Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity ....
Transcript of Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity ....
![Page 1: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/1.jpg)
Belchatow 858 MW WTP
By Rami E. Kremesti M.Sc.
ALSTOM
![Page 2: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/2.jpg)
Block Diagram
• Raw water pumping station/Rotating band screens
• 2 sludge bed upflow clarifiers @ 2x1000 m3/hr
• Filtration plant: 2 x 5 double chamber sand filters with capacity 2x1000 m3/hr/line
• SBS dechlorination dosing station
• Demin plant: 2 x (MMF – CIX – Degas – AIX- MBX) capacity each line 80 m3/hr. DOWEX UPCORE process
• ClO2 dosing station (Biggest in Poland)
• 3 neutralization pits
• Allan-Bradley PLC
![Page 3: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/3.jpg)
Chemical Tanks
• HCl tank and NaClO2 tank for production of ClO2
• HCl and NaOH tanks for Demin plant regeneration
• FeCl3 tank for coagulant
• Flocculant dosing station (PROMINENT)
![Page 4: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/4.jpg)
Chemical Unloading HCl
![Page 5: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/5.jpg)
ClO2 Dosing Station
![Page 6: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/6.jpg)
Resin Loading
![Page 7: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/7.jpg)
Clarifier
![Page 8: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/8.jpg)
Clarifier Bad
![Page 9: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/9.jpg)
Clarifier Good
![Page 10: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/10.jpg)
Filling The Cooling Tower
![Page 11: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/11.jpg)
Sand Filtration Plant
![Page 12: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/12.jpg)
Lime Preparation and Dosing
![Page 13: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/13.jpg)
Mixed Bed
![Page 14: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/14.jpg)
Contractor Working Hard
![Page 15: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/15.jpg)
Resin Backwashing
![Page 16: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/16.jpg)
Resin Loading
![Page 17: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/17.jpg)
Anion Exchanger Feed Pump
![Page 18: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/18.jpg)
Water Quality
• Clarifier reduced SS and hardness down to 10 ppm
• SFP reduced SS down to 1 ppm
• Demin plant produced demin water with near 0.055 uS/cm conductivity
![Page 19: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/19.jpg)
Technical Problems - I
• 1. raw water control valves not working properly due to high delta P
• 2. original resin backwash vessels scrapped for nothing
• 3. decarbo water pumps cavitating
• 4. demin pump impellers after CIX made from CS corroded
• 5. bolts in neutralization basin made from inox
![Page 20: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/20.jpg)
Problems - II
• 6. Difficult to commission the clarifers no good instructions
• 7. ClO2 attacking the flocculant
• 8. no bypass line for ClO2 for the clarifiers
• 9. chemical unloading area no containment
• 10. regeneration with closed drain valves not foreseen
safety logic
![Page 21: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/21.jpg)
Problems - III
• 11. Sludge pumps oversized for recirculation for clarifiers
• 12. Big decarbo pumps were noisier than 85 dB
• 13. degasifiers were carrying over and the acidic water was destroying the outside of bldg
• 14. there was no flushing line for the acid/base unloading lines
![Page 22: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/22.jpg)
Problems - IV
• 15. bad HCl acid leak from flange on one of the unloading cabinets lead to destruction of aluminum housing
• 16. Lime mixing impellers were eroded after one year: make sure material is suitable.
• 17. Some pumps were vibrating and we needed to reinforce the supports
• 18. Issues with CO2 contamination of demin water tank. Prefer filling line to come to bottom of tank to avoid splashing. Issues with overflow line air lock
![Page 23: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/23.jpg)
Problems - V
• Leaking pipe wall penetration for neutralization basins (Civil)
• Prominent recommended changing gaskets/membranes for ClO2 plant every 6 months (too early)
• Client was acting difficult (political)
![Page 24: Belchatow 858 MW WTP · •Demin plant produced demin water with near 0.055 uS/cm conductivity . Technical Problems - I •1. raw water control valves not working properly due to](https://reader030.fdocuments.in/reader030/viewer/2022040320/5e4a3f90304da30307740668/html5/thumbnails/24.jpg)
Delays in Commissioning
• Permanent power supply delayed
• Raw water supply delay
• Clarifier commissioning delay
• No hoses ordered by engineering for resin loading