Descriptions of Past Research Boiler and Turbine Steam and Cycle Chemistry Program 3002004151 Descriptions of Past Research Boiler and Turbine Steam and Cycle Chemistry Program 3002004151 Technical Update, June 2014 EPRI Project Manager M Caravaggio ELECTRIC POWER RESEARCH INSTITUTE 3420 Hillview Avenue, Palo Alto, California 94304-1338 ▪ PO Box 10412, Palo Alto, California 94303-0813 ▪ USA 800.313.3774 ▪ 650.855.2121 ▪ askepri@epri.com ▪ www.epri.com DISCLAIMER OF WARRANTIES AND LIMITATION OF LIABILITIES THIS DOCUMENT WAS PREPARED BY THE ORGANIZATION(S) NAMED BELOW AS AN ACCOUNT OF WORK SPONSORED OR COSPONSORED BY THE ELECTRIC POWER RESEARCH INSTITUTE, INC (EPRI) NEITHER EPRI, ANY MEMBER OF EPRI, ANY COSPONSOR, THE ORGANIZATION(S) BELOW, NOR ANY PERSON ACTING ON BEHALF OF ANY OF THEM: (A) MAKES ANY WARRANTY OR REPRESENTATION WHATSOEVER, EXPRESS OR IMPLIED, (I) WITH RESPECT TO THE USE OF ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT, INCLUDING MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE, OR (II) THAT SUCH USE DOES NOT INFRINGE ON OR INTERFERE WITH PRIVATELY OWNED RIGHTS, INCLUDING ANY PARTY'S INTELLECTUAL PROPERTY, OR (III) THAT THIS DOCUMENT IS SUITABLE TO ANY PARTICULAR USER'S CIRCUMSTANCE; OR (B) ASSUMES RESPONSIBILITY FOR ANY DAMAGES OR OTHER LIABILITY WHATSOEVER (INCLUDING ANY CONSEQUENTIAL DAMAGES, EVEN IF EPRI OR ANY EPRI REPRESENTATIVE HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES) RESULTING FROM YOUR SELECTION OR USE OF THIS DOCUMENT OR ANY INFORMATION, APPARATUS, METHOD, PROCESS, OR SIMILAR ITEM DISCLOSED IN THIS DOCUMENT REFERENCE HEREIN TO ANY SPECIFIC COMMERCIAL PRODUCT, PROCESS, OR SERVICE BY ITS TRADE NAME, TRADEMARK, MANUFACTURER, OR OTHERWISE, DOES NOT NECESSARILY CONSTITUTE OR IMPLY ITS ENDORSEMENT, RECOMMENDATION, OR FAVORING BY EPRI THE FOLLOWING ORGANIZATION PREPARED THIS REPORT: Electric Power Research Institute (EPRI) This is an EPRI Technical Update report A Technical Update report is intended as an informal report of continuing research, a meeting, or a topical study It is not a final EPRI technical report NOTE For further information about EPRI, call the EPRI Customer Assistance Center at 800.313.3774 or e-mail askepri@epri.com Electric Power Research Institute, EPRI, and TOGETHER…SHAPING THE FUTURE OF ELECTRICITY are registered service marks of the Electric Power Research Institute, Inc Copyright © 2014 Electric Power Research Institute, Inc All rights reserved CITATIONS This report was prepared by Electric Power Research Institute (EPRI) 1300 W.T Harris Blvd Charlotte, NC 28262 Principal Investigator M Caravaggio This report describes research sponsored by EPRI This publication is a corporate document that should be cited in the literature in the following manner: Descriptions of Past Research: Boiler and Turbine Steam and Cycle Chemistry Program EPRI, Palo Alto, CA: 2014 3002004151 iii PRODUCT DESCRIPTION This document contains summaries of many past Electric Power Research Institute (EPRI) Boiler and Turbine Steam and Cycle Chemistry Program research and development (R&D) efforts Results and Findings Although not all-inclusive, this document will assist utility personnel in quickly identifying related EPRI R&D products on www.epri.com Challenges and Objectives This document will assist plant personnel who are responsible for boiler and turbine maintenance, operation, risk management, or troubleshooting in quickly locating the appropriate EPRI reports on www.epri.com Applications, Value, and Use This document is a useful reference resource for EPRI member organizations that are seeking past reports on specific topics of interest EPRI will update this document periodically to include new research reports and software produced in the Boiler and Turbine Steam and Cycle Chemistry Program EPRI Perspective The R&D projects completed by the EPRI Boiler and Turbine Steam and Cycle Chemistry Program provide a comprehensive integration of the knowledge and guidance of disciplines within the program This document is a catalogue of the topical reports that will provide assistance in locating and identifying information in research areas of interest With such a reference, chemistry, engineering, managerial, and plant personnel can quickly locate reports of interest, as well as related material and background research Such availability greatly enhances the transfer of research technology to EPRI members Approach A compilation of well over 100 product summaries describing EPRI research performed over the previous 30 years is contained in this document The summaries are arranged in the following categories: • • • • • • • • • • • • Cycle chemistry Copper Flow-accelerated corrosion (FAC) Turbine steam chemistry Corrosion Boiler corrosion Deposition Instrumentation ChemExpert Condensate polishing and filtration Turbine corrosion Stator cooling v • • • • Condenser Value and cost Reliability and productivity Proceedings Keywords Cycle chemistry Boilers Turbines Steam Corrosion Deposition vi ABSTRACT A compilation of over 100 product summaries describing EPRI research performed over the previous 30 years is contained in this document The summaries are arranged in the categories of cycle chemistry, copper, flow-accelerated corrosion (FAC), turbine steam chemistry, corrosion, boiler corrosion, deposition, instrumentation, ChemExpert, condensate polishing and filtration, turbine corrosion, stator cooling, condenser, value and cost, reliability and productivity, and proceedings Each product summary contains an abstract; a description of the report’s objective, approach, and results; optionally, the report’s application, value, and use; an EPRI perspective; and keywords This document is a useful reference resource for EPRI member organizations who are seeking past reports on specific topics of interest EPRI will update this document periodically to include new research reports and software vii Condenser Conferences Condenser Technology Conference Product Number 1010322 Date Published August 2005 Details Technical Report – Available Online Abstract This report documents the proceedings of EPRI’s 2005 Condenser Technology Conference This meeting, held every three years, is designed and organized to provide a forum for the exchange of knowledge and experience, to identify major problems, and to determine priorities for additional R&D The conference attracted participants from throughout the industry, including vendors, consultants, utilities, and EPRI experts Examples of the six papers presented over two days in the plenary sessions included “Condenser Tube Failures—Theory and Practices: An EPRI Manual” and “Gray Water Cooling in Surface Condensers and Heat Exchangers—Trend or Aberration.” Multiple presentations in separate sessions also were made on fouling control and performance and maintenance technologies Each conference day ended with panel discussions exploring a variety of topics, including but not limited to performance monitoring, leak detection, and condition assessment Background A large body of information exists on damage in condenser tubes and related condenser components such as tubesheets and waterboxes Although technical understanding of damage mechanisms is generally good, past efforts often have not emphasized the practical, actionoriented steps needed to effectively deal with the various forms of damage These proceedings were organized to help utility users identify, resolve, and prevent tube failure Objectives • To provide a forum to exchange knowledge and experience • To identify major problems and to establish a clear understanding of priorities for additional R&D to improve condenser technology Approach The conference was held in San Diego, California, and spanned two days, 31 August to September, 2005 Participants included representatives from vendors, consultants, utilities, and EPRI experts 17-24 Key Points Each of the conference’s two days included a plenary session Plenary presentations for day one were “Condenser Tube Failures—Theory and Practices: An EPRI Manual,” “Improving The Reliability of a BWR Through a Condenser Condition Assessment,” and “Modification of Extraction Steam Expansion Joints in Low Pressure Condensers to Improve Plant Reliability, Availability, and Reduce Maintenance.” Day two’s plenary session topics were “Vibration Prevention Goes Beyond Support Plate Spacing,” “AmerenUE Labadie Unit Copper-Beryllium Tube Development of a Cobalt-Phthalocyanine Catalytic Thin Film to Inhibit Tubeside Biofilm Adherence in Copper-Beryllium Heat Exchanger Tubing,” and “Gray Water Cooling in Surface Condensers and Heat Exchangers—Trend or Aberration.” Over the two days, multiple presentations also were made on both performance and maintenance technologies as well as fouling control Each day ended with a panel discussion, “Innovations in Performance Technology” on day one and “Innovations in Maintenance Technology” on day two 17-25 Condensate Polishing Conferences Proceedings: 2003 EPRI Workshop on Condensate Polishing Product Number 1010322 Date Published August 2005 Details Technical Report – Available Online Abstract Successful condensate polishing operations maintain control of ionic and particulate impurity transport to the pressurized water reactor (PWR) steam generator and the boiling water reactor (BWR) reactor and recirculation system, thus allowing the units to operate more reliably This report contains the work presented at EPRI's 2003 Workshop on Condensate Polishing, where 30 papers were presented on current issues, research, and utility experiences involving polishing issues at both PWR and BWR units Background EPRI sponsors the Workshop on Condensate Polishing approximately every eighteen months to provide a forum for technical exchange concerning new technologies, data, research, and practical experiences concerning polishing issues in both nuclear and, to some extent, fossil plants Members of the utility, academic and vendor communities have traditionally attended this workshop The last two workshops were held in 2000 and 2002 (EPRI reports 1001490 and 1007028, respectively) Objective • To facilitate exchange of information on current events and new technology developments in condensate polishing for both PWR and BWR units Approach These workshops have traditionally focused on five main areas: (1) current issues in condensate polishing, (2) PWR issues and plant experience, (3) BWR issues and plant experience, (4) condensate polishing and system performance, and (5) ion exchange performance On utility recommendation, recent workshops have expanded to include reactor water cleanup (RWCU) issues RWCU was carried forward into this workshop and also included the chemical and volume control system (CVCS) As part of the workshop agenda, a poster session and reception were included, which facilitated the exchange of information in a more informal atmosphere for the attendees An informal discussion session also was held during the last hour of the second day, in which all participants had the opportunity to discuss topics of their choice 17-26 Results Over 100 participants attended the 2003 workshop, held on June 16-18, 2003, in San Diego, California Participants included personnel from domestic and foreign utilities, consultants, nuclear steam supply system (NSSS) vendor representatives, resin and filter suppliers, university faculty members, and EPRI staff members Thirty formal papers were presented, along with poster presentations at the poster session A variety of topics were discussed They included ongoing work investigating resin fouling associated with ethanolamine (ETA) use in PWRs; results from BWR performance monitoring funded through EPRI; utility operating experiences with new resins, polisher bypass, and alternate system configurations (including retrofits and vessel servicing); and scientific developments and considerations EPRI Perspective Continued industry enthusiasm for cooperation and technical exchange results in tangible benefits for all participants Long-term advancements have been made in condensate polishing technology over the years, with significant improvements continuing to be made These advancements are driven by the type of exchange made during workshops such as this one EPRI plans to continue sponsoring these workshops as long as utility feedback endorses their usefulness Program 2005 Program 041.0 Nuclear Power History 2004 Program 014863 Water Chemistry Control 2004 Program 041.0 Nuclear Power 2003 Program 041.0 Nuclear Power 17-27 Interactions of Materials, Water, and Steam (Including Organics) Conferences Proceedings: Second International Conference on the Interaction of Organics and Organic Cycle Treatment Chemicals with Water, Steam and Materials Product Number 1020761 Date Published March 2010 Details Technical Report – Available Online Abstract The current worldwide suite of cycle chemistry guidelines contains little information on the presence of organics in the cycle In addition, the guidelines not advocate the use of organic additives during operation or shutdown This second international conference was organized to continue the discussion initiated at the first international conference on all aspects of organics in power plants Objective The presence and use of organics in power plants remain controversial and subjective because of insufficient unbiased research or detailed monitoring The objectives of the conference were to evaluate and exchange technical information and practical experiences and to derive a set of needed research and development (R&D) activities Approach EPRI and PowerPlant Chemistry sponsored this international conference on organics in Lucerne, Switzerland, on November 4–6, 2008 The 30 presentations focused on all aspects of organics in fossil, nuclear, heat recovery steam generator, and industrial power plants A series of discussion groups was also held The results of the needed R&D and the conference summary are included in these proceedings Results These proceedings contain the papers from the 2008 International Conference on the Interaction of Organics and Organic Cycle Treatment Chemicals with Water, Steam, and Materials Key points include the following: • There was no irrefutable quantitative evidence that organics and/or organic breakdown products are directly involved in power plant damage • A great deal of work has been conducted on the identification of organics in the plant cycle, but a more thorough understanding of decomposition products and chemical properties (such as surface tension, viscosity, and solubility) is required 17-28 • More research is needed on the application of organics as treatment chemicals and for shutdown and layup • Very little work has been conducted on the use of organics to improve power plant efficiency or on the economics of use Application, Value, and Use The papers, discussions, and summary contained in these proceedings are applicable to all power plants EPRI Perspective This conference was the fifth in a series dealing with the fundamental scientific and technical aspects of the interaction of materials with water and steam The first conference, Interaction of Iron-Based Materials with Water and Steam: Proceedings of an International Conference (Electric Power Research Institute [EPRI] report TR-102101) held in Heidelberg, Germany, in 1992, was focused on iron-based materials The second conference, Interaction of Non-IronBased Materials with Water and Steam (EPRI report TR-108236), held in Piacenza, Italy, in 1996, was dedicated to the fundamental aspects of oxidation, corrosion, erosion, and dissolution of non-iron-based materials and their oxides in high purity and contaminated water and steam The third conference, Steam Chemistry: Interaction of Chemical Species with Water, Steam, and Materials During Evaporation, Superheating, and Condensation (EPRI report TR-114837), held in Freiburg, Germany, in 1999, concentrated on the aspects of evaporation, condensation, nucleation, and corrosion in the phase transition zone of the low-pressure steam turbine The fourth conference, International Conference on the Interaction of Organics and Organic Cycle Treatment Chemicals with Water, Steam, and Materials (EPRI report 1013630), held in Stuttgart, Germany, in 2005, reviewed the current state of knowledge on organics with respect to cycle chemistry The current conference was a follow-up effort and will similarly lead to further EPRI research that will allow the current suite of cycle chemistry treatment guidelines to be revised Program 2009 Boiler and Turbine Steam and Cycle Chemistry 17-29 Proceedings: International Conference on the Interaction of Organics and Organic Cycle Treatment Chemicals with Water, Steam, and Materials Product Number 1013630 Date Published August 2006 Details Technical Report – Available Online Abstract The current worldwide suite of cycle chemistry guidelines contains little information on the presence of organics in the cycle The guidelines also not advocate the use of organic additives during operation or shutdown This international conference was organized in order to provide a forum for discussion on all aspects of organics in power plants Objective The presence and use of organics in power plants remain controversial and subjective due to insufficient unbiased research or detailed monitoring The objectives of the conference were to evaluate and exchange technical information and practical experiences, and to derive a set of needed research and development activities Approach EPRI and PowerPlant Chemistry sponsored this international conference on organics in Stuttgart, Germany, on October 4–6, 2005 The 38 presentations focused on all aspects of organics in fossil, nuclear, HRSG, and industrial power plants A series of discussion groups was also held The results of the needed research and development and the conference summary are included in this proceedings Results These proceedings contain the papers from the 2005 International Conference on the Interaction of Organics and Organic Cycle Treatment Chemicals with Water, Steam, and Materials Some key points are: • There was no irrefutable quantitative evidence that organics and/or organic breakdown products are directly involved in power plant damage • A great deal of work has been conducted on the identification of organics in the plant cycle, but a more thorough understanding of decomposition products and chemical properties (surface tension, viscosity, and solubility) is required 17-30 • More research is needed on the application of organics as treatment chemicals and for shutdown and layup • Very little work has been conducted on the use of organics to improve power plant efficiency or on the economics of use Application, Value, and Use The papers, discussions, and summary contained in these proceedings are applicable to all power plants EPRI Perspective This conference was the fourth in a series dealing with the fundamental scientific and technical aspects of the interaction of materials with water and steam The first conference, Interaction of Iron-Based Materials with Water and Steam: Proceedings of an International Conference (see EPRI report TR-102101 for the proceedings) held in Heidelberg, Germany in 1992, was focused on iron-based materials The second conference, The Interaction of Non Iron-Based Materials with Water and Steam (see EPRI report TR-108236 for the proceedings), held in Piacenza, Italy in 1996, was dedicated to the fundamental aspects of oxidation, corrosion, erosion, and dissolution of non-iron-based materials and their oxides in high purity and contaminated water and steam The third conference, Steam Chemistry: Interaction of Chemical Species with Water, Steam, and Materials During Evaporation, Superheating, and Condensation (see EPRI report TR114837 for the proceedings), held in Freiburg, Germany, in 1999, concentrated on the aspects of evaporation, condensation, nucleation, and corrosion in the phase transition zone of the lowpressure steam turbine The current conference will similarly lead to further EPRI research that will allow the current suite of cycle chemistry treatment guidelines to be revised Program Program 064.0 Boiler and Turbine Steam and Cycle Chemistry 17-31 Steam Chemistry: Interaction of Chemical Species with Water, Steam and Materials During Evaporation, Superheating and Condensation: June 22-25, 1999, Frieburg, Germany Product Number TR-114837 Date Published August 2000 Details Technical Report – Available Online Abstract The continued protection of the steam turbine in the phase transition zone (PTZ) is vital to the reliability of power generating and other energy-related equipment This conference was dedicated to the fundamental aspects of the corrosion processes and efficiency improvements that involve the formation of moisture droplets, liquid films, and deposits on turbine surfaces Background This conference was the third of a series dealing with the fundamental scientific and technical aspects of the interaction of materials with water and steam The first conference (Heidelberg, Germany, 1992) was focused on iron-based materials (EPRI Report TR-102101) The second conference (Piacenza, Italy, 1996) was dedicated to the fundamental aspects of oxidation, corrosion, erosion, and dissolution of non iron-based materials and their oxides in high purity and contaminated water and steam (EPRI Report TR-108236) Over the last 8-9 years, much research effort has been directed towards understanding the phase transition zone (PTZ); and thus there was a need to bring together the latest knowledge Objective • To review research on corrosion processes in the phase transition zone (PTZ) and means of mitigating them Approach EPRI (United States) and VGB (Germany) cosponsored a conference on chemical interactions in the PTZ of steam turbines An organizing committee solicited and selected papers for presentation The conference was held in Freiburg, Germany on June 22-25, 1999 Over 100 participants from 21 countries attended the conference Application, Value, and Use The conference included sessions on the following themes: • Volatility and Solubility Phenomena • Early Condensate • Moisture Generation and Steam Condensation 17-32 • Measurement Techniques • Problems and Solutions • Corrosion • Steam Guidelines • Chemical Cleaning and Layup EPRI Perspective It is over 20 years since research was initiated to improve the understanding of processes in the salt zone and of deposit buildup and behavior in the phase transition zone (PTZ), and how these influence the major corrosion mechanisms However, it is clear that these results have not led to a marked improvement in the overall reliability statistics of steam turbines The conference was introduced to the newly measured phenomena of charged condensate and the whole area of electrostatics in steam and condensate in the PTZ, the turbine exhaust, and the condenser entry Research in electrostatics has already led to measurements of the potential in the liquid films on blade and other surfaces in the PTZ There is also evidence that some of the wetness losses and erosion processes can be reduced by control of the surface tension of the aqueous fluids and/or the surface finish The consensus was that this new developing knowledge may result in two major breakthroughs: improvement in overall unit efficiency by modifying the condensation process by the application of a high potential (corona) across the turbine exhaust or at the condensate entry and improvement in corrosion control by combining the electrochemistry of the charged liquid films with the chemistry and the applied stress Program 2005 Program SST501 Strategic Science & Technology 2005 Program 041.0 Nuclear Power History 2004 – 2001 Program 041.0 Nuclear Power 2004 Program SST501 Strategic Science & Technology 2002 Program SST501 E501 Strategic Science and Technology 2000 Program 031.0 Nuclear Power 17-33 The Interaction of Non Iron-Based Materials with Water and Steam Product Number TR-108236 Date Published July 1997 Details Technical Report – Available Online Abstract Continued protection of non-iron-based materials is vital to the reliable operation of power generating and other energy-related equipment This conference was dedicated to the fundamental aspects of oxidation, corrosion, dissolution, and transport of non-iron-based materials and their oxides in high-purity and contaminated water and steam Objective • To organize and conduct an international conference on the interaction of non-iron-based materials with water and steam; to determine the state of knowledge; and, to identify areas for further research and development Approach Co-sponsors for the conference were ENEL (Italy), EPRI (United States), and VGB (Germany) An organizing committee solicited and selected papers for presentation An international advisory committee of 36 scientists from organizations worldwide reviewed all the papers that were then revised by the authors The conference was held in Piacenza, Italy, on June 11-13, 1996 Application, Value, and Use The conference included sessions on the following themes: • Copper base alloys in condensate and feedwater • Volatility and transport of copper and its oxides • Electrochemistry and monitoring of copper alloys in high-purity feedwater systems • Chemical cleaning • Titanium in power plants • Materials in light water reactor (LWR) nuclear plants • Generator water cooling systems 17-34 EPRI Perspective Cycle chemistry in fossil cycles with copper or copper alloys is a compromise, which means that the optimum can never be achieved for both iron-based or copper-based materials Despite conference papers on the use of oxidizing feedwater chemistries, the consensus was that reducing conditions in cycles with copper alloys remains the only reasonable alternative Titanium and stainless steel are a reasonable alternative for condenser and feedwater heater tubing Elimination of all copper or copper-alloys in a fossil plant cycle makes the application of oxygenated treatment possible The papers confirmed the incomplete understanding of the actual copper corrosion process, copper oxide transport around the cycle, and particularly deposition of copper oxides onto highpressure turbine surfaces The deposition in, and the cleaning of, water-cooled generator windings is a very important issue for utilities operating large generators Conference papers document the necessity of further investigations that should result in optimum generator cooling system chemistry Non-iron-based materials are applied in nuclear power plants on a large scale Conference presentations covered the state of the art for interactions of pressurized water reactor (PWR) steam generator tubing materials (Alloys 600, 690, 800) and of fuel cladding tubing materials (zirconium alloys) with the operational environment Further investigations in this area are clearly needed and are important for the availability and the reliability of nuclear plant cycles A compilation of all plant cycle-related thermodynamic and physical chemistry data into one volume is urgently needed Program 2005 Program SST501 Strategic Science & Technology History 2004 Program SST501 Strategic Science & Technology 2002 Program SST501 E501 Strategic Science and Technology 1997 Program T6101 Exploratory Research 1997 Program T6102 Applied Science & Technology 2002 Program 064.0 Boiler and Turbine Steam and Cycle Chemistry 17-35 The Electric Power Research Institute, Inc (EPRI, www.epri.com) conducts research and development relating to the generation, delivery and use of electricity for the benefit of the public An independent, nonprofit organization, EPRI brings together its scientists and engineers as well as experts from academia and industry to help address challenges in electricity, including reliability, efficiency, affordability, health, safety and the environment EPRI also provides technology, policy and economic analyses to drive long-range research and development planning, and supports research in emerging technologies EPRI’s members represent approximately 90 percent of the electricity generated and delivered in the United States, and international participation extends to more than 30 countries EPRI’s principal offices and laboratories are located in Palo Alto, Calif.; Charlotte, N.C.; Knoxville, Tenn.; and Lenox, Mass Together…Shaping the Future of Electricity © 2014 Electric Power Research Institute (EPRI), Inc All rights reserved Electric Power Research Institute, EPRI, and TOGETHER…SHAPING THE FUTURE OF ELECTRICITY are registered service marks of the Electric Power Research Institute, Inc 3002004151 Electric Power Research Institute 3420 Hillview Avenue, Palo Alto, California 94304-1338 • PO Box 10412, Palo Alto, California 94303-0813 • USA 800.313.3774 • 650.855.2121 • askepri@epri.com • www.epri.com