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4313 Nebraska Court
Pomfret, MD 20675
USA
Phone:  (301) 934-5605
Fax: (301) 934-5606
Copyright (c) 2012  Jonas, Inc.  All Rights Reserved
jonasinc@steamcycle.com
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Steam Cycle Water Chemistry Commissioning Guidelines
Water and steam chemistry and corrosion control is often a neglected area during the storage, erection, and commissioning of the equipment when building new units.  There are no industry-wide guidelines.
The lack of readiness of the related equipment, accumulation of corrosion products, and often the use of incorrect water treatment chemicals can lead to significant delays of commissioning and costly delays in transferring the steam cycle to the customer.  One day of delay may cost as much as a quarter million dollars and delays of several weeks are not uncommon.  In addition, bad water chemistry caused by condenser leaks, air inleakage, accumulation of corrosion products, and inappropriate chemicals may cause scale and deposits and permanent corrosion damage; particularly to the boiler or HRSGs and turbines.
Description
-  condenser leak leading to cycle contamination by seawater
 
- destructive overspeed of turbine due to high boiler carry-over and valves stuck open
 
- pitting and stress corrosion cracking of stainless steel feedwater heater tubes due to contamination during storage and erection
 
- pitting of turbine blades during storage, leading to their replacement
 
- improper operation - no training and guidelines
 
- system corrosion because water chemistry control was not functioning
Examples of Encountered Problems
1  Review of Cycle and Component Design
2  Preservation during Manufacture, Transport, Storage, Erection, and Layup
3  Water Chemistry Control and Management
4  Training of Operators and Chemists
5  Manuals
6  Inspections: Methods and Results
7  Pre-Operational Cleaning, Hydro Tests
8  Maintenance Procedures
9  Pre-steaming Checks - Boiler, Turbine, Condensate Polishing, Send-out Steam System, GT Injection
10  Performance Testing
The Commissioning Guidelines are Customized Based on Cycle Design and Type of Operation and can include:
      10.1  Steam Purity/Carry-over
      10.2  Boiler Hideout
      10.3  Makeup/Water Storage
      10.4  Condensate Polishing/Regeneration
      10.5  Deaeration
      10.6  Chemical Addition Equipment
      10.7  Condenser:  Leaks, Deaeration
      10.8  Send-out Steam and Return Condensate
      10.9  GT Injection System
      10.10  Iron (and Cu) Transport
      10.11  Sampling and Monitoring Equipment
      10.12  System Corrosion
11  Cooling Water System
12  Chemical Discharges/Disposal
13  Chemical Laboratory
14  Commissioning Schedule
15  Safety Issues
16  Checklist - a list of tasks to be completed and signed off as a record for the transfer of the unit to the customer
Serving the power industry since 1983
Specializing in Sampling and Instrumentation, Corrosion,
Water and Steam Chemistry, and Failure Analysis
Jonas, Inc.