EPRI ChemExpert: Steam Plant Specific Cycle Chemistry Management Tool

<body topmargin=0 leftmargin=0 marginheight=0 marginwidth=0> <table cellpadding=0 cellspacing=0 border=0><tr> <td valign="top" colspan=2 height=100 BGCOLOR="#CCCCFF" TEXT="#080000" bgproperties="fixed" background="0d200640egdysm.jpg"> <div> <FONT SIZE="6" COLOR="#000066" FACE="Arial" ><B>Jonas, Inc.</B></FONT><FONT SIZE="5" COLOR="#000099" FACE="Arial" ><B> </B></FONT><FONT SIZE="1" COLOR="#000099" FACE="Arial" ><B>   </B></FONT><FONT SIZE="3" COLOR="#000099" FACE="Arial" ><B> |</B></FONT><B>     </B><A HREF="index.htm" TARGET="_top" TITLE="Jonas, Inc."><U><B>Home</B></U></A><B> </B><B> </B><B>   </B><B> |    </B><A HREF="contact.htm" TARGET="_top" TITLE="Contact Us"><U><B>Contact Us</B></U></A><B>                                           </B></div> <div> back to<B>  </B><A HREF="products.htm" TARGET="_top" TITLE="Products"><U><B>Products</B></U></A><FONT SIZE="3" COLOR="#000099" FACE="Arial" ><B> 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Management Tool</B></div> <div> <B>For control and prevention of chemistry upsets, monitoring, and training, for operators, chemists, and management; utility and industrial steam systems; fossil and nuclear.</B></div> <bR> <div> <B>Background</B></div> <bR> <div> Today's competitive environment and shortages of electric power require operation of the utility power plants at top efficiency with minimum forced outages.  Corrosion, scale, and deposits have been the number one contributor to the increased cost of steam and power generation [1].  The highest component of this cost is the cost of replacement power.  At the same time, many plants do not have a round-the-clock chemist, and the control room operators, often not trained in water chemistry control, are the first line of defense.  Each year, serious contaminant events happen and the operators must know how to properly respond.  </div> <bR> <div> Jonas, Inc. developed and extensively field testes an expert system “ChemExpert” for the Electric Power Research Institute (EPRI)  [4 ,5]   and is a licensed distributor of the software.  EPRI ChemExpert was developed to assist plant operators and chemists in water/steam chemistry and corrosion control and problem diagnosis and to help with the operation of the plant with a minimum number of forced outages and at top efficiency.  It is an expert system that quickly detects chemistry related problems cycle as they occur (Figure 1), and recommends corrective actions.  </div> <bR> <div> <B><IMG SRC="21361c80.jpg" border=0 width="609" height="456" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B>Figure 1.</B></div> <div> <B>Cycle Diagram Showing the Detection of Air Inleakage below the Condenser Hotwell Water Line in a 2000 psi Drum Boiler Unit using Phosphate Boiler Water Treatment.</B></div> <bR> <div> Using ChemExpert improves control of water and steam chemistry, thereby reducing the likelihood of equipment damage and efficiency loss.  Its capability to simultaneously display the current cycle chemistry status of multiple units, and its ability to be viewed remotely over a computer network make this program useful for operators and chemists, as well as plant and corporate managers.  The water chemistry features are based on the philosophy and action and target levels of fossil plant cycle chemistry guidelines and experience.</div> <bR> <div> <B>Description</B></div> <bR> <div> This program detects cycle chemistry problems in real time and recommends corrective actions.  It contains the following features:</div> <bR> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Verification of analytical results including a check of the ion balance</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Warnings for parameters outside user customized limits</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Identification of current water and steam cycle chemistry problems and their consequences and alarms</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Recommendation of corrective actions and action times</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Automatic control of chemical feeds and blowdown (optional)</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Pressure dependent impurity limits for drum boiler water</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Data storage for the life of the unit</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Plotting of current and historical data vs. time and customized plots</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Automatic or user-initiated daily, monthly, and yearly reports</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Plant specifics training module</div> <bR> <div> As shown in Figure 2, ChemExpert uses data from on-line chemical analytical instruments, other on-line data, and manually entered grab sample analysis data to determine if any cycle chemistry-related problems are occurring.  It can access existing data acquisition systems (DAS) or distributed control systems (DCS) through a network using Dynamic Data Exchange (DDE) communications.</div> <bR> <div> In addition to the above capabilities, the program can calculate percent (%) carry-over for drum boilers, and the sodium to phosphate molar ratio for units on phosphate treatment time.  The carry-over is calculated using the current values for saturated steam sodium and blowdown/downcomer sodium. </div> <bR> <div> Using the current on-line instrument and grab sample values, which are displayed on the Data Display screen, along with the Action Level limits, the probability of the occurrence of each problem is calculated.  The computation is based on influence diagrams (Figure 3) prepared by experts in which the relationship between each monitored parameter (mostly chemical, but also operational parameters) and the individual water chemistry problems is determined.  The values from the influence diagram (`A' Constants) have been selected and tested.  In some cases, the `A' Constants may have to be customized for a particular unit by a water chemistry expert.</div> <bR> <div> <B><IMG SRC="21864830.gif" border=0 width="612" height="387" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B>Figure 2.</B></div> <div> <B>Block Diagram Showing the Basic Data Flow through the ChemExpert.</B></div> <bR> <div> The `A' Constants (Figure 3) can range from -15 to 15.  A positive `A' Constant for a particular parameter means that an out of spec value for the parameter is an indication that the problem may exist, while a negative `A' Constant means that an out of spec value for the parameter is an indication that the problem does not exist.  The more positive (or negative) an `A' constant is, the more influence that parameter has in determining the existence of that problem.  If a parameter does not have an `A' Constant associated with it, it receives a value of zero indicating that the parameter is not used in determining the existence of a particular problem.  </div> <bR> <div> Using a relationship between the current value and normal limit for each parameter, along with the sets of 'A' constants, a value, which is related to the probability that a particular problem is occurring, is determined for each cycle chemistry-related problem that the program can detect.  If the calculated value for a particular problem is above a minimum threshold, it is considered to be occurring and the user is alerted through the displays and alarms.</div> <bR> <div> <B><IMG SRC="217289e0.jpg" border=0 width="552" height="414" ALIGN="BOTTOM" HSPACE="0" VSPACE="0"></B></div> <div> <B>Figure 3. </B></div> <div> <B>Influence Diagram Showing the 'A' Constants (in rectangles) Relating Relevant Parameters with Air Inleakage Below the Hotwell Water Line. </B></div> <bR> <div> The lines connect the “problem” with the parameters having an influence, degree of which is indicated in the rectangles.</div> <bR> <div> <B>Products and Services</B></div> <bR> <div> The following products and services are available:</div> <bR> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">ChemExpert 3.0 - for one plant with one boiler</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">ChemExpert 4.0 - for one plant with up to nine boilers, includes intranet access</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Customization of the ChemExpert for a specific plant</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Installation of the ChemExpert at the plant and training</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Addition of automatic control of chemical feeds and blowdown</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Incorporation of the ChemExpert into the distributed control system</div> <bR> <div> <B>Specifications</B></div> <bR> <div> To run EPRI ChemExpert 3.0 and 4.0, the following equipment is required for the Host Computer on which the programs will reside:</div> <bR> <div> <B>Processor</B> - 933 MHz Pentium III processor (minimum)</div> <div> <B>Memory</B> - 256 MB of random access memory (RAM) (minimum)</div> <div> <B>Storage/Disk Drive</B> - 500 MB of free space on the hard drive, and one (1) Gigabyte of disk space storing at least one years worth of data.</div> <div> <B>CD-ROM or DVD Drive</B> - Needed for installation via CD-ROM. </div> <div> <B>Display</B> - A 800 x 600 VGA Video Driver with a minimum of 256 colors.</div> <div> <B>Pointing Devices</B> - A Mouse, or other pointing device, compatible with Microsoft Windows.</div> <div> <B>Printer</B> - A graphics capable printer is needed in order to print reports </div> <div> <B>Operating System</B> - Microsoft Windows 2000, XP, or NT.</div> <div> <B>Network Adapter</B> - A network connection is required to allow access to ChemExpert 4.0 from a Remote Computer. Minimum: 128 kilobytes per second. A dial-up connection will not work. </div> <div> <B>Static IP Address</B> - The IP address for the Host Computer must be fixed for ChemExpert 4.0.  It cannot change each time the computer is restarted. </div> <bR> <div> To access EPRI ChemExpert 4.0 from a Remote Computer, the following equipment is required:</div> <bR> <div> <B>Processor</B> - 400 MHz Pentium II processor (minimum)</div> <div> <B>Memory</B> - 128 MB of random access memory (RAM) (minimum)</div> <div> <B>Display</B> - A 800 x 600 VGA Video Driver with a minimum of 256 colors.</div> <div> <B>Pointing Devices</B> - A Mouse, or other pointing device, compatible with Microsoft Windows.</div> <div> <B>Operating System</B> - Microsoft Windows 2000, XP, or NT.</div> <div> <B>Web Browser</B> - Microsoft Internet Explorer or Netscape Navigator</div> <div> <B>Network Adapter</B> - A network connection is required to remotely access ChemExpert. Minimum: 10/100 Base-T Ethernet Port. A dial-up connection will not work. </div> <bR> <div> <B>References</B></div> <bR> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Economic Effects of Metallic Corrosion in the United States, NBS Special Publication 511-1 and 511-2, May 1978.</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Cost of Corrosion in the Electric Power Industry, EPRI Report 1004662, October 2001.</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">O. Jonas, “Corrosion and Water Chemistry Problems in Steam Systems - Root Causes and Solutions”, Materials Performance, December 2001. </div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">O. Jonas, L. Machemer, B. Dooley, EPRI ChemExpert: Cycle Chemistry Advisor for Fossil Power Plants, Proceedings: Sixth Int'l. Conference on Fossil Plant Cycle Chemistry, EPRI 1001363, April 2001; also International Water Conference, Technical Program, October 21-25, 2001, Pittsburgh, PA.</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Interim Consensus Guidelines on Fossil Plant Cycle Chemistry, EPRI CS-4629, Final Report, June 1986.</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Cycle Chemistry Guidelines for Fossil Plants:  Phosphate Treatment for Drum Units, EPRI TR-103665, Final Report, December 1994.</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Cycle Chemistry Guidelines for Fossil Plants:  All-Volatile Treatment, EPRI TR-105041, Final Report, April 1996.</div> <div> <IMG BORDER="0" SRC="Symb075c00b700c800000000.gif" HEIGHT="13" WIDTH="24" ALIGN="bottom" HSPACE="0" VSPACE="0">Interim Cycle Chemistry Guidelines for Combined Cycle Heat Recovery Steam Generators (HRSGs), New Guidelines in 2006. </div> </td> </tr></table></body>