Water Chemistry and Corrosion Control in Steam Systems
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Two-day workshop for system and station chemists, operators, maintenance personnel (engineers and technicians), managers, engineers, metallurgists, and designers.
Background
With the increase of unit sizes, stresses and heat fluxes, equipment aging, unit cycling, and the high cost of replacement power and steam, corrosion protection of the steam cycle components during operation and layup, and the control of chemistry are of critical importance.
The cost of corrosion, and scale and deposit buildup in U.S. utility systems is over $3 billion/year.  It is even higher for industrial systems.  As much as 50% of the outage time has been attributed to problems with the boiler tubes, condensers, turbines, feedwater heaters, carbon steel piping, PWR steam generators, and BWR pipe welds.  Similar trends are found in industrial applications as well.  The cost of replacement power can be as high as $100/MWh or over one million dollars a day for a large utility unit ($7,000/MWh during the summer of 1998).  The cost of reduced or lost production in an industrial plant can be equally high.
Significant improvements can be achieved at all levels by a better understanding of the steam cycle chemical transport, local concentration of corrosive impurities on component surfaces, and by knowledge of relevant corrosion properties of the materials used.  Cooperation of operators, chemists, the mechanical and thermodynamic designers, engineers, and management is needed to achieve these improvements.
Objectives of the Workshop
To improve knowledge of water and steam chemistry control and monitoring, related equipment operation and maintenance, corrosion design and protection, operation and maintenance.
To improve communication and cooperation between operators, chemists, management and vendors.
To jointly analyze the current operating and design practices, and problems and to make recommendations where improvements can be made.
Agenda for 2-Day Version of Course
Day 1
Hours
1.  Introduction: Cost of Corrosion and Scale
1
2.  Water Chemistry and Corrosion Problems
2
3.  Basics of Corrosion
1
4.  Basics of Water Purification
1
5.  Steam Cycle Chemistry
2
Day 2
Hours
6.  Guidelines for Operation, Layup, and Chemical Cleaning
1
7.  Sampling and Instrumentation
1
8.  Water Chemistry Management Roles of Operators, Maintenance, Engineering and Chemists
1/2
9.  Troubleshooting and Failure Analysis
1
10.  Analysis of Practices and Problems
1
11.  Applications and Case Studies
1 1/2
12.  Conclusions and Recommendations
1
NOTE: Participants should prepare case histories and questions and bring samples of damaged components for demonstrations and discussion.
Agenda for 1-Day Version of Course
Day 1
Hours
1.  Introduction, Cost of Corrosion and Scale
1/2
2.  Water Chemistry and Corrosion Problems
2
3.  Basics of Corrosion
1/2
4.  Basics of Water Purification
1/2
5.  Steam Cycle Chemistry, Guidelines for Operation, Layup, and Chemical Cleaning
2
6.  Sampling and Instrumentation
1/2
7.  Analysis of Practices and Problems
1
8.  Conclusions and Recommendations
1

NOTE: Participants should prepare case histories and questions and bring samples of damaged components for demonstrations and discussion.