bill stroman - air-cooled condenser users...
TRANSCRIPT
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Amines in Air Cooled Condensers San Diego Annual Conference
September 24, 2014
Bill Stroman
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AIR COOLED CONDENSER• Large iron surface area• Potential for air inleakage• Air inleakage can lead to problems with freezing
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Chemistry Control Limits and Action Guidelines for Addressing:
• Steam Cycle Chemistry – Preboiler, Boiler, Steam, Condensate
• Online Monitoring • Routine Grab Sample Testing • Abnormal Conditions-What is done? • Cycling conditions for Startup & Shutdown • Layup
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Chemistry Program Requires Representative Sample In Order To:
• Measure • Maintain • Manage • Make Improvements
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FAC corrosion in duct and Inlet tube areas
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For ~10 years the chemistry was hydrazine/morpholine then was changed during 2006 to ammonia treatment. Problem was not previously noted. This picture was provided to use as DHACI #4
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18 inch crack below steam turbine exhaust
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Vacuum kPa(a) vs Iron Corrosion
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g/L
kPa(a) Iron - mg/l
Started ammonia treatment
air leaks repaired
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Corrosion byproduct accumulation
• Leads to deposition and corrosion related failures
• Cost to chemical clean HRSG boilers is very expensive
• Cost to dispose of post chemical cleaning waste is very expensive
• HRSG units are not designed for conventional chemical cleaning methods to address tube corrosion issues
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HRSG corrosion by products migrate into boilers
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Underdeposit Corrosion
• Problem with HRSG units is the tubes have fins. NDE for oxide thickness not viable.
• If underdeposit corrosion has developed can do some NDE but only the leading row.
• When was a tube specimen removed to evaluate the internal condition?
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Amine Use • Have been successfully used in steam
generating equipment for >40 years • Used in essentially all US Nuclear facility
steam generators • EPRI recommends the use of ammonia for
feedwater pH control in all ferrous systems but needs to be maintained in desired pH control range.
• However, if not controlled in desired pH range corrosion occurs in ACC.
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~30 years service On Neutralizing amine treatment
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Feedwater pH
• pH must be alkaline to minimize iron corrosion
• For all ferrous units 9.2-9.6 is recommended units with ACC 9.4-10 with 9.8-10 preferred.
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Common Amines in Steam Production
• Cyclohexylamine • Morpholine • Ethanolamine (monoethanolamine) [MEA] • Methoxypropylamine (MOPA) • Diethylaminoethanol (DEAE)
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MEA/Ammonia blend • Plants with discharge limits that prevents
operation in the high 9 pH range require a chemistry treatment to provide better metal passivation.
• MEA/Ammonia was evaluated and found a reduction in iron transport and better passivation with slight increase in specific and cation corrected conductivity.
• Anodamine is in the process of being evaluated to address intermittent operation for better protection while off line.
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Ethanolamine (MEA)
• Also called monoethanolamine
• Formula: C2H7NO • Molecular Weight : 61.08 • Amine Type Primary • Carbon: Nitrogen ratio 2:1
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B&W filter iron test
MEA & Ammonia Blend
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Problem with Grab Sampling
• Filter and iron grab sample is only representing the time when sample was taken and does not capture events that continuous sampling would observe.
• Turbidity and particle counter & monitors can provide continuous monitoring.
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Average 2 - 3 micron particle count
0
100
200
300
400
014
4028
8043
2057
6072
0086
40
1008
0
Minute of the week
2 -
3 m
icro
n P
art
icle
Co
un
t
Average Count before MEAAverage Count after MEALinear (Average Count before MEA)Linear (Average Count after MEA)
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Average 3 - 5 micron particle count
0
20
40
60
80
100
014
4028
8043
2057
6072
0086
4010
080
Minute of the week
3 -
5 m
icro
n P
arti
cle
Co
un
t
Average Count before MEA
Average Count after MEA
Linear (Average Count before MEA)
Linear (Average Count after MEA)
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Average 5 - 7 micron particle count
0
10
20
30
40
50
014
4028
8043
2057
6072
0086
4010
080
Minute of the week
5 -
7 m
icro
n P
arti
cle
Co
un
t
Average Count before MEA
Average Count after MEA
Linear (Average Count before MEA)
Linear (Average Count after MEA)
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Average 7 - 10 micron particle count
0
1
2
3
4
5
014
4028
8043
2057
6072
0086
4010
080
Minute of the week
7 -
10 m
icro
n P
arti
cle
Co
un
t
Average Count before MEA
Average Count after MEA
Linear (Average Count before MEA)
Linear (Average Count after MEA)
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validation
• Physical inspections
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2009 inspection
2011 inspection
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2009 inspection
2011 inspection
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2009 steam turbine condensate Duct drain.
2011 inspection
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Air Cooled Condensers
• Backpressure for air cooled condensers is higher than water cooled condensers.
• When air in-leakage is high enough to affect backpressure it is more difficult to detect with air cooled condensers.
• Elevated air in-leakage increases the potential for corrosion that can affect the rest of the steam cycle.
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Concerns-Cycling
• Maintaining condenser vacuum is recommended when cycling.
• Air in-leakage potential is high when offline.
• High dissolved oxygen and carbon dioxide promote corrosion in oxygen pitting, corrosion fatigue, stress corrosion cracking and corrosion byproduct transport and down stream deposition.
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Source: GEA Power Cooling Systems, Inc.
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Continuous Monitoring
• Provides detection of increases in air in-leakage before backpressure is affected.
• Provides real-time air in-leakage rates. • Awareness is required in order to
implement corrective measures.
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Vacuum Decay Test
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Anodamine Filming Amine • An Alternative to other off line storage
programs? • Following industry publications such as Power
Plant Chemistry, The International Edition, May 2011 publication showing significant corrosion rates improvement to fossil units that were regulated to intermittent service.
• Conference presentations showing favorable reductions in iron corrosion
• Plant decided to evaluate.
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Dosing Anodamine Manufacturer recommends achieving a 2 – 3 ppm Anodamine residual throughout cycle and once this is reached a 300 – 400 ppb injection is recommended to maintain residual.
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Plant began trial on an intermittent operation unit with ACC
• Unit did not run much during 2013. • Unit did run for couple of months
beginning 2014 that allowed for the Anodamine to get established.
• The following are inspection pictures during March 2014 scheduled maintenance outage
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Plant Status
• Plant to continue to dose Anodamine/MEA • Plant in process of installing particle monitor • Plant in process of installing continuous air
meter on air removal system • Operations noted that when returning to service
from being off line the samples not longer have color (corrosion by products) present.
• Upper ACC duct inspection next spring.