COS-ISO-00-OIN/OPS/CHEM/004

Rev. No. : 0 October 2000

OPERATION INFORMATION NOTE

Recommendations of Chemistry
Workshop on Operational Problems
of Condensate Polishing Unit
(Held at Korba on 7th and 8th August 2000)

OPERATION SERVICES DIVISION

National Thermal Power Corporation Ltd.

NATIONAL THERMAL POWER CORPORATION LTD.

OPERATION AND MAINTENANCE FORMAL DOCUMENTATION SYSTEM
OPERATION INFORMATION NOTE : COS-ISO-00-OIN/OPS/CHEM/004
Rev. No.: 0

Date : October 2000

Recommendations of Chemistry
Workshop on Operational Problems
of Condensate Polishing Unit
(Held at Korba on 7th and 8th August 2000)

Approved for
Implementation by ..
A.G.M.(COS)
Date: ..
Enquiries to: Head of Corp. Operation Services

Recommendations of Chemistry Workshop on Operational Problem of

Condensate Polishing Unit (held at Korba on the 7th and 8th August 2000)

INDEX

Sl. No.

Contents

Page No

1.0

Introduction

2.0

Superseded Documents

3.0

Feedback and Discussions

4.0

Recommendations

5.0

Conclusion

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COS-ISO-00-OIN/OPS/CHEM/004
Rev. No.: 0
Recommendations of Chemistry Workshop on Operational Problems of
Condensate Polishing Unit (held at Korba on 7th and 8th August 2000)

Recommendations of Chemistry Workshop on Operational

Problems on Condensate Polishing Unit (held at Korba on
7th and 8th August 2000)
1.0 INTRODUCTION
Workshop on operational problems of condensate polishing units was held on
7thand 8th August 2000 at NTPC Korba. The workshop was inaugurated by E.D.
(WR) and in the concluding session EPRI expert Dr. Berry Dooley was present
while formulating the workshop recommendations. About 64 delegates from
various NTPC stations, R&D, Engineering, OS, PMI, UPSEB, MSEB, Tata
Electric, BSES Dahanu and equipment manufacturers like M/S Driplex Water
Engg. Ltd., M/S Ion Exchange Ltd. and M/S GEA (Energy System) Ltd.
participated in the deliberations.
2.0 SUPERSEDED DOCUMENTS

Nil

National Thermal Power Corporation Ltd.

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COS-ISO-00-OIN/OPS/CHEM/004
Rev. No.: 0
Recommendations of Chemistry Workshop on Operational Problems of
Condensate Polishing Unit (held at Korba on 7th and 8th August 2000)
3.0 FEEDBACK AND DISCUSSIONS
The following is the general feed back on the functioning of the CPU at various
stations.
3.1

NTPC Korba representative described the salient feature of condensate

polishing system. He further explained the advantages derived from
running the CPU on continuous basis e.g. (a) reduction of crud level in
condensate, (b) reduction of blow down, (c) no drum pressure restriction
etc. CPU is running in Hydrogen cycle for 18-21 days meeting all
parameters. However the on-set of ammonia cycle triggers off chloride
leakage leading to sharp increase in chloride level in boiler.

3.2

NTPC Rihand representative shared almost identical view as that of

NTPC Korba. He was of the opinion that auto ammonia dosing at CPU
outlet will greatly influence the performance of CPU.

3.3

BSES Dahanu power station representative gave an elaborate description

of the design and layout of condensate polishing at Dahanu. They have
on-line chloride and silica analysers. But the flow rate across CPU vessel
is around 250-270 m3/hr against the design value of 350 m3/hr. Besides
this, the CPU is running satisfactorily in H-cycle operation but they are
also facing high chloride problem in ammonia cycle operation.

3.4

NTPC R&D representative explained the importance of selection of resin

for optimal performance in CPU with special reference to the separation
profile of cation and anion resin and uniform size distribution.

3.5

CPU with seprex type of regeneration system (supplied by Ion Exchange

Ltd.) in all the three stations i.e. NTPC Vindhyachal, Ramagundam and
Farakka is facing almost similar problems like (a) reduced output even in
hydrogen cycle (b) cross contamination of resin during regeneration,
(c) high differential pressure across the vessel and (d) high chloride and
sodium values at CPU outlet with onset of ammonia cycle.

3.6

NTPC Talcher representative explained the salient features of CPU at

Talcher Super Thermal Power Station, which is akin to that of NTPC
Korba. Some of the problems being encountered at Talcher are (a)
variation in condensate flow, (b) partial separation of resin during
transfer, (c) high temperature of condensate and (d) chloride leaching in
ammonia cycle operation. It was pointed out that CO2 loading has to be
considered while designing the anionic load in condensate.

3.7

NTPC Singrauli representative presented the layout and salient features

of CPU at Singrauli. It was informed that the CPU is running
satisfactorily in hydrogen cycle while in ammonia cycle it is also facing
the problem of chloride leakage. Another typical problem they are
experiencing is high air ingress in condensate.
National Thermal Power Corporation Ltd.

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COS-ISO-00-OIN/OPS/CHEM/004
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Recommendations of Chemistry Workshop on Operational Problems of
Condensate Polishing Unit (held at Korba on 7th and 8th August 2000)

4.0

3.8

Corporate Engg. representative gave a detailed account of design criteria

being adopted for CPU in NTPC. It was informed that in coming 660
MW stations, the number of vessels being considered are three with 3 x
33 % + 1 (one) stand by.

3.9

M/S BHEL representative explained the merit of deep mixed bed type
CPU, but he stressed the need to review the specification of CPU
specifically with respect to ammonia cycle mode of operation, given the
fact that no where CPU is running in ammonia cycle with the guaranteed
parameters within limit. It was further pointed out that full opening of
100 % bypass valve and closing of inlet and outlet valves should be
incorporated in the event of power failure in CPU panel.

3.10

Representative of Chandrapur Thermal Power Station (M/S MSEB)

shared their experience of CPU at Chandrapur. The plant is supplied by
M/S Ion Exchange Ltd. They also informed that CPU is working
satisfactorily in Hydrogen cycle mode of operation. But in ammonia
cycle they are also facing the chloride and sodium leakage from CPU for
which they are resorting to two hours blow down in alternate days.

3.11

Representative of Anpara Thermal Power Station shared their experience

of CPU with the forum. The plant has been designed and installed by M/S
PWT Projects Ltd., London and for UPSEB supplied by M/S Mitsui &
Co. Ltd., Japan in 1990 and commissioned in 1994. The plant consists of
2 sets of 3 nos. of mixed bed unit, one set for each turbogenerator set,
treating 1230 m3/hr of boiler feed water with 2 beds in service and one
bed as standby. He explained the ansar technique of cleaning of resin.
Other salient feature of the plant was also discussed. From the discussion
it emerged that the plant is running satisfactorily in hydrogen cycle where
as the ammonia cycle mode of operation witness high chloride and
ammonia leaching problem from CPU vessel.

3.12

The acknowledged suppliers of condensate polisher units, M/S Ion

Exchange Ltd., M/S Driplex Engg. Ltd and M/S GEA (Energy) System
Ltd. have listened to the problems raised by the participants. They have
highlighted the modifications being envisaged in their respective design
to improve the performance of CPU. M/S GEA (Energy) Ltd. informed
that their plant is running successfully in hydrogen cycle mode of
operation in a number of stations in Europe.

RECOMMENDATIONS
4.1

All NTPC stations (with deep mixed bed CPU facilities) and other reputed
power utilities like M/S Tata Electric, M/S BSES, M/S Anpara Power
Station, and M/S Chandrapur Thermal Power Station (MSEB) have
reported that condensate polishing unit are working satisfactorily in
National Thermal Power Corporation Ltd.

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COS-ISO-00-OIN/OPS/CHEM/004
Rev. No.: 0
Recommendations of Chemistry Workshop on Operational Problems of
Condensate Polishing Unit (held at Korba on 7th and 8th August 2000)
Hydrogen cycle mode of operation only. This point was vetted by EPRI
expert Dr. Berry Dooley. Therefore it is recommended to run deep bed
mixed bed type CPU in Hydrogen cycle only on continuous basis.
4.2

The general opinion was that auto ammonia dosing on the basis of
condensate flow and specific conductivity at CPU outlet is to be
incorporated in the existing projects (where the same is not available) and
also in future projects for maintaining proper ammonia concentration in
condensate.

4.3

Almost all participants felt that during rinsing operation of CPU, the rinse
water is not to be re circulated to hot well due to poor quality (high
conductivity and crud) and other operational problems (drop in condensate
vacuum) etc..

4.4

After detailed discussion it was felt that air scouring provision at service
vessel would facilitate effective mixing of resin and hence lead to better
performance of CPU. In this context Engg informed that for new and
future projects, the provision of air scouring is being provided. For
existing stations, site can adopt air scouring arrangement.

4.5

Low level sodium analyzers at individual CPU service vessel outlet to be

provided for proper monitoring of performance of CPU.

4.6

For proper measurement of regenerants (acid and alkali), measuring tanks

in the regeneration area are to be provided in the existing projects (where
the same is not available) and also for future projects. This is being taken
up by Corp. Engineering.

4.7

It was opined that possibility may be explored for pre-filter / lead cation
vessel for effective removal of crud from condensate in case of future
projects. However Engg. informed that as per specification crud is being
removed by CPUs.

4.8

R & D will review the specification of resin for CPU.

4.9

It was opined that CO2 loading has to be considered while assessing the
anionic load in condensate.

5.0 CONCLUSION
All the participants appreciated the efforts of COS-Chem. group for arranging
this workshop which provided a forum to sort out the operational problems of
condensate polishing units on regular basis.

National Thermal Power Corporation Ltd.

Document for Distribution to:

CONTROLLED
I. Power Stations
1. General Manager

Rihand

2. General Manager

Vindhyachal

3. General Manager

Kahalgaon

4. General Manager

Farakka

5. General Manager

Dadri (Coal & Gas)

6. General Manager

Unchahar

7. General Manager

Korba

8. General Manager

Ramagundam

9. General Manager

Badarpur

10. General Manager

Talcher Kaniha

11. General Manager

Anta

12. General Manager

Talcher Thermal

13. General Manager

Kayamkulam

14. General Manager

Simhadri

15. General Manager

Singrauli

16. Addl. General Manager(I/C)

BALCO Captive

17. Addl. General Manager(I/C)

Auraiya

18. Addl. General Manager(I/C)

Kawas

19. Addl. General Manager(I/C)

Jhanor Gandhar

20. Addl. General Manager(I/C)

Faridabad

21. Addl. General Manager(I/C)

Tanda

National Thermal Power Corporation Ltd.

UNCONTROLLED
II Regional Head Quarters
22. Executive Director (NR), Lucknow
23. Executive Director (SR), Hyderabad
24. Executive Director (WR), Mumbai
25. Executive Director (ER), Patna
26. Executive Director (NCR), New Delhi

III Corporate Head Quarter

27. Chairman & Managing Director, SCOPE, New Delhi
28. Director (Technical), SCOPE, New Delhi
29. Director (Operations) , SCOPE, New Delhi
30. Director (Commercial), SCOPE, New Delhi
31. Director (Projects) , SCOPE, New Delhi
32. Executive Director (OS), EOC, Noida
33. Executive Director (Engg.), EOC, Noida
34. General Manager (R&D), Noida
35. Concerned Group Heads in Operation Services, CC

IV Head of O&M
36. Singrauli

37. Korba

38. Ramagundam

39. Farakka

40. Vindhyachal

41. Rihand

42. Kahalgaon

43. Dadri(Coal)

44. Unchahar

45. Talcher Kaniha

46.Talcher Thermal

47. Badarpur

48. BALCO Captive

49. Auraiya

50. Anta

51. Kawas

54. Kayamkulam

55. Faridabad

52. Jhanor Gandhar 53. Dadri (Gas)

56. Simhadri

57. Tanda

National Thermal Power Corporation Ltd.