STEAM AND WATER ANALYSIS SYSTEM (SWAS)

5.01.00 A SWAS room shall be provided to house the sample coolers and analyzer racks for the steam and water analyser system. The system shall be designed in accordance to the recommendation of ASME PTC 19.11 Part-II, water & steam in power cycle. The sampling system shall obtain samples from steam and water system, which shall be adequately conditioned and fed to analyzers for continuous analysis and provide parallel facility for grab sampling as specified.
5.02.0 Sample Piping System
a) All process connection , piping, valve etc of SWAS analysers shall be conform to ANSI/ISA SP 77.70- 1994 (R 2005) “Fossil Fuel Power Plant Instrument Piping Installation”, ANSI B 31.1 “Power Piping”, PTC 19.11,ASTM D 1066 for steam & IBR unless otherwise specified.
b) All sample piping shall be three fourth inch NB seamless type of material ASTM A213 TP 316H, conforming to ANSI B 36.19. Bidder shall provide sample nozzle for steam as per ASTM D 1066.
c) All fitting shall be socket welding type and of material ASTMA 182 F316 H conforming to ANSI B 16.11.
d) Single and multi tubes shall run with the minimum No. of changes in direction. Suitable identification tags shall be provided for easy check up and for proper connections.
e)The valves to be used in sample piping shall be of globe type, forged construction and stainless steel conforming to ASTM A182. The pressure Temp. ratings shall be as per ANSI B 16.34. The valve design shall be such that the seats can be reconditioned and stem and disc can be replaced without removing valve body from the line. Blow down valve shall be gradual open type.

5.03.00 Primary cooling of all samples having temperature in excess of 45 deg C shall be provided through an individual sample cooler (primary cooler) of submerged helical coil type of shell and tube design with removable shell, meeting the intent of ASTM D 1192-1977, to bring down the temperature to around 45°C. These coolers shall be rack – mounted and located at the field. The primary coolers shall use water from equipment cooling water system. The design, construction materials and technical features of the coolers shall be subject to Purchaser’s approval. However, the sizing of the coolers should consider total sample flow plus 500 ml / min grab sample and a fouling factor of 0.2 and cooling water temp shall be 33 deg C. All fittings, tubes & other wetted parts shall be 316 SS. . All high pressure samples shall be provided with pressure reducing valves after primary cooler in the field.

5.04.00 SWAS Panels

5.04.01 Sample conditioning panel (wet section) shall house bulk head type fittings, removable cartridge type filters, pressure reducing elements, flow rate control, secondary coolers, grab sample valve and other sample conditioning equipments. For each sample, pressure gauge, temperature gauge, flow indicator, back pressure regulating valve, grab sample valve shall be provided on front of panel. The grab sampling facility and quick disconnect patch board facilities shall be provided on this panel. Analyzer panel (dry section) shall house cells, analyzers, monitors etc.

5.04.02 The above panels shall be physically separate from each other and shall be mounted in the air-conditioned SWAS room (common for 2 units). Sample conditioning panel shall be corridor type with walkway. The analyzer panel shall be free standing and of totally enclosed construction. The panel sheet thickness shall be 2.5mm( CRCA IS 513)except for doors which shall be of 2.0 mm thickness. All SWAS panels shall be designed for ready access of components for easy maintenance. The layout and general arrangement of these panels shall be subject to Purchaser’s approval.
5.04.03.All samples will be passed through cartridge type filters before being cooled in respective secondary coolers.
Sample particulars removal shall be accomplished by passing all sample through cartridge filters with type sintered 316 stainless steel body. Removable type filter element shall be capable of retaining particles of 40 micron and larger. These elements shall be installed down stream of solenoid operated sample shut of valves at each branch of analyser sample stream.
5.04.04 Each sample stream with the required flow rate shall be finally cooled from approximately 45Deg C to 25DegC+/-1DegC or to a preset temperature required by the analyzer through an individual secondary cooler before passing the sample to the respective measuring cells and analyzer even in case, the corresponding analyzer is rated for higher sample temperature. The pressure of the samples shall be about 2 kg/cm2 and flow rates shall be as required by the individual analysers. The secondary cooler shall use condensate quality chilled water at 20Deg C.

5.04.05.The secondary coolers will also be of submerged helical coil type of shell and tube design meeting the intent of ASTMD 1192-1977. All tubes, fittings & wetted parts shall be 316 SS. The chilled water for SWAS should be drawn from chiller plant/unit. Loss in chilled water pressure, flows and rise in temperature shall be alarmed.
5.04.06 The coolers shall be protected by safety relief valve.
5.04.07 The system shall be designed in accordance to the recommendation of ANSI/ASTM D 1192 and ISO 5667-7( Guidance on sampling of water and steam in boiler plants).
5.04.08 The cooling water header shall be provided with pressure gauge, temperature gauge ,rotameter , flow switch and isolating valves.
Provision shall be made for heat exchanger shell drain which will be connected to drain header.
Potential free contact shall be provided for annunciating loss of cooling water.
5.04.09 Grab sample valves(3 way needle valve) shall be arranged to allow grab sample flow to be directed to either a drain header or through a grab sample nozzles to samples trough. Back pressure regulator and Enough flexible tubing shall be furnished to allow sample collection without splashing. A grab sample collection facility consisting of a common 304 stainless steel sink .

5.04.10 Isothermal Bath :
Provision shall be made for supply of isothermal bath.
In isothermal bath each sample stream shall be finally cooled to the required temperature as specified by the analyzer manufacturer and as approved during engineering within a variation +1 Deg. C before passing sample to the respective measuring cells. This shall be accomplished in isothermal bath by counter current heat exchange of each sample against the flow of chilled water at 20 Deg. C. The chilled water for isothermal bath shall be provided by package refrigeration unit (chillers).
Sufficient heat exchange capacity shall be provided to obtain the required temperature at sample outlet for maximum flow rate required by the analyzers and grab samples requirements considering adequate fouling factor at both ends of the coils. Capacity calculations shall be furnished.
Provision shall be made of adjusting each sample temperature individually. Temperature control shall be provided to maintain the isothermal bath temperature at the required value.
5.04.11 Bidder shall be provide pressure reducing valve and safety relief valve after secondary cooler .
A grab sample collection facility consisting of a common 304 stainless steel sink .
5.04.12)Bidder shall provide
i) sample recoverable drain header( 304SS or 316 SS)
ii)waste drain header(304 SS or 316 SS) It shall be provided with connections for all installed analyzers. .
5.05.00 Analyzer panel (Dry panel) housing all display units
(Digital panel meters for PH & conductivity signals)
analysers for sodium, phosphate, hydrazine, silica etc.
and annunciation system. Further, two 4-20 mA isolated analog signal for each measurement including PH & conductivity shall be fed to DDCMIS for monitoring. Necessary signal distributors, if required shall be Provided . Bidder shall provide 50 Annunciator windows, push button for test, acknowledge and reset, and hooter.

5.06.00 Chiller
Two (2) 100% capacity water cooled chillers shall be provided for the SWAS package.
Each chiller unit shall be designed with sufficient refrigeration capacity to ensure each sample stream temperature to 25 deg. C ± 1 deg. C when all streams are simultaneously at maximum flow rate and maximum temperature. The chiller capacity shall have a provision of 25% spare capacity for future samples.
Suitable temperature monitoring and control systems shall be provided for maintaining the chilled water temperature at chiller outlet at 20 deg. C or at a designed preset value and within the desired band. The compressor shall be readily accessible for service and shall include low noise hermetically sealed motors. Compressor assembly shall also include crank case heaters, suction and discharge valves, oil sight glasses, forced feed lubrication system and an integrated motor protection system along with the necessary instruments.
The condenser shall be water cooled, cleanable shell and tube with water regulating valve. The cooling water shall be supplied from closed cooling water system.
Chiller shall be of the direct expansion type with refrigerant tubes inside a shell, completely insulated and to be constructed in accordance with the ASME code for unfired pressure vessels.
Refrigerant circuit shall be complete with a thermostatic expansion valve, liquid line solenoid valve, sight glasses, filter-dryer, refrigerant shut-off and charging valves.
The chiller water pump(2x100%) shall be of the centrifugal type, close coupled, bronze fitted construction, complete with motor. Pump & motor shall be designed for continuous operation. Vibration dampeners shall be mounted between the packaged chiller and the channel base.
Vibration dampeners shall be mounted between the packaged chiller and the channel base. The bidder shall provide 2x100% recirculation pumps with chiller units .
Cooling water and chilled water piping shall be provided with block valves, flow switch, temp switch and other instrument as per requirement.
The Bidder shall provide detailed calculation for chiller capacity and other technical particulars like foundation details/mounting etc. and the same shall be subject to Owner's approval.
The chiller system shall be provided with 100% redundant chilled water pumps with suction and discharge pressure gauges and temperature gauges; Chilled water circulation pump with 100% standby facility; Storage tank automatic water make up with manual by-pass facility, temperature indicator, level gauge and drain and overflow connection, in addition to any other instruments/equipments required for smooth, convenient operation of the system, which shall also be furnished by the Bidder.
5.07.00 The exact sample points, their location, type of
chemical analysis to be carried out for each sample,
measurement ranges etc. shall be subject to the
approval of the owner.

5.08.00 Following analytical measurement have been envisaged but not
limited to -

5.08.01 D M Make-up to Condenser

i) Specific Conductivity
ii) Cat Conductivity
iii) Silica

5.08.02 Hotwell

i) Spec Conductivity (insertion type)on both side

5.08.03 Cond. Pump(CEP) Discharge

i) Cat Conductivity
ii) pH
iii) Dissolved Oxygen
iv) Specific Conductivity
v) Silica
vi) Sodium


5.08.04 Condenser Cooling Water

i) pH
ii) Specific Conductivity

5.08.05 Deaerator Inlet

i) PH
ii) Dissolved Oxygen
iii) Specific Conductivity

5.05.06 Deaerator Outlet

i) Dissolved Oxygen

5.08.07 Feed Water at ECO I/L

i) Hydrazine
ii) Specific Conductivity
iii) Phosphate
iv) pH
v)Dissolved Oxygen
vi)cat conductivity
5.08.08 Drum Water

i) Specific Conductivity
ii) pH
iii) Sodium
iv) Silica
v) Phosphate
vi) chloride

5.08.09 Saturated Steam (SH out)

i) Specific Conductivity
ii) Cat Conductivity
iii) pH

5.08.10 Main Steam (after attemperation)

i) Specific Conductivity
ii) PH
iii) Silica
iv) Cat conductivity
v) Sodium
vi) chloride
5.08.11 HRH Steam
i) Specific Conductivity
ii) pH

5.08.12 CBD –
i)Phosphate


5.08.13 ECW pump discharge

i)PH

5.08.14 Cond discharge after CPU

i) sp conductivity
ii)cat conductivity
iii)pH
IV) Sodium
v) Silica

5.08.15 DMCW water
i)pH

5.08.16 Any other Analyzer recommended by Boiler/ Turbine Manufacture or pollution board.

5.09.00 All the analysers/ cells shall have -

A) Automatic Temp. compensation shall be provided. The
protection class of all analysers shall be IP- 65 &
operating Temp range shall be 0- 50 deg C.

(B) All chemical re-agents etc required for 12 months operation is to be supplied.

(C) Analysers/ Monitors/ Cells shall be suitable for

operating under the conditions specified.

(C) The Analyzer supplies shall indicate the preparation

procedure/ formula of Regent to be used in Analyzer’s
System.

(E) Bidder shall submit cooler sizing, calculation, PID diagrams etc. of SWAS system for approval during detail Engineering.

(F) Bidder shall provide startup kit for Analyzers, Buffer
Solution etc for PH, Conductivity simulator etc.

5.10 00.Specification of Analysers

5.10 .01 Conductivity Analyser

i) Type: a) Cell Flow through type / removable type withdrawable with sealing valve)
b) Monitors Electronic (microprocessor based) indicating type with multi range facility
ii) Material:a) Cell Epoxy resin
a) Electrode Platinised
b) Monitor body Carbon steel
iii) Monitor output: a) 4 to 20mA DC for recorder
b) 4 to 20mA DC output for DDCMIS
iv) Power supply 240V, AC, 50Hz
v) Accuracy ± 1 % of full scale span
vi) Stability ± 1% of full scale per month
vii) Repeatability ± 0.3 of span
viii) Annunciation contacts for monitors
a) Number 2 SPDT
b) Type Snap action micro switch
c) Rating 5 Amp, 240V; 0.2Amp, 220V DC
ix) Mounting
a) Cell On line/ pipe mounted (on line in sample table)
b) Monitors Flash panel mounting
x) Connection:
a) Process ¼ inch NPT(F) screwed for on line type ¾ inch NPT (M) screwed for pipe mounted
b) Electrical 1/2 inch NPT (F) screwed
xi) Accessories
a) Automatic temperature compensation in the range
0-1000 C.
b) Ammonia (NH3) removal equipment.
c) Sample coolers.
d) Flow and pressure regulators.
e) SS impulse tubing and fittings
f) Isolation & drain valves as required.
g) Other accessories as required.
h) Adequate length of cables for connecting coils to monitors.
i) Sample rate set valves.
j) Alarm settings and Alarm indications on monitor.
xii) Range As per sample stream .
xiii) Other particulars Cell shall be suitable for maximum pressure of 7 kg/cm2 and maximum temp.of 100deg c

5.10.02 pH Analyser

i) Type- a) Cell Measuring and reference electrode combination with flow through type (polypropylene flow chambers).IS-6804
b) Monitors Electronic (microprocessor based) indicating type with adjustable range facility.
ii) Material a) Measuring & reference Toughened sensitive.
b) Electrode pH glass
c) Monitor body Die-cast aluminum.
iii) Monitor output a) 4-20m A DC for recorder
b) 4-20 m A DC isolated output for DDCMIS
iv) Power Supply 240V AC, 50 Hz
v) Accuracy/repeatability. ± 0.03 pH/ + 0.02pH
vi) Resolution ± 0.01 pH
vii) Stability 0.02 pH per week.
viii) Annunciation contacts for monitors.
a) Number 2 SPDT high and low
b) Type Snap action micro switch.
c) Rating 5 A 240V AC, 0.2 A 220VDC.
ix) Connection.
a) Process 1/4 inch NPT(F) screwed
b) Electrical 1/2 inch NPT(F) screwed
x) Mounting a) Cell Pipe Mounted.
b) Monitors Flush panel mounting.
xi) Accessories
a) Automatic temperature compensation with fast response integral temperature sensors in the range 0-100 deg
b) Co-axial cable as required
c) Sample coolers.
d) Flow and pressure regulators.
e) Standard pH solutions.
f) SS impulse tubing and fittings.
g) Isolation & drain valves as required.
h) Electrode holders.
i) Other accessories as required
j) Sample rate set valves.
k) Alarm settings and indications on monitor.
l RF/EMI shielded, weather and corrosion proof casing.
xii) Ranges As per sample stream .

5. 10.03 Dissolved Oxygen Analyser.

i) Type Electro-chemical
ii) Material Die-cast aluminium
iii) Output a) 4-20m A DC for recorder
b) 4-20 m A DC isolated output for DCS.
iv) Supply 240V AC, 50 Hz.
v) Accuracy +/- 4% of full scale value.
vi) Response:
a) Sensitivity ± two (2) per cent overall.
b) Time (sensor) Less than 30 seconds for
90% step change.
vii) Connection:
a) Process 1/4 inch NPT (F) SCRD.
b) Electrical 1/2inch NPT(F) SCRD.
viii) Accessories
a) Sample cooler assembly with shut off valve at cooling water inlet,
with thermometer and reducing valve at sample outlet.
b) Flow stabilizer.
c)Automatic temperature compensation.
d) Other accessories as required including chiller.
e) Calibration device.
ix) Ranges as per sample stream
x) Mounting Flush
xi) Annunciation contacts
a) Number 2 SPDT.
b) Type Snap action micro switch.
c) Rating 5 Amp 240V AC, 0.2 amp 220V DC.


5.10.04 Silica Analyzer (SIOX)

i) Type Calorimetric Analyzer (with auto reagent shut off feature in case of sample loss or power loss) built in phosphate inhibition feature. Micro processor based.
ii) Case material : Die cast aluminum
iii) Cycle time Twelve (12) minutes maximum
iv) Analyser out put a) 4 to 20m A DC recorder
b) 4 to 20m A DC Isolated output for DCS
v) Power supply 240V DC, 50Hz
vi) Accuracy ± 1% of span
vii) Repeatability ± 2% of full scale
viii) Sensitivity 0.2 micrograms / liters
ix) Connection
a) Process 1/4 inch NPT(F) SCRD.
b) Electrical 1/2 inch NPT(F) SCRD
x) Ranges As per sample stream.
xi) Mounting Flush
xii) Annunciation contacts
a) Number 2 SPDT.
b) Type Snap action micro switch.
c) Rating 5 A 240V AC, 0.2 A 220V D.C.

xiii) Accessories a) Chilling plant (if required)
b) Automatic temperature compensation
between 5 deg.to 50deg C.
c) Automatic zeroing provision.
d) SS tubing & vessels.
e) All chemical reagents for 12 months
operation of the analysers.
f) Sample rate set values.
g) Comprehensive diagnostic and alarm

features.
5.10.05 Hydrazine Analyser

i) Type Electrochemical
ii) Case material Die-cast aluminum
iii) Analyser output 4-20mA DC for Recorder
4-20 mA DC isolated output for DDCMIS
iv) Power supply 240V AC, 50 Hz.
v) Accuracy ± 2% of full scale.
vi) Sensitivity 1.0 microgram/litre.
vii) Annunciation contacts
a) Number 2 SPDT
b) Type Snap action micro switch.
c) Rating 5A 240V AC, 220V D.C.
viii) Mounting Flush mounting.
ix) Accessories a) Flow regulator.
b) Flow gauges.
c) Other accessories as required.
d) Sample rate set valves.
e) Chemical reagents as applicable
for 12 months consumption.

5. 10.06 Sodium Ion Analyser.

i. Type Continuous flow through sample type with
sodium responsive electrode and reference
electrode having pH adjustment facility
ii. Case material Die-cast aluminium
iii. Analyser power
supply 240V AC , 50 Hz.
iv. Analyser output
a) 4-20mA DC for Recorder.
b) 4-20mA DC isolated output for
DDCMIS.
v. Accuracy Better than ± 5% of full scale.
vi. Sensitivity 0.1 ppb.
vii. Annunciation contacts
a) Number 2 SPDT
b) Type Snap action micro switch.
c) Rating 5A 240V AC, 0.2A 220V DC.
viii. Mounting Flush.
ix. Accessories a) Flow regulator.
b) Flow gauges.
c) Sample rate set valves.
d) Other accessories as required to
Make the system complete.

5. 10.07 Chloride Analyser

i. Type Continuous flow through sample type
ii. Analyser power 240V AC, 50 Hz supply
iii. Analyser output a) 4-20mA DC spare output.
b) 4-20mA DC isolated output for DDCMIS.
iv. Accuracy Better than + 5 microgram/liter full scale.
v. Sensitivity 0.1 ppm.
vi. Annunciation contacts:.
a) Number 2 SPDT
b) Type Snap action micro switch.
c) Rating 5A, 240V, AC, 0.2A,220V DC.
vii) Mounting Flush.
Viii. Terminal points All component piped &wired.
ix. Accessories a) Flow regulator.
b) Flow gauges.
c) Sample rate set valves.
d) Other accessories as required to
make the system complete

VENDERS:
1.HACH,USA http://www.hach.com/
2. www.abb.com
3. http://www.yokogawa.com/
4. www.thermo.com
5. www.ermersonprocess.com
6. www.hachultra.com