Steam and Water Analysis System (SWAS) – Corrosion Control in Boiler & Turbine

To monitor and control the purity of boiler feed water Steam and water analysis system (SWAS)
designed.

Steam and water analysis system (SWAS) is a system that is used to analyse and display critical
information about steam or water in the power cycle. For any power plant running on steam, it is
absolutely crucial to ensure about the purity of boiler feed water and steam during electricity
generation; especially to steam equipment like steam turbine, super heater, boiler valves,
condenser, steam boiler. A well designed steam and water analysis system can help prevent
damage of steam boiler, steam turbine, and other critical parameters in the steam. These
parameters contains pH, silica, sodium, Conductivity, Dissolved Oxygen, Phosphate and
Chlorides etc. To keep the power plant operating and functioning with minimum corrosion, the
power plant have fully integrated steam and water analysis system (SWAS).
To protect these equipment SWAS works in to stages:-
1. Sample Extracting
2. Sample Transport
3. Sample Conditioning
4. Sample Analysis

1. Sample Extracting: In the sampling system, sample extraction probe is the first important
component. The correct choice of sample extraction probe should never be over looked
as analysis of extracted sample is going to represent the exact process condition. As the
probe is directly attached to the process pipe work, it may have to withstand severe
conditions. For most applications, this sample probe is made up of stringent codes, which
is application to high-pressure and high-temperature pipework. It is used to measure
sample flow rate and sample extraction probe.

2. Sample Transport: The sample meets least resistance is important while transporting the
sample. To process the flow of sample joints and bends in the pipeline need to be
minimal.

3. Sample Conditioning System: It is also known as sampling system and Wet Panel in
some countries. In this stage, The sample coolers is used to cool the sample at the
required temperature, then depressurized in pressure regulators and then transfer to
various analyser while the flow characteristics is kept constant through black pressure
regulatory. While working with these systems, there are a lots of safety equipment
provided in wet panels for operators safety.

There are few important components of sampling systems (WET RACK)

1. Sample Cooler: In the sampling system, sample coolers are CIOL-IN-SHELL type
CONTRA-FLOW heat exchangers that plays an important role in bringing down the
temperature of hot steam. The preferable sample cooler design should be double
helix. The coil should be in shell type to provide contra-flow heat exchange. Coil
Materials are available such as Stainless steel AISI 316, Monal 400 & Inconel 625
and so on. It must meet ASME PTC 19.11 standard requirements.

2. High Pressure Regulator:

Piston Type High Pressure Regulations: These type of high pressure regulators are
used in primary conditioning where sample pressure are higher than 100 Kg/cm2.

3. Back Pressure Regulator (BRP): These type of regulators is used to avoid low flow
conditions to analysers in the events grab sample valve operations. In the absence of
such a device, when the grab sample valve is opened the sample would flow to grab
sample line. The combination of a pressure regulator and back pressure regulator in
Steam and water analysis system provides very stable pressure and flow conditions,
thereby ensuring reliable, accurate, and efficient analysis.
4. Sight Glass: This component is used to view the sample flow inside the sample line. The
presence of cooling water is indicating through a rotating wheels and the side glass is
made up of high grade stainless steel.

5. Sample Filter: To ensure particle-free sample, sample filter is used. Using this any
particle of size up to 40 microns can be filtered out. Forged stainless steel body and
hexagonal cap are the two part in sample filter which help easy cleaning of filter
element.
 6. Pressure Relief Valve: This components is fitted with sample cooler and protects sampler
cooler in case the coil fails.

7. Hi-Temp Isolation Valve: This valve is used for most high pressure and temperature
applications as it is easy to operate. It is designed with plug/seat geometry and stuffing
box that allow these valves to operate for extended period of time.

4. Sample Analysis System: A sample analysis system is also known as Analyser Panel, Dry Panel
or Dry Rack in some countries. It is usually a free-standing enclosed panel containing
transmitter electronics. The system mounted on panels. In this system stage, sample is
analysed on the basis of pH, conductivity, chloride, dissolved oxygen, hydrazine, phosphate,
silica, and sodium etc.

What Happen If You Don’t Have SWAS?

1. Steam and Water Analysis system is mandatory in thermal power plant as it keeps constant
watch on problem associated with corrosion, dosing optimization, plant effluents, and boiler
blow down.
2. In thermal power plant 50% of forced power plant shutdowns can be attributed to
impurities. Steam and water analysis system is important to analyse the impurities in the
turbine.
3. SWAS are properly maintained in power plant that run at 95+PLF / PAF.
 4. People who have good knowledge, expertise and experience prefer on-line monitoring of all
the necessary parameters involved in plant cycle chemistry.

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control-in-boiler-&-turbine