CCGT-3, SABIYA POWER PLANT

HRSG’s CHEMICAL
DOSING SYSTEM
PRESENTED BY
KANAGVEL
 INTRODUCTION

 The phosphate dosing system shall dose the chemicals to

prevent scale formation from water and steam cycle for the plant.
 Phosphate dosing system shall be furnished high quality of
equipment and accessories according to the specification and
industrial standards.
 Phosphate dosing system shall be provided all equipment
necessary for the proper and safe operation of
phosphate dosing system
 SYSTEM COMPONENT DESCRIPTION

 Phosphate dosing system for HRSG shall be complete with all equipment
and accessories necessary for the safe, efficient and reliable operation of
the plant including but not limited to the
following :
 SYSTEM FUNCTION DESCRIPTION
AND MAJOR COMPONENT

 Phosphate Dosing System for HRSG.

The water used for The Heat Recovery Steam Generator (HRSG) usually
contains various impurities such as suspended solids, dissolved solids and
gases. Since they are operated at high temperature and pressure, the presence
of a few impurities can cause problem such as
scale problem in the super heater and turbine, etc.
 In order to prevent these problems and to operate the HRSG safely and
efficiently, chemical treatment suitable for HRSG drum is required.
 Phosphate dosing system consists of Phosphate dosing
 Phosphate Dosing System
- Phosphate will be dosed to avoid deposits of hardness in the HP/IP/LP boiler drum.
- Phosphate dosing system consists of two(2) Phosphate solution tanks and six(6) dosing
pumps.
 Phosphate Solution Tank
No. : Two (2) x 100%
- Type : Vertical & Cylindrical
- Capacity : 2.4 m3
- Material : SS316L
- Accessories : Agitator, Level Transmitter, etc.
 Phosphate Dosing Pump
- No. : Two (2) x 100% (1 Operating X 1 Stand-by for HP drum)
Two(2) x 100% (1 Operating X 1 Stand-by for IP drum)
Two(2) x 100% (1 Operating x 1 Stand-by for LP drum)
Type : Single Diaphragm, Auto control
- Required Capacity : 9.7 l/hr x 158.62 bar.a (Dosing pump for HP drum)
3.9 l/hr x 35.78 bar.a (Dosing pump for IP drum)
10.3 l/hr x 4.63 bar.a (Dosing pump for LP drum)
- Material : Head, Seat : SS316(HP), SS316L(IP, LP) / Diaphragm : PTFE
 DESCRIPTION OF OPERATION

 PUMP
Hydraulic single diaphragm type pump designed for accurate metering and
proportioning of chemicals. Stroke adjustment for capacity control shall be
provided. Capacity shall be continuously Adjustment may be depending on the
application either manual dial or automatic stroke adjustment mounted directly on
pump. Provided ball check valves on discharge to prevent the reverse flow. Internal
pressure relief valve protects the gear, diaphragm, pump head and external piping
from overpressure. Phosphate dosing pump shall be operated for a moment as
required by operator (If the pump doesn't work for a while. Since internal air or
some interference
reason.).
 PULSATION DAMPENER:
Pulsation dampeners are on discharge line. It is used to smooth the pulsation of the flow in the piping and
prevent knocks arising from mass acceleration.
 PIPES:
 Interconnecting piping is designed as shown in the P & I Diagram and General Arrangement Drawing. The
piping material is 316 stainless steel.
 VALVES:
 Valve shall be supplied as shown in the P&I diagram. The material shall be suitable for the service intended.
Each skid-installed unit shall be complete with all integral pipework, fittings and isolating valves.
 CALIBRATION POT:
Three (3) calibration pot is on suction line. Pump flow rate to be measured during a period of approximately
one minute when initial operation or anytime that operator wants.
 OPERATING MODES

 START-UP
The Phosphate Dosing System should be started up after check as following:
Verify the following:
- The operator have to be familiar with the Phosphate Dosing System.
- All required safety equipment shall be placed near by phosphate dosing
system shelter and it has to be able to use.
- Tag-outs are cleared.
- All equipment and instruments properly shall be installed and calibrated.
- Electrical power is available to pumps.
- Line up the phosphate dosing system is completed.
 NORMAL OPERATION

 During normal operation, Flow rate of phosphate pump shall be controlled automatically
by HRSG Feedwater flow rate of signal respectively from DCS.
The system operation must be constantly monitored for alarms or conditions that are
abnormal and which require operator attention. This monitoring is done through the
plant DCS.
 In manual mode of Phosphate dosing pump, each pump will be started by the operator
regardless the status of another pump, and the operator can select any of pump A &
B(HP dosing pumps), C & D(IP dosing pumps), E & F(LP dosing pumps) for manual
start
 Phosphate solution tank is continuous operation and it shall be changed operation
concept by adjusting isolation valve at local.
 Flow rate of chemical dosing pump shall be checked with calibration pot and controlled
by globe valve installed on suction line at local.
 All pumps shall be manually started in local control panel or DCS. Stand by pump start
automatically in case of the running pump trip or discharge flow is low. Chemical dosing
pumps shall be operated for chemical reaction required by the operator.
 THE OPERATION CONCEPT FOR
PHOSPHATE DOSING SYSTEM

 A. Control and Monitoring at DCS

1) Each pump flow rate is controlled by signal from DCS through Local Control
Panel.
2) All feedback (run, stop and fault) of each pump can be monitored at DCS.
3) “High”, "Low" and "Low-Low" level alarm of each tank can be monitored at
DCS.
4) Remote/Local mode selection can be monitored at LCP or DCS.
5) Auto/Manual selection for pumps and Agitator operated for LCP or DCS.
 B. Interlock
1) Each pump is stopped by tank level Low-Low.
2) Each agitator is stopped by respective tank level Low.
 SHUT DOWN

 Stop’ signal is occurred for Phosphate dosing pump from the plant DCS
or the ‘Stop’ switch is operated in the local.

‘Stop’ signal is occurred for Phosphate dosing pumps from the plant DCS
at HRSG Unit shutdown.
 DESCRIPTION OF PROCESS & CHEMICAL
FILLING

 PRIOR TO OPERATION
1) Main Power Supply.
2) Sufficiency for Pump Lubricant.
3) Tank Level.
4) Flow rate calibration for Pump.
5) Check the Open & Close status for valve .
 CHEMICAL DOSING PROCESS
1) Pumps and agitators can be operated ‘start’ by local panel and ‘stop’ by
interlocked with level transmitter Installed at storage tank.
2) It is possible to sound the alarm at level low, trip the pump at the level low-low
by level transmitter installed at storage tank.
3) In addition to DCS as well as locally manual adjustments, dosing rates can be
automatically adjusted in LCP by receiving signals from DCS for boiler feedwater
flow rate.
4) Fill a tank with water from demi water observing level gauge in order to
dissolving phosphate in the tank.
PHOSPHATE FILLING PROCESS
(POWDER TYPE)
 CHECK THE PUMP FLOW RATE

A stop watch or standard wrist watch is required.

1) With the pump operating normally, tank full or nearly full and both chemical
outlet valve and calibration pot block valve in the full open position, the
calibration pot will be filled with liquid.
2) When the liquid level reaches the top division mark (on calibration pot), close
chemical outlet valve(on tank suction line).
3) Allowed liquid level to drop for a period of at least 1 minute before reopening
chemical outlet valve.
4) Finally, divide the number of divisions that the liquid has dropped by the
number of minutes used.
5) Check the actual measured flow rate against the pump flow curve sheet.
6) When the calibration pot is not in use, calibration pot block valve may be closed
and chemical outlet valve must retain open at all the times except while the
calibration pot is in
use.
 INSTRUMENT AND CONTROL

 The phosphate dosing system shall be completed with all accessories necessary
for efficient and reliable operation of the plant.

 The phosphate dosing system shall be operated from the local control panel and
the DCS of central control room.
CONTROL PHILOSOPHY FOR PHOSPHATE
DOSING SYSTEM

 LEVEL CONTROL
1) Each pump is stopped by tank level low-low at remote and local mode.
2) Each agitator is stopped by tank level low
 LOCAL CONTROL PANEL
RELAY PANEL
1) Remote/Local only can be selected by select switch.
2) Push button of lamp can stop pumps or start. And pump PID
control by boiler feed water is accepted by LCP.
3) Run and stop status of pump can be monitored form Push button
Lamp.
4) High, Low, Low-Low tank level and pumps, agitators fault alarm.
P&ID OF PHOSPHATE DOSING SYSTEM
HRGS PHOSPHATE DOSING SYSTEM - HMI
DESIGN CALCULATION SHEET
Conclusion

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Questions??

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