Boiler Performance Automation

Chris Golden Senior Account Manager Nalco Company

for Boilers

3D TRASAR for Boilers

3D

TRASAR for boilers delivers maximum performance.

Safer operation Improved system reliability Lowest Cost of Operation

Technology

scope

Advanced monitoring & control Performance sensors New chemistry Software Wireless communication

for Boilers
for Boilers

Performance Management for Boiler Boiler Systems Performance Management for Systems

3D TRASAR Boiler Basic System

@T ORP
T M

Controller & Fluorometer

Boiler Sample

Performance Management for Boiler Systems

for Boilers

3D TRASAR Internal Treatment

45
45

TRASAR Automation
45 40

40
40

35 30 25 20 15 10 5 0

35

TRASAR Automation Detect

35 30 25 20

Automatically responds

ppm 22310 ppm 22310

30

25
15

System Upsets

20
10

15

Maintain optimum treatment levels

01/20/99 01/30/99 02/09/99 Date 02/19/99 03/01/99 03/11/99 03/21/99

10

0 01/10/99

0 01/10/99

01/20/99

01/30/99

Optimum Operation
02/09/99 02/19/99 03/01/99 Date

03/11/99

03/21/99

10/11/1997

20/11/1997

30/11/1997

10/12/1997

20/12/1997

30/12/1997

09/01/1998

19/01/1998

Date

Keeps your boiler clean

Good for Boilers from 10 psig to over 2400 psig

Performance Management for Boiler Systems

for Boilers

3D TRASAR Preboiler Corrosion Control

@T ORP
3D TRASAR Preboiler Corrosion Control

Starter Controller & T3 Fluorometer

Boiler Sample

Performance Management for Boiler Systems

for Boilers

Preboiler Corrosion Control Vision

Today: Test Oxygen Test Scavenger Residual Inspect Equipment Tomorrow: Continuous, RealTime Measurement of Corrosion Potential Automation of Oxygen Scavenger Feed
for Boilers

Performance Management for Boiler Systems

(at Temp vs Room Temp 200 MW Coal Fired Plant)

-100 0 -100 -200 -300 -400 -500 Time (hrs)
@TPerformance ORP moreManagement sensitive than RT Systems ORP to for Boiler optimize CHZ feed

@T ORP vs RT ORP

@ Temp Orp (mv)

-200 -300 -400 -500 -600 -700

RT ORP (mv)
for Boilers

-600

@T ORP vs Dissolved O2
0 500 400

@T ORP vs EPBRE (V)

-0.1

300 -0.2 200

DO (ppb)

-0.3 100

ORP -0.4 Cell Internal Configuration

20 Minutes

Performance Boiler Systems @T ORP faster Management response for than DO monitor

for Boilers

3D TRASAR Preboiler Corrosion Monitoring

Typical Corrosion Control High Low

Underfeed Results in Corrosion

Chemical Treatment
High

Potential

Overfeed leads to Excess Treatment Costs

Low

Today we have fixed feed rates regardless of the boilers waters potential to corrode
Performance Management for Boiler Systems
for Boilers

New Best Practice for Preboiler Corrosion Control

@T ORP
Performance based control of corrosion stress Maintains Reduced Conditions Minimizes corrosion Promotes passivation
Phase 1: AEPCO Controlled Feed Of Eliminox Baseline Monitoring LP #3 AT-T ORP

Phase 2: LP #3 AT-T ORP Controlled Feed Of Eliminox

0.2

Customer Value
Safety, Reliability
Mitigates failures Reduce boiler iron deposits

LP #3 AT-T ORP vs EPBRE (V)

-0.2

-0.4
LP #3 AT-T ORP Set Point = -350 mV

Minimize Cost
Asset protection Minimize downtime Maximize Availability Improve turbine efficiency

-0.6

1/23/2006 0:00:00

Figure 1: LP #3 AT-T ORP Results During Phase 1 and 2 of AEPCO Trial

Performance Management for Boiler Systems

for Boilers

6/12/2006 0:00:00

2/12/2006 0:00:00

2/22/2006 0:00:00

3/14/2006 0:00:00

3/24/2006 0:00:00

4/13/2006 0:00:00

4/23/2006 0:00:00

5/13/2006 0:00:00

5/23/2006 0:00:00

2/2/2006 0:00:00

3/4/2006 0:00:00

4/3/2006 0:00:00

5/3/2006 0:00:00

6/2/2006 0:00:00

-0.8

3D Boiler Automation Starter Performance

Controller Host Module Web Interface
Boiler Optimizer

Boiler Configurator

Web Server

ISE Breakthrough Detection

At -T ORP probe TRASAR 3 probe

TRASAR 3 probe TRASAR 1 probe

pH

Conductivity

Particle counter

NCM & LCM

pH

Level sensor or other 4 -20 mA inputs

Pretreatment

Preboiler

Boiler

Condensate

Misc.

Performance Management for Boiler Systems

for Boilers

Performance Automation

Dynamic Control - Expanded MOC Systems Approach Performance Management for Boiler

for Boilers

3D TRASAR Web System Performance Monitoring

3D TRASAR Web is... A convenient way for Nalco Reps and Customers to monitor system performance, and the value of 3D TRASAR control View performance summary of all systems Display performance detail for a single system Generate, print, and schedule graphs and reports Download data to your PC for advanced analysis and reporting with Vantage V100 Alarming

Performance Management for Boiler Systems

for Boilers

3D Boiler Starter
@T ORP Preboiler corrosion stress Monitoring & Control TRASAR Treatment Control

@T ORP
3D TRASAR Web data analysis, reporting and alarming
+

Controller & Fluorometer

Performance Management for Boiler Systems

for Boilers

Performance Under Pressure

3D TRASAR for boilers delivers maximum performance under pressure, resulting in a safer operation, improved system reliability, and reduced total operating costs.
Safety Reliability

for Boilers

TCO
Performance Management for Boiler Systems
for Boilers