines to specific units

The Cycle Chemistry Improvement Program (CCIP) represents the culmination of benchmarking processes and embodiment of research results To fully use the benefits of CCIP and CCIP workshops, the program's ten (10) key cycle chemistry guidelines are incorporated into this complication CCIP workshops held at member sites reinforce accurate understanding of the guidelines for proper application and appropriate transfer of technology

Approach

The program team identified the ten (10) key cycle chemistry guidelines essential to achieving the benefits of program membership These benefits included all the complementary guidance needed to support all aspects of operations

Results

The ten (10) key cycle chemistry guidelines represent the "Crown Jewels" of the Boiler and Turbine Steam and Water Cycle Chemistry Program The guidelines represent over two decades

of research and development to establish a complete approach to fossil plant chemistry that can

be employed in every fossil plant This suite has three guidelines for the five fossil plant boiler water treatments and three feedwater treatments: all-volatile treatment (1004187); phosphate continuum and caustic treatment (1004188); and oxygenated treatment (1004925) Other

guidelines address controlling flow-accelerated corrosion, or FAC (1008082); startup,

shutdown, and layup (TR-107754); chemical cleaning (1003994); condensate polishing

(1010181); makeup water treatment (TR-113692); instrumentation and control (1012209); and copper in fossil plants (1000457) The Integrated Boiler Tube Failure Reduction/Cycle

Chemistry Improvement Program (1013098) provides tools for utilities to assess, benchmark, optimize, and improve specific unit chemistry programs

Application, Value, and Use

The EPRI benchmarking process for cycle chemistry clearly shows the enormous benefit of operation with an optimized chemistry methodology for all types of boiler designs, metallurgy, and operating conditions Complete integration of the guidelines for monitoring and control through appropriate instrumentation and use of condensate polishing and proper makeup water are essential to successful application of a chemistry program Implementation of FAC

inspection and cycle-chemistry-based approaches will be a cost-effective method of increasing personnel safety and plant availability in the approximately 60% of conventional fossil plants experiencing FAC Roadmaps and frequently asked question in the guidelines provide a

thorough approach to chemistry control and optimization

EPRI Perspective

The quality of water and steam is central to ensuring fossil plant component availability and reliability Fossil plant equipment availability and performance problems influenced by cycle chemistry, corrosion, and/or deposition are technically well understood This compilation of EPRI’s suite of key fossil plant chemistry guidelines can be employed in every fossil plant In future research, EPRI's Boiler and Turbine Steam and Cycle Chemistry Program will be addressing deposition around cycle and boiler corrosion

Program

Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

operation and maintenance cost reductions and greater unit availability

OT hybrids that do not meet the key operational parameter (less than 0.5 ppb Fe at the

economizer inlet) and that require chemical cleaning of the boiler Also, there are a number of misunderstandings about exactly what oxygen in the cycle can and cannot do in providing

protection This revision should correct these deficiencies

Approach

EPRI reviewed the experience of hundreds of units operating on OT and developed an initial skeleton of the OT guidelines to include all the recent pertinent research results Following this, the EPRI team developed a draft document, which was circulated to 75 members of EPRI's Boiler and Turbine Steam and Cycle Chemistry Program for review and comment

Results

These OT guidelines, based on 15 years of experience, include the following new features and control philosophies:

• Control limits and action levels are based on over 14 years of EPRI research into the

partitioning and volatility of salts, oxides, and contaminants between water and steam

• New steam limits are based on the latest EPRI understanding of the phase transition zone (PTZ) of the low pressure turbine to minimize corrosion of blades and disks

• A feedwater shutdown limit based on cation conductivity has been developed for

once-through units

• Sections have been included on the science, background, and operating experience of OT, as well as on the conversion activities

The OT guidelines are applicable to baseload, startup, cycling, and peaking operation and

provide corrective actions to be taken when guideline limits are exceeded

Application, Value, and Use

The EPRI benchmarking process for cycle chemistry clearly shows the enormous benefit of operation with OT It can be applied to all once-through and drum units meeting the necessary feedwater cation conductivity limits of less than 0.15 µS/cm The roadmaps and frequently asked questions in the guidelines provide the approach to optimization

EPRI Perspective

These OT guidelines will help utilities achieve plant-specific goals in the areas of availability, reliability, and performance This revision now becomes part of EPRI's suite of nine key fossil plant guidelines that can be employed in every fossil plant EPRI now has three guidelines for the five fossil plant boiler water treatments and three feedwater treatments: all-volatile treatment (1004187), phosphate continuum and caustic treatment (1004188), and oxygenated treatment (1004925) Other guidelines address controlling flow-accelerated corrosion, or FAC (1008082), startup, shutdown, and layup (TR-107754), chemical cleaning (1003994), condensate polishing (TR-104422), makeup water treatment (TR-113692), and copper in fossil plants (1000457)

In future research in the Boiler and Turbine Steam and Cycle Chemistry Program, EPRI will be addressing deposition around the cycle and boiler corrosion

Program

2005 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

History

2004 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

2003 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

Background

EPRI's Interim Consensus Guidelines (ICG) on Fossil Plant Cycle Chemistry (EPRI report 4629), issued in 1986, provided direction and guidance on the use of all-volatile treatment (AVT) for feedwater and boiler water In the United States, the typical practice was to deoxygenate the feedwater for once-through or drum units either mechanically or chemically through the addition

CS-of an oxygen scavenger such as hydrazine These treatments result in the generation and

transport of feedwater corrosion products, which are directly responsible for a number of

problems in the cycle such as boiler tube failures and the need to frequently clean the boiler This contrasts with international practice where oxygen is added to the feedwater to produce a more oxidizing environment, thus eliminating the problems associated with feedwater corrosion

Results

The main characteristics of once-through and drum units that can be converted to OT are an all ferrous feedwater system and an ability to produce feedwater of purity better than 0.15

microSiemen/cm cation conductivity For drum units, a sampling point is required on the

downcomer to monitor the boiler water Oxygen is injected in the range of 30-150 ppb for through units and 30-50 ppb for drum units, with pHs in the range of 8.0-8.5 for once-through units and 9.0-9.6 for drum units Guidance for both once-through and drum units is presented in

once-a series of cycle dionce-agronce-ams thonce-at includes once-a set of tonce-arget vonce-alues once-and once-action levels for criticonce-al sonce-ample points throughout the cycle The guidelines also include a detailed road map on how to convert a unit to OT and how to react to contaminant ingress The Appendices include detailed information

on several U.S converted units and survey results from units in Europe and the former USSR

EPRI Perspective

These guidelines are the second major revision of the ICG A new phosphate treatment guideline

is now available (EPRI report TR-103665) The OT guidance represents a radical change in control philosophy for feedwater chemistry Clearly the addition of oxygen reduces the corrosion rate and the solubility of the oxide formed, thus producing a major reduction in feedwater

corrosion products that flow into the boiler Over 40 units have been converted to OT in the United States Some immediate benefits include increased periods between condensate polisher regenerations, reduced boiler deposition rates, and large chemical cost savings One of the

indirect results of the guideline development has been the recognition that for all-ferrous

feedwater heater systems, the use of an oxygen scavenger should be carefully reviewed In most cases a scavenger is not required, but some of the benefits of OT will still accrue

Program

2005 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

History

2004 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

2003 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

2002 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

2001 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry

2000 Program 057.0 Boiler and Turbine Steam and Cycle Chemistry

1999 Program 070.0 Boiler and Turbine Steam and Cycle Chemistry

1998 Program 051 Boiler and Turbine Steam and Cycle Chemistry

1997 Program T2420 Fossil Steam Boiler O&M Cost Reduction (Domestic)

1997 Program T2423 Boiler Life Optimization/Cycle Chemistry