VGB-Standard

Chemical Feeding and

Feed Systems for
Water/Steam Circuits

1st edition 2018

VGB-S-042-00-2018-01-EN

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 VGB-Standard
Chemical Feeding and
Feed Systems for
Water/Steam Circuits
VGB-S-042-00-2018-01-EN
First Edition 2018

Published by
VGB PowerTech e.V.

Obtainable from:
VGB PowerTech Service GmbH
Verlag technisch-wissenschaftlicher Schriften
PO BOX 10 39 32, 45039 Essen
Tel. +49 201 8128-200
Fax +49 201 8128-329
E-Mail: [email protected]
ISBN 978-3-96284-028-0 (Print)
ISBN 978-3-96284-029-7 (eBook)

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protected by international copyright. VGB PowerTech owns and controls the copy-
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The term “work“ covers the publication at hand as printed hard copy and as digital-
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Disclaimer
VGB-Standards are recommendations, the application of which is optional. VGB-
Standards represent the state of the art at the time of publication. No claim regarding
its completeness and correctness is made as a matter of principle.
Application of VGB-Standards is carried out at the user's own responsibility and risk.
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sulting from the application of VGB-Standards.

The German-language version of this VGB-Standard is the reference edition for

translations.

Treatment of proposing amendments

Amendments can be sent to the e-mail address [email protected]. The sub-
ject line should contain the exact specification of the relevant document in order to
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Preface
This VGB-Standard VGB-S-042-0-2018-01-EN shall supplement the VGB Standards
S-010-T-00;2011-12.EN “Feed Water, Boiler Water and Steam Quality for Power
Plants / Industrial Plants” and VGB-Standard VGB-S-006-00-2012-09-EN “Sampling
and Physico-Chemical Monitoring of Water and Steam Cycles” and contains recom-
mendations for the correct location, design and instrumentation as well as operation
and maintenance of chemical feed equipment in the water/steam circuit (WSC).
This is the first time that comprehensive recommendations for chemical feeding
(sometimes also called “dosing” in some European countries) and chemical feed
equipment for water/steam circuits have been established.
This VGB-Standard has been established in close cooperation with power plant own-
ers and manufacturers of power plants and chemical feed equipment as well as ser-
vice providers on the power plant sector.
The VGB offices is looking forward to receive supplementary information or pro-
posals for improving this VGB-Standard to be sent to the following e-mail address
[email protected] indicating the short designation of this document VGB-S-042-
00-2018-01-EN.

Essen, January 2018

VGB PowerTech e.V.

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Authors
The following companies and associations participated in the establishment of this
VGB-Standard:

- Helge Ducret, Standardkessel Baumgarte GmbH

- Sener Guenes, MHPS Europe GmbH
- Jens Hagge, Siemens Power AG
- Wolfgang Hater, Kurita Europe GmbH
- Christiane Holl, Hydro-Engineering GmbH
- Frank Udo Leidich, GE Power AG
- Heiko Peer, sera ProDos GmbH
- Martin Reckers, Fortum Service Deutschland GmbH
- Michael Rziha, Siemens Power AG
- Heinz-Peter Schmitz, FDBR e.V.
- Andreas Wecker, VGB PowerTech e.V.
- Heiko Woizick, RheinEnergie AG
- Roman Wusch, MPT Meß- und Prozeßtechnik GmbH
- Rolf Zipperle, Prominent GmbH

Our thanks are due to all participants for their careful and thorough work that has
gone into the making of this guideline during numerous committee meetings.

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Content

1 Scope and exclusions .................................................................................. 8

1.1 Scope ............................................................................................................. 8
1.2 Exclusions ...................................................................................................... 8
1.3 Normative and other references ..................................................................... 8
1.4 Legal framework as regards product and operational safety .......................... 9

2 Abbreviations and definitions ................................................................... 10

2.1 Definitions ..................................................................................................... 10
2.2 List of abbreviations ...................................................................................... 14

3 Positioning and design of feed points ...................................................... 16

3.1 Make-up water .............................................................................................. 16
3.2 Condensate .................................................................................................. 17
3.2.1 Turbine condensate ...................................................................................... 17
3.2.1.1 Water-cooled condenser............................................................................... 17
3.2.2 Process condensate ..................................................................................... 18
3.2.3 Condensate collecting tanks ......................................................................... 18
3.3 Feed water .................................................................................................... 18
3.4 Feed water treatment for drum boilers .......................................................... 19
3.5 Boiler water treatment for triple-pressure HRSG systems ............................ 20
3.5.1 Triple-pressure with drums in LP, IP and HP section.................................... 20
3.5.2 Triple pressure HSRG with Benson-type HP stage ...................................... 21
3.6 Boiler water treatment for shell boilers.......................................................... 21
3.6.1 Shell boilers with steam superheating .......................................................... 21
3.6.2 Shell boilers for saturated steam generation ................................................ 22
3.7 Steam ........................................................................................................... 22
3.8 Typical plant configurations .......................................................................... 22

4 Requirements for chemical feed and delivery systems .......................... 28

4.1 Introduction ................................................................................................... 28
4.2 Feed points ................................................................................................... 28
4.3 Material and nominal widths ......................................................................... 29
4.4 Requirements for chemical feed systems ..................................................... 31
4.4.1 Function and control ..................................................................................... 32
4.4.1.1 Simple controller: PID ................................................................................... 33
4.4.1.2 PID controller with feedforward control ......................................................... 33
4.4.2 Feeding of ammonia ..................................................................................... 35
4.4.3 Feeding of amines ........................................................................................ 35
4.4.4 Feeding of oxygen ........................................................................................ 36
4.4.5 Feeding of solid alkalizing agents ................................................................. 36
4.4.6 Control and working range of chemical feed systems................................... 36
4.5 Signal transfer............................................................................................... 36
4.6 Feed stations ................................................................................................ 36
4.6.1 Ammonia ...................................................................................................... 37

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4.6.2 Solid alkalization ........................................................................................... 43

4.6.2.1 Sodium hydroxide ......................................................................................... 43
4.6.2.2 Phosphate .................................................................................................... 44
4.6.2.3 Lithium hydroxide.......................................................................................... 45
4.6.3 Feed systems for oxygen scavengers .......................................................... 53
4.6.4 Oxygen feed system ..................................................................................... 54
4.6.5 Amines and other treatment chemicals......................................................... 57

5 Requirements for the purity of feed chemicals and dilution water ........ 58
5.1 Water quality ................................................................................................. 58
5.2 Ammonia ...................................................................................................... 58
5.3 Caustic soda and sodium hydroxide ............................................................. 58
5.4 Tri-sodium phosphate (as solid).................................................................... 59
5.5 Lithium hydroxide solution ............................................................................ 59
5.6 Oxygen scavengers ...................................................................................... 59
5.6.1 Hydrazine ..................................................................................................... 59
5.6.2 Carbohydrazide ............................................................................................ 60
5.6.3 DEHA............................................................................................................ 60
5.6.4 Sodium sulfite/sodium bisulfite ..................................................................... 60
5.6.5 Ascorbic acid ................................................................................................ 60
5.7 Oxygen ......................................................................................................... 61
5.8 Amines and other treatment chemicals......................................................... 61
5.8.1 2-Aminoethanol (Monoethanolamine) ........................................................... 61
5.8.2 Diethylaminoethanol ..................................................................................... 61
5.8.3 Oleylpropylendiamine ................................................................................... 61

6 Operation, maintenance and quality assurance ...................................... 63

6.1 Operation ...................................................................................................... 63
6.1.1 First putting into operation with liquid fluids .................................................. 63
6.1.2 Normal operation .......................................................................................... 63
6.1.3 Shutdown ...................................................................................................... 64
6.1.4 Restart of the system .................................................................................... 64

7 Quality assurance and technical documentation .................................... 65

7.1 Plant design and fabrication ......................................................................... 65
7.2 Safeguarding of trouble-free operation ......................................................... 66

8 Applicable legal stipulations, directives and standards ......................... 68

8.1 European legal stipulations and directives .................................................... 68
8.2 National Law ................................................................................................. 69
8.3 European Standards (EN ISO) and other Technical Rules ........................... 69
8.4 US American Codes and Standards ............................................................. 71
8.5 VGB Standards, Guidelines and Instruction Sheets ..................................... 71

9 Literature ..................................................................................................... 73

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10 Examples for faulty installation of chemical feed systems .................... 74

11 Annex ........................................................................................................... 76
11.1 Examples for feed point design .................................................................... 76
11.2 Example for test and inspection sequence plan ........................................... 78

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1 Scope and exclusions

1.1 Scope
The aim of this standard is to specify and explain methods and systems for the
chemical treatment of make-up water, boiler feed water, steam and condensate for
the operation of water/steam cycles.
This standard contains instructions and recommendations for both the planning and
operating stages. The methods described, equipment as well as chemical feed sys-
tems may also apply correspondingly to the internal chemical treatment/feeding of
other systems (e.g. intermediate cooling system, district heating, and the like).

The following items are specifically considered:

― Determination and design of feed feed points/injection points
― Design of delivery lines from the chemical feed system to the feed point
― Chemical feed system (metering pumps, feed vessels/tanks incl. accessories)
― Chemical transfer equipment for storage tanks and feed vessels
― Storage tanks and feed tanks
― Accessories and protective equipment / EHS requirements
― Requirements for internal treatment chemicals
― I&C integration and control of chemical feed systems
― Instructions for operation and maintenance

The chemical feed concept (chemical processes) have been described in

VGB-S-010;2012-12.EN “Feed Water, Boiler Water and Steam Quality for Power
Plants/Industrial Plants”.

1.2 Exclusions
This standard does not apply to nuclear power plants, district heating nets and geo-
thermal plants.
For cooling water circuits and auxiliary plants (e.g. water treatment, flue-gas cleaning
systems) the respective guidelines/standards shall be taken into account.

1.3 Normative and other references

This standard contains stipulations from other publications by dated or undated ref-
erences. These normative references are cited at the respective text passages and
the publications are cited under Section 8. In the case of dated references, later

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amendments or revisions of these publications will only be covered by this standard if

they have been incorporated by amending or revising this standard.
1.4 Legal framework as regards product and operational safety
Within the EC Contract (Article 95 – Provisions with basic requirements for safe
products/Article 137 – Provisions with minimum requirements for the safety and
health of workers) the safety of equipment, products and operation was uniformly laid
down within a European legal framework.
Equipment and product safety comprises all developed, manufactured and/or sold
products and services. They shall be safe to conform to the state-of-the-art and meet
the respective legal provisions such as not to present any risk for anyone’s life, safety
or material assets. Among these prescriptions are the Machinery Directive, the pres-
sure Equipment Directive, The Low-Voltage Directive, etc.. A risk analysis and risk
assessment to EN ISO 12100 shall ensure compliance with the principles of equip-
ment and product safety.
Operational safety means that work equipment and operating supplies for the pur-
pose of industrial safety cause no dangers. To this end, the plant user shall request a
hazard assessment of operating supplies and working equipment for the purpose of
industrial safety and health.

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2 Abbreviations and definitions

2.1 Definitions
For the purpose of this standard, the following definitions apply:
ACC Air-cooled condenser in which the turbine ex-
haust steam flows through tubes and is con-
densed by indirect heat exchange with ambi-
ent air.
Acid conductivity Conductivity of water measured downstream
of a strongly acidic cation exchanger or cation
conductivity.
Actual value Value of a variable quantity at a given instant
Atttemperator spray waterl Water for injection to control steam tempera-
ture
Boiler water See Evaporator circulation water
Closed-loop control; feed- Process whereby one variable quantity,
back control namely the controlled variable is continuously
or sequentially measured, compared with an-
other variable quantity, namely the reference
variable, and influenced in such a manner to
adjust to the reference variable
Cold-condensate storage Storage tank in which a specific condensate
tank volume is stored for the water/steam circuit.
The stored volume will be fed into or with-
drawn from the circuit during start-up or shut-
down processes or in case of load changes
Controlled variable Output variable of the controlled system that
will be acted upon by one or more manipulat-
ed variables; the value to be obtained is the
desired value
Delivery line This is the line between system shut-off valve
on the feed system and the inlet valve at the
feed point
Desired value Value of variable quantity wanted at a given
instant, under specified conditions
Deviation Difference between the actual value and the
desired value of a variable quantity at a given
instant

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Diagnosis parameter Quality criterion for the purity of feed water,

steam or condensate, which as a rule is only
analysed when action level AL1 is reached or
exceeded. This parameter is used to deter-
mine the cause of limit value violation.
District heating conden- Condensate returned from district heating
sate condensers
District heating condenser Condenser supplying heat to a district heating
grid
Drum water Water contained in the upper drum of natural
or assisted-circulation boilers
Evaporator circulation wa- Water within the evaporator section of a boil-
ter er, i.e. in the case of drum boilers during all
operational stages, and in the case of once-
through boilers during start-up/shut-down as
well as low-load operation
Feedback control See Closed-loop control.
Feed water Mixture of return condensate and/or make-up
water supplied to the boiler inlet
Feed water, demineralized See VGB-S-010-T-00;2011-12.EN (Chapter
6.2)
Feed water, salt containing Water with either high or low salt content;
VGB-S-010-T-00;2011-12EN (Chapter 6.3)
Feed water of high salt Water with an electrolyte content according to
content a conductivity of > 30 μS/cm
Feed water of low salt con- Water with an electrolyte content according to
tent a conductivity of ≤ 30 μS/cm
Final controlling element Functional unit forming part of the controlled
system and arranged at its input, driven by
the manipulated variable and manipulating the
mass flow or energy flow
Fully demineralized water Water with the quality characteristics to VGB-
(DI water/de-ionized water) M 407e.
HRSG Heat-recovery steam generator
Hotwell Vessel at the turbine condenser where the
condensate is collected and from which it
flows to the condensate pump

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Key parameter Quality criterion for the purity of feed water,

boiler water and steam, which as a rule is
continuously recorded by means of adequate
sampling systems in accordance with VGB-S-
006-T-00;2012-09.EN.
Main system System (e.g. condensate, feed water, steam)
into which chemicals are fed
Make-up water Water which compensates for losses of water
and steam from the system
Manipulated variable Output variable of the controlling system,
which is also an input variable of the con-
trolled system
Multi-phase system In this standard, distinction is made between
single-phase and dual-phase fluids to relate to
the aggregation state of water or steam as the
working fluid. Suspended solid matter is not
considered a separate phase
Natural or assisted- Water tube boilers in which water to be evap-
circulation boilers orated is circulated due to the differences in
density (natural circulation) or by means of
pumps (forced or assisted circulation). They
are also called drum boilers
Once-through boiler Water-tube boiler in which the water flow is
effected by the feed pump such that the wa-
ter, as a rule, is evaporated completely
Open-loop control Process whereby one or more variable quanti-
ties as input variables influence other variable
quantities as output variables in accordance
with the proper laws of the system
Feed point This is the point where the chemical is fed into
the main system (hydraulic interface between
feed system and superior system)
Process condensate Condensate returned from industrial process
plants
Reference variable Input variable to a comparing element in a
controlling system, which sets the desired
value of the controlled variable and is deduct-
ed from the command variable

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Reproducibility The same measuring results shall be obtained

under same test conditions (within the range
of calculable measuring errors)
Resolution Digital resolution describes
― how finely stepped an originally continu-
ously variable quantity can be represented
digitally during a digital measuring process
or arithmetic operation - or
― how exactly – by the digitization process
alone, without further measuring equip-
ment errors – the quantity can be repre-
sented digitally.
Root valve See System shut-off valve
Sampling line The line between shut-off valve and inlet
valve of sample conditioning device
Sampling station Location in the power plant where, in the case
of grab sampling, the sample is taken, or
sample transfer into on-line measuring in-
struments is effected
Sampling point The sampling point comprises the sampling
probe, the connecting nozzle as well as the
first isolation valve (system shut-off valve). In
the case of sample temperatures > 575 °C,
the sampling point additionally comprises a
cooling section and a downstream shut-off
device
Shell boiler Boiler in which the exterior tube surfaces are
wetted by boiler water. The hot flue gases or
process gases flow through the inside of the
bundled tubes
Specific conductivity Direct-measured conductivity of water
System shut-off valve The formerly used term “root valve” is re-
placed by “system shut-off valve” to clearly
assign the valve to the system. It shuts off the
delivery line from the main system

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2.2 List of abbreviations

The abbreviations used in this VGB-Standard are listed and explained hereafter:

AVT All Volatile Treatment

CAS Chemical Abstracts Service
CPP Condensate polishing plant
CCPP Combined Gas-Steam Turbine Plant (Combined cycle power plant)
DEHA Diethylhydroxylamine
DOC Dissolved Organic Carbon
ECO Economizer/Preheater
EHS Environmental Health and Safety
EPDM Ethylen-Propylen-Diene (Monomer) Rubber
FAC Flow-Assisted Corrosion
FPM/FKM Fluorocaoutchouc / Fluoroelastomer
FW Feed water
HP High-pressure
HRSG Heat-Recovery Steam Generator
I&C Instrumentation and control
IBC Intermediate Bulk Container
IP Intermediate-pressure
LP Low-pressure
NDT Non-destructive testing
NC valve Normally closed valve (in the case of failure of control fluid, automati-
cally closing valve)
OT Oxygenated Treatment
PE Polyethylene
PID Proportional–Integral–Derivative (Controller)
PN Sampling
PP Polypropylene
PTFE Polytetrafluorethylene
PVC Polyvinylchloride
PVDF Polyvinylidenfluoride

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QA Quality Assurance
RH Reheater
SPP Steam Power Plant
TC Temperature Control
TE Temperature Element
TOC Total Organic Carbon
TSV Thermal Shut-off valve
UPS Uninterrupted Power Supply
WSC Water/Steam Cycle

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3 Positioning and design of feed points

In the following, the specific feed points are described which are necessary for the
various plant configurations and chemical feeding concepts. The allocation of feed
points (D-1.0 to D-5.6) is shown in Table 3-1. Sampling points are represented in the
principal sketches hereafter as S-X.X (cf. VGB-S-006-T-00;2012-09.EN).

3.1 Make-up water

Normally, chemical treatment of make-up water is not required in power plants and
constructions of make-up water systems made of stainless high-grade steel or plas-
tics.
Chemical treatment of make-up water prior to entry into the water/steam cycle may
be required e.g. to cover a regularly occurring, strongly varying make-up water de-
mand (e.g. in case of process steam extraction with only partial or occasional con-
densate return). In such cases, it is recommended to de-aerate the make-up water
prior to chemical feeding, as otherwise the alkalizing agent (e.g. ammonia) will react
with the dissolved carbon dioxide to form the respective carbonate or bicarbonate,
thus impairing the chemical operating parameters (acid conductivity).
Often chemical treatment is also required in industrial power plants and cogeneration
stations or if the make-up water system is made of carbon steel. In this case, an ad-
ditional sampling point may be provided, where required, to control the make-up wa-
ter supply (see Figure 3-1).
As a rule, make-up water is fed into the condenser or feed water tank. Where an ion
exchange condensate polishing plant (CPP) is provided, chemical feeding is only
possible directly downstream of the CPP

Figure 3-1 – Feed point for make-up water in case of strongly varying make-up water demand

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3.2 Condensate

3.2.1 Turbine condensate

3.2.1.1 Water-cooled condenser

In case of a split-stream CPP, steam-volatile chemicals shall be fed directly into the
manifold downstream of the CPP (D-2.1). For control purposes, the sampling point
on the discharge side of the main condensate pump (S-2.0) shall be used (see Fig-
ure 3-2). Where the water/steam cycle is operated without CPP, the chemicals shall
be fed via feed point D-2.0.

Figure 3-2 Figure 3-3 Figure 3-4

Sampling points for condensate

In case of a full-stream CPP with bypass, the chemicals will usually be fed down-
stream of the bypass. Here, the sampling point S-2.0 shall also serve to control
chemical feeding (see Figure 3-3).

Where no CPP is provided, feeding shall be effected on the discharge side of the first
condensate pump group if the make-up water is fed into the condenser. Care shall be
taken to ensure that in this case a sufficiently long mixing pipe between feed point
D-2.0 and sampling point S-2.0 is provided (Figure 3-4).

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3.2.2 Process condensate

Process condensates are condensates returned from process steam extractions.
Where it is required to treat these condensates with ion exchange CPP, additional
feeding shall be effected, if necessary. See process schemes in Figure 3-12 or Fig-
ure 3-3.
The position of sampling points shall be selected such that on the one hand a suffi-
ciently long mixing distance is available, but on the other hand dead times are not too
long.

3.2.3 Condensate collecting tanks

Where a feed point is required, feeding shall be effected on the suction side of the
condensate pump. See process schemes in Figure 3-2 and Figure 3-3.

3.3 Feed water

The allocation of feed points for feed water (D-3.0 to D-3.2) is shown in Figure 3-5.
The feed points D-3.0 to D-3.2 shall be considered equivalent for steam-volatile
chemicals. However, oxygen for OT operation cannot be fed at feed point D-3.1. To
control the amount of chemicals, sampling point S-3.5 is used in case of large steam
power plants, otherwise sampling point S-3.0. Where make-up water is fed into the
de-aerator/condenser, it is recommended to feed steam-volatile chemicals directly
into the feed water tank below the water line (feed point D-3.1).

Figure 3-5 – Feed points for feed water

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3.4 Feed water treatment for drum boilers

The allocation of possible feed points for boiler water treatment purposes (D-4.0 to D-
4.3) is shown in Figure 3-6. It is absolutely necessary that the feed point is located at
sufficient distance downstream of the attemperator spray water take-off to ensure
that no solid alkalizing agents can enter the spray-attemperator water.

Figure 3-6 – Feed points for boiler water

The feed points D-4.0 to D-4.2 have the following advantages over feed point D-4.3:
 there is no back-mixing or backflow into the economizer
 faster thorough mixing with boiler water, thus less risk of oscillation of the con-
trol-loop

The feed point D-4.3 (directly downstream of the feed water control valve) offers the
advantage of additionally safeguarding the economizer against flow-assisted corro-
sion (FAC). However, in this case it shall be ensured that no evaporation processes
can take place in the economizer at any operating condition.
This feed point cannot be utilized in modern waste-heat boilers (HRSG) of gas-steam
turbine power plants if downstream of the economizer heat is extracted and the
cooled condensate is returned into the feed water train.
It is recommended to take samples at a downcomer (sampling point S-4.0) for the
purpose of boiler water treatment control.

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3.5 Boiler water treatment for triple-pressure HRSG systems

The instructions hereafter shall apply accordingly to single- or dual-pressure HRSG
systems.

3.5.1 Triple-pressure with drums in LP, IP and HP section

According to VGB-Standard VGB-S-010 waste-heat boilers (HRSG) can be operated
both with all-volatile treatment (AVT) and solid alkalizing agents. In this standard, re-
spective instructions are given as regards the selection and determination of the op-
erating mode.
In case of all-volatile treatment no separate chemical feeding of the make-up water is
required.
Solid alkalizing agents may be fed at different locations either by means of a distrib-
uting lance within the drum or upstream of the drum into the feed water. Where
chemicals are fed into the feed water, it is compulsorily required that the feed point is
located at sufficient distance downstream of the attemperator water take-off point to
ensure that no solid alkalizing agents can enter the spray attemperator water. In ad-
dition, it is important that in this case steaming of the economizer can be safely ex-
cluded at any load condition. Otherwise, chemical feeding is strongly recommended
via the distributing lance in the drum or downstream of the economizer directly up-
stream of the point of entry of the water into the drum.
The requirements for water chemistry are:
 rapid distribution and thorough mixing
 avoidance of locally high concentrations (local evaporation)

This is special importance for waste-heat boilers (HRSG) with natural circulation and
horizontal tubing. This also applies to waste-heat boilers with supplementary firing
system, as local “hot spots” will occur in such boilers.
For the purpose of boiler water treatment control, it is recommended to take samples
at a downcomer (sampling point S-4.0).
In case of solid alkalization, fully automatic control of chemical feeding is not re-
quired. Where faulty values are measured by the sampling system (e.g. no sample-
flow at the measuring cell), this may lead to dangerously excessive feeding. Chemi-
cal feeding need not be continuous, but may also be intermittent in which case the
time intervals between individual feedings can be several days.
Automatic shutdown of the chemical feed system or interlocking is strongly recom-
mended where the minimum feed water mass flow is less than required.

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3.5.2 Triple pressure HSRG with Benson-type HP stage

Due to its design, the high-pressure once-though waste-heat stage can only be oper-
ated with volatile chemicals (AVT or OT). Consequently, the HP boiler need not be
provided with a feed point. Feeding of chemicals shall be effected into the conden-
sate or feed water to meet the stipulations of chapters 3.2 or 3.3, respectively.
Since the intermediate and low-pressure waste-heat boiler stages are generally con-
structed as drum boilers, the same stipulations as in chapter 3.5.1 apply.
Where the low-pressure stage which is usually constructed as drum boiler, is used as
quasi feed-water tank for the intermediate and high-pressure stage of the HRSG, no
solid alkalizing agents shall be fed into the low-pressure stage of such a boiler system.
3.6 Boiler water treatment for shell boilers

3.6.1 Shell boilers with steam superheating

The feed point for boiler water treatment in shell boilers with steam superheating (see
Figure 3-7) is located in the feed water line downstream of the attemperator spray
water take-off used for temperature control (D-4.3). In this case, it is absolutely nec-
essary that the feed point is located at sufficient distance downstream of the attem-
perator spray water take-off to ensure that no solid alkalizing agents can enter the
spray-attemperator water. Alternatively, the solid alkalizing agents may be fed direct-
ly into the water space below the water line (D-4.4).
For control purposes, the sampling point S-4.4 (conductivity measurement by means
of insertion electrode) or preferably the cooled sampling point S-4.0 in the blowdown
line (pH measurement) shall be used.

Figure 3-7 – Feed points for boiler water in case of shell boilers with steam superheating

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3.6.2 Shell boilers for saturated steam generation

As a rule, boiler water treatment chemicals for shell boilers with saturated steam
generation (see Figure 3-8) shall already be fed into the feed water tank (D-3.1).
For control purposes, the sampling point S-4.4 (conductivity measurement by means
of insertion electrode) or preferably the cooled sampling point S-4.0 in the blowdown
line (pH measurement) shall be used analogously to 3.6.1.

Figure 3-8 – Feed points for sheell boilers with saturated steam generation

3.7 Steam
Normally, no chemicals are fed into the steam. Should a high-level alkalization of
process steam be required to prevent corrosion, additional feeding into the steam line
may be purposeful. This additional chemical feeding shall then be controlled sepa-
rately in this steam/condensate section.

3.8 Typical plant configurations

Typical plant configurations are shown in Figures 3-9 to 3-13. The related description
of sampling points is contained in Table 3-1.

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Figure 3-9 – Triple pressure CCPP with reheater, Benson-type HP stage

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Figure 3-10 – Triple pressure CCPP, drum-type HRSG with reheater

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Figure 3-11 – Once-through steam generating plant with reheater

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Figure 3-12 – Drum boiler power station with reheater

Figure 3-13 – Industrial steam generator

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VGB-S-042-00-2018-01-EN

Tabelle 3-1 – Description of sampling points

WSC Triple-pressure HRSG Shell boiler

Position- with once- with with HP once- with saturated
Feed point 3-drum with steam
no. through drum through steam steam genera-
HRSG superheating
boiler boilerl generator tion
D-1.0 Make-up water to condenser
D-1.1 Make-up water to feed water tank
D-1.2 Make-up water for various consumers
Main condensate
D-2.0 (downstream of CPP) downstream of main con- (F)1 (F)1 F
densate pump
Main condensate
D-2.1 (downstream of CPP) upstream of main conden- F (F), (O)
sate pump
D-3.0 Suction line of feed water pump O; (F) O O O
1 1
D-3.1 Feed water tank below water line (F) (F) F F, N
D-3.2 Feed water line downstream of feed pump
Feed water line downstream of drum inlet valve
D-4.0 N N (F)
(directly upstream of drum)
D-4.1 Boiler drum below water line (N)
D-4.2 Feed water line upstream of drum inlet valve (N)
D-4.3 Feed water line upstream of ECO or reheater (N) N
D-4.4 Water space of shelll boiler below water line (N) (N)
D-4.5 Feed water tank below water line N
F. Volatile treatment chemicals ( ): optional
N: Non-volatile (solid) alkalizing agents O: oxygen
(F)1: In case of WSC with drum boiler, feeding of volatile
treatment chemicals may be effected either at
feed point D-2.0 or D-3.

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4 Requirements for chemical feed and delivery systems

4.1 Introduction
Chemical feed and delivery systems in power plants are used at various locations for
the preparation and feeding of chemicals. The requirements for these systems de-
pend on plant configuration and degree of automation. In general, chemical feed sys-
tems shall operate correctly and trouble-free and shall ensure that the liquid to be
delivered is provided on demand at correct dosage and concentration. Further basic
requirements for chemical feed systems are maintenance-free and continuous opera-
tion.
Figure 4-1 shows the principal layout of a chemical feed system.

Figure 4-1 – Principle layout of a chemical feed system

Several chemical feed stations may be comprised to form one system. In this case, it
is possible to commonly use individual plant equipment (especially the control cabi-
net).
4.2 Feed points
The feed point, also called injection point, injection quill, injection lance etc., forms
the hydraulic interface of a chemical feed station to the main system. Feed points
shall be resistant to the fluid contained, and the design pressure and temperature of
the required application shall be observed.
The correct positioning of feed points in power plants has already been dealt with in
Chapter 3. The nominal width, material and installation angle will be described in the
sub-clauses hereafter.

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The minimum equipment of a feed point is shown in Figure 4-2.

Figure 4-2 – Minimum equipment of a feed point

It consists of a check valve and a shut-off valve directly at the system boundary to
the process line and the injection quill protruding into the process line.
At a nominal pressure ≥ PN 64 the delivery line shall be provided with a double isola-
tion valve set at the transition to the process pipe. Depending on the pressure, the
connection at the system boundary may be made by flange, welding end, or com-
pression-type fitting. Figure 4-3 shows a possible design. Further designs are shown
in the Annex.

Figure 4-3 – Example for the equipment of a feed point for a pressure stage equal to or greater than
64 bar

4.3 Material and nominal widths

Units for feeding chemicals into the water/steam circuit shall only be fabricated of
materials being resistant to the chemicals used and to the fluid conditions prevailing
(pressure, temperature). Instructions on resistance to chemicals can be found in the
specific resistance documentation of chemicals and equipment suppliers.
The fluid lists of the DIBt (German Institute for Construction Technology) or compa-
rable specific standards valid in other countries shall be observed in addition to other
chemicals resistance data, where the strength reduction factors for chemicals can be
found. The pressure strength e.g. of plastic lines may be reduced considerably de-
pending on the chemicals used and the temperature.

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Ambient conditions may also strongly influence the selection of suitable materials.
The fluid temperature limits and ambient conditions shall be checked and necessary
measures be taken, where required (e.g. UV or weathering protection).
Table 4-1 lists the recommended materials used for the various components in
chemical feed systems. It does not consider materials to be used for feed points
which, starting at the first shut-off valve, shall be made of materials suited for the
conditions in the main system into which feeding is to be effected.

Table 4-1 – Recommended materials

Chemical

Plant part Ammonia Phosphate Sodium hy- Hydrazine Amines / Oxygen

(NH4OH) (Na3PO4) droxide (N2H4) Inhibitors** (O2)
(NaOH, LiOH)
Tank / ves- PE, PP, PE, PP, PE, PP, PE, PP, PE, PP, -
sel Austenite Austenite Austenite1 Austenite Austenite
Transfer PP*, PVC*, PP*, PVC*, PP*, PVC*, PP*, PVC*, PP*, PVC*, -
pump PVDF* PVDF* PVDF* PVDF* PVDF*
Austenite Austenite Austenite Austenite Austenite
Suction line PVC*, PP*, PVC*, PP*, PVC*, PP*, PVC*, PP*, PVC*, PP*, -
PE*, Austen- PE*, Austen- PE*, Austen- PE*, Austen- PE*, Austen-
ite ite ite ite ite
Discharge Austenite Austenite Austenite Austenite Austenite Austenite
line
Metering Austenite, Austenite, Austenite, Austenite, Austenite, Messing
pump PP*, PVC*, PP*, PVC*, PP*, PVC*, PP*, PVC*, PP*, PVC*, Austenite
PVDF* PVDF* PVDF* PVDF* PVDF*
Gaskets PTFE, PTFE, PTFE, PTFE, PTFE PTFE,
EPDM EPDM, FPM EPDM EPDM metallic
Legend: *: Low-pressure range up to 10 bar design pressure (observe pressure resistance of plastics in differing
fluids)
**: Consult chemicals producer/supplier for resistance
Data apply to an ambient temperature ranging between 0 °C and 40 °C
1)
: Where solid sodium hydroxide is to be fed, stainless steel or PP shall preferably be used due to the extreme
development of dissolution heat

The delivery lines for transporting chemicals to the feed point shall have adequate
cross-sections.
The displacement pumps usually used show differing flow rates on the suction and
discharge side. Generally, the average flow rate on the suction side should be signifi-
cantly less than the flow rate on the discharge side. For the suction side an average
flow rate of < 0.6 m/s is recommended. On the discharge side, the flow rate should
range between 1.0 and 1.5 m/s. On this basis, the required cross-section/nominal
widths can be determined.

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In case of displacement pumps, it is important to take line length and routing into ac-
count. High and low points should be avoided because air or gas inclusions can be
generated at these points which may considerably obstruct or even interrupt the de-
livery of chemicals. Ideally, the lines continually rise to the feed point.

4.4 Requirements for chemical feed systems

Chemical feed systems for the water/steam circuit are systems used to attain and
maintain the required chemical conditions of boiler feed water, condensate and boiler
water for various plant configurations
The systems shall be designed for continuous operation.
Even in case of strong load variations, chemical feed systems should be capable of
covering all operating conditions ranging between full load, low load and shutdown
(increase of pH value by 1 to 2 units). To this end, the required degree of automation
should be laid down by the plant owner.
The incorporation into the complete process shall be ensured to control the water
and steam quality in the WSC according to the requirements. These requirements
are set by e.g. the type of boiler, the provision of a condensate polishing plant (CPP),
the mode of operation, etc. and should be subject to a process analysis. The me-
chanical and electrical components and interfaces required for incorporation into the
water/steam circuit and its control shall be provided on the chemical feed system.
The provision of redundant components will minimize standstill periods due to
maintenance and possible repairs. The amenability to operation, maintenance and
repair should be ensured. This shall be considered as early as at the planning stage,
e.g. to ensure unobstructed access to all components.
The safety of system handling shall have priority. The necessary protective equip-
ment shall be provided. The legal prescriptions shall be observed and corresponding
declarations of conformity be available or be established. This may lead to require-
ments for the design of chemical feed systems, such as chemicals retention equip-
ment/vessels with regulatory approval. The legal prescriptions valid at the respective
plant site shall be observed.
Depending on the chemical used, the required protective equipment may differ (see
Chapter 4.7). The safe operation of chemical feed systems shall be described in the
supplier’s operating manual (see Chapter 6).
Recommendations for personnel protective equipment and the necessary organiza-
tional measures taken by the plant owner for safe chemicals handling shall be laid
down in safety data sheets. Necessary and purposeful prohibitions, warning and in-
formation signs shall be provided on the plants.
As a rule, a chemical feed system consists of several feed stations – for each intend-
ed use and thus for each chemical - which are considered in the following clauses.
Normal operation is usually conducted in automatic mode.

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4.4.1 Function and control

The chemical feed system shall be controlled in dependence of the chemicals and
the type, design and operating mode of the WSC by means of open-loop control for
continuous feeding or closed-loop control for intermittent feeding (see Figure 4-4).

Figure 4-4 – Principle sketch of open-loop control (above) and closed-loop control (below)

Open-loop control and closed-loop control are intended to attain the correct chemi-
cals dosage in the respective system. Differentiation is made between continuous
and intermittent feeding. Volatile chemicals are fed continuously for all-volatile treat-
ment (AVT) or combined oxygen treatment (OT), non-volatile chemicals are fed con-
tinuously or intermittently. Feeding may be intermittent if the concentration only di-
minishes slowly (e.g. in case of minor blowdown rate).
In continuous feeding the actual value of the controlled variable is measured down-
stream of the feed point to compare the actual value with the desired value. From the
difference between the actual value and the desired value, i.e. the deviation, the ma-
nipulated variable for the chemical feed system is calculated.
Where a closed-loop control is installed, the dead time between process changes
and signal time may have considerable influence on the control quality (risk of control
loop oscillation). The problem of measuring the actual value of the controlled variable
is that upon sampling a signal is delivered with considerable time delay to the pro-
cess. The signal itself is well resolved for continuously measured variables such as
conductivity, pH value or sodium. The time delay will be determined by the length of
the sampling line, the actual sampling flow rate and system pressure so that the time
delay is variable and often ranges between a few and ten minutes. For this reason,

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conventional PID controllers (Figure 4-5) can satisfactorily be optimized only for one
operating condition, e.g. full-load operating mode. The controller concept therefore
has to be adapted to the operating concept.

4.4.1.1 Simple controller: PID

The simplest controller is the PID controller (see Figure 4-5). Setting of the controller
shall preferentially be made without the differential component (D-component). Opti-
mization is only possible for one operating mode. This controller is only suited for
simple operating concepts and plants such as base-load power stations with drum
boiler operating to the AVT concept. Especially due to frequent load changes, the
actual value will vary considerably with respect to the desired value because of the
variable time delay of the signal.

Regelabweichung Regler Stellgröße an Dosierpumpe

(deviation) (controller) (output to feedpump)

Beispiel:

spez. LF [0..30µS/cm] PID Stellgröße an Dosierpumpe

‐ Sollwert 0..100% (output to feedpump)

Figure 4-5 – Principle sketch of a simple PID controller

4.4.1.2 PID controller with feedforward control

To minimize the influence of the time delay of the actual value on the PID controller,
a second process variable is used by which the time-delayed change of the actual
value (dead time) can be balanced. The flow rate of the process fluid at the feed
point is well suited for this purpose. This may be the directly measured flow rate or a
calculated flow rate, e.g. obtained from a specific valve position. This additional in-
formation will be added up as multiplying disturbance variable, i.e. as factor, to the
result if the PID controller. Therefore, the PID controller with feedforward control (see
Figure 4-6) can compensate well for the time delay of the actual value.

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Beispiel c (example c):

Figure 4-6 – Principle sketch of a PID controller with feedforward control

Through the consideration of the flow rate signal, this PID controller is capable of fol-
lowing load changes during operation. In case of start-up and shutdown operations,
process changes, such as connection and disconnection of the condensate polishing
plant, or temporarily high make-up water demand, the control function has to be ex-
tended to avoid strong deviations. When doing so, the flow rate signal is formed by
the sum of various flow rates or the control structure is changed on unit control level.
In addition, the actual value of the controlled variable may be measured upstream of
the feed point to include the difference of the controlled variable prior to and upon
chemical feeding. In any case, the control quality will be improved by means of fur-
ther information such that chemical feeding can be quickly adapted to changes of the
actual value.

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4.4.2 Feeding of ammonia

Ammonia is steam-volatile. Continuous feeding of ammonia is made to balance am-
monia losses on account of feed water de-aeration, vacuum maintenance in the con-
denser, leakage, and steam extraction as well as by condensate treatment in the
condensate polishing plant. The concentration of ammonia can be measured at best
via the measurement of the specific conductivity.
The measurement of the pH value in demineralized feed water will be difficult and
inaccurate. The pH probe also requires regular maintenance and calibration.
The specific conductivity can be recorded reliably and precisely so that the conver-
sion makes it possible to determine the ammonia concentration with high accuracy.
Where during the OT mode the influence of salts is considerable, it may be compen-
sated by calculation using the acid conductivity. Details can be found in the
VGB-S-006-00-2012-09.EN.

4.4.3 Feeding of amines

Feeding of the following amines to effect alkalization may be made analogously to
the feeding of ammonia if individual substances are fed (see 4.4.2):
2-Aminoethanol (Monoethanolamin) CAS-Nr.: 141-43-5
Cyclohexylamine CAS-Nr.: 108-91-8
2-Amino-2-methylpropanol CAS-Nr.: 124-68-5
2-Diethylaminoethanol CAS-Nr.: 180-37-8
Morpholine CAS-Nr.: 110-91-8
3-Methylpropylamine CAS-Nr.: 5332-73-0
Where these substances are mixed, they may be fed in amounts proportionally to the
make-up water.
The filming amines mentioned hereafter shall usually be fed proportionally to the
amount of make-up water:
Octadecylamine (ODA) CAS-Nr.: 124-30-1
Oleylamine (OLA) CAS-Nr.: 112-90-3
Oleyl Propylenediamine (OLDA) CAS-Nr.: 7173-62-8
In addition, the filming amine concentration in the water steam circuit should be de-
termined in the laboratory and be added as disturbance variable for feedforward con-
trol. The filming amine concentration cannot be determined by measuring the con-
ductivity. On-line measuring instruments for the determination of the chemical’s activ-
ity are still under development. Therefore, the installation of a closed-loop control cir-
cuit for feeding of amine solutions cannot be recommended.
In the case of other than the aforementioned treatment chemicals, the suppliers’
feeding control recommendations should be observed.

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4.4.4 Feeding of oxygen

Oxygen is steam-volatile. Continuous oxygen feeding is made to compensate for
losses on account of feed water de-aeration, vacuum maintenance in the condenser,
and oxygen consumption due to reaction with the metal surfaces of the WSC (for-
mation of protective layers) or oxidation of water constituents (e.g. TOC). In addition,
air leakage may cause entry of oxygen into the system. Oxygen is directly measured
as dissolved oxygen. As the desired value may be exceeded due to air leakage it is
important that oxygen feeding permits control down to zero feedrate.

4.4.5 Feeding of solid alkalizing agents

Solid alkalizing agents are non-volatile. They shall be fed to compensate for losses
due to boiler water blowdown and sampling.
The concentration of solid alkalizing agents can be well determined by measuring the
specific conductivity in combination with acid conductivity.
Direct measurement of the pH value is difficult and inaccurate in boiler water of low
conductivity. In addition, the pH probe requires regular maintenance and calibration.
In case of solid alkalization with phosphate, spot measurements of the phosphate
concentration are additionally recommended.

4.4.6 Control and working range of chemical feed systems

The manipulated variables on feed pumps may be the motor frequency, stroke length
and speed, or a combination thereof, thus making a ratio of 1 : 50 (min/max volume
flow) realizable.
Where possible, the feed pump control range should be 0% to 100% in which case
0% will cause pump shutdown, and the actual delivery range of the feed pumps
starts at approx. 5% depending on the type of pump. A 100% volume flow should
clearly exceed the planned maximum dosage required. The typical working range is
between 20% and 80%.

4.5 Signal transfer

The signal of the controller should be transferred in real time to the chemical feed
control circuit. This means that the actual value signal is transmitted continuously and
with high time resolution from the sampling system.
Usually the signal of the actual value is transmitted as 4-20mA signal. Alternatively,
the signal may also be provided as bus protocol with high signaling rate.

4.6 Feed stations

Various properties of substances and mixed substances require the adaptation of the
chemical feed stations. Special care shall be taken that the materials used for stor-

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 VGB-S-042-00-2018-01-EN

age tanks, delivery lines, gaskets, valves, and catch basins are resistant to the chem-
icals used.
In the following clauses, the requirements and recommendations for the design of
chemical feed stations are dealt with for chemicals that are fed most commonly into
the water/steam cycle.

4.6.1 Ammonia
Ammonia as steam-volatile feed chemical is the most widespread chemical used for
adjusting the pH value in the water/steam cycle and has proved its effectiveness for
decades.
Properties: Besides the health warning information in the safety data sheet the fol-
lowing properties of ammonia solutions shall be taken into account when designing
chemical feed stations:
 substance of acute aquatic toxicity
 corrosive to many metals
 outgassing, ammonia gas will form explosive mixtures with air

Concentration of delivery: 15 to 25 % aqueous solution

Usual application concentration: 1.0 to 5.0 % aqueous solution

As regards the purity of the delivered ammonia solution reference is made to chapter
5.2.2.

Essential components of the ammonia feed system with automatic dilution (see
Figure 4-7)

A: Chemicals packaging and discharge

There are several options as regards the preparation of the ammonia solution taken
from the transport package:
 IBC as transport and storage tank – chemical feed tank
 IBC as transport container – separate storage tank – chemical feed tank
 Drum, canister - chemical feed tank
 Tank truck as transport tank – storage tank - chemical feed tank
 etc.

Note:
Where the chemical is delivered in drums or canisters, it shall be extracted by means
of a suction lance. However, during change-over from one type of package to anoth-

37
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 VGB-S-042-00-2018-01-EN

er type ammonia will be released, and complete drainage of the package is not pos-
sible. Sufficient ventilation shall be provided to suck off the released ammonia gases.
The explanations hereafter refer to the commonly used combination of “IBC as
transport and storage tank – chemical feed tank”.
The ammonia solution is delivered in IBC equipped with integral shut-off valve and
sealed nozzle.
Where the IBC serves as transport and storage tank, the IBC shall be connected to
the gas displacement line of the feed station via inherently stable, flexible connec-
tions and adequate adapters.
The IBC storage site shall be equipped to satisfy the respective national rules and
regulations and shall have adequate load-bearing capacity. Heat input that may
cause excess of the allowable temperature shall be avoided.
The hoses should be protected and be laid with a slope to make complete drainage
of the package possible.
An intermediate tank is strongly recommended to ensure safe operation. This tank
shall be equipped with shut-off valves at the inlet, outlet and for residual drainage. In
addition, it shall be equipped with fill level switches to indicate need of refilling or
empty condition.

B: Transfer unit
The transfer unit shall consist of at least the following plant parts and components:
 Suction line of transfer pump with shut-off valve and strainer
 Flushing connection on suction side with shut-off valve (blanked-off)
 Branch with shut-off valve in suction line for concentrate metering
 Diaphragm pump
 Flushing connection on discharge side with shut-off valve (blanked-off)
 Discharge line to feed tank with shut-off valve and idle-run protection

Diaphragm pumps shall preferably be used. Magnetically coupled centrifugal pumps

are also used as transfer pump. For the pumps, it shall be ensured that dry-run pro-
tection is provided.
An ejector pump may also be used for transfer (and dilution) of treatment chemicals if
sufficient motive-water pressure is ensured. In such a case, the agitator in the feed
tank may be omitted.

C: Feed tank
The feed tank shall have the following properties and consist of at least the following
plant parts and components:

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 Be designed for atmospheric operation

 Be made of material to Table 4-1
 Be dimensioned for a certain volume acc. to plant owner’s or planner’s re-
quirements (as a rule, daily or weekly metering volume), standard dimensions
shall be preferred
 Filling pipe as submerged pipe for bottom-up filling. This will reduce the re-
lease of gas
 Dilution water supply with shut-off valve, drain valve (blanked-off), manual
control valve, automatic shut-off valve (solenoid valve)
 Level indicator in the tank as by-pass line with level switches Min-Min, Max,
Max-Max and local level indication with shut-off valves to the tank; alternative-
ly an analogue level indicator may be used
 Overflow protection in the tank
 Agitator. Where possible, the agitator shall be arranged to avoid running dry
 Connecting nozzle to gas displacement system
 Adsorber for ammonia vapours for discharging the exhaust air to a safe loca-
tion
 Drain valve (blanked-off), extraction valve

D: Metering pump unit

The metering pump unit shall have the following properties and consist of at least the
following plant parts and components:
 For availability purposes one operational and one standby pump each shall be
installed per feed point
 Calibration vessel with shut-off valve to suction side and gas displacement
system to feed tank
 Suction line with shut-off valves, drain valve (blanked-off), strainer, and flush-
ing connection per pump
 Diaphragm metering pump with manually adjustable stroke length, suited for
frequency inverter operation
 Discharge line with shut-off valves, pulsation damper, relief valves
 Local pressure gauge, isolatable
 On the pump discharge side, all valves shall be designed as double isolation
valve set at a pressure equal to or higher than 64 bar, except for the shut-off
valve at the discharge line outlet to the process which may be a single valve.

E: Feed points in the WSC

See chapter 4.2.

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F:Additional equipment
In addition, the following EHS relevant items of equipment shall be provided:
 Catchment device for parts of the feed station or the complete station. Leak-
ages shall be easily removable
 Leak detection probes for catchment devices
 Emergency or eye showers in proximity of the station

Figure 4-7 – Ammonia feed system for diluted ammonia solution

Essential components of the ammonia feed system with manual metering (see Figure
4-8)

A: Chemicals packaging and discharge

There are several options as regards the feeding of the ammonia solution taken from
the package:
 Drum, canister – chemical feed tank
 IBC as chemical feed tank
 etc.

Note:
Where the chemical is delivered in drums or canisters, it shall be extracted by means
of a suction lance. However, during changeover from one type of package to another

40
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 VGB-S-042-00-2018-01-EN

type, ammonia will be released and complete drainage of the package is not possi-
ble. Sufficient ventilation shall be provided to suck off the released ammonia gases.
The following explanations refer to the combination of “Canister as transport and
storage tank – chemical feed tank“.

The canister storage site shall be equipped to satisfy national rules and regulations.
Heat input that may cause excess of the allowable temperature shall be avoided.

B: Transfer unit
The transfer unit shall consist of at least the following plant parts and components:
 Suction line of transfer pump
 Diaphragm pump
 Discharge line to feed tank
 Gas displacement system

C: Feed tank
The feed tank shall have the following properties and consist of at least the following
plant parts and components:
 Be designed for atmospheric operation
 Be made of material to Table 4-1
 Be dimensioned for a certain volume acc. to plant owner’s or planner’s re-
quirements (as a rule, daily or weekly metering volume), standard dimensions
shall be preferred
 Dilution water supply with shut-off valve
 Fill level indicator on tank with impressed scaling
 Low-level switches (Min-Min, Min)
 Manual mixer
 Connecting nozzle to gas displacement system
 Absorber for ammonia vapours for discharging the exhaust air to a safe loca-
tion
 Drain valve (blanked-off), extraction valve

D: Metering pump unit

The metering pump unit shall have the following properties and consist of at least the
following plant parts and components:
 Normally one operational pump is installed per feed point and a standby pump
is provided for availability purposes

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 Suction line with flushing connection

 Diaphragm metering pump with manually adjustable stroke length and control-
lable drive
 Discharge line with shut-off valves, pulsation damper, relief valve, and con-
stant-pressure valve
 Local pressure gauge, isolatable

E: Feed points in the WSC

See chapter 4.2.

F:Additional equipment
In addition, the following EHS relevant items of equipment shall be provided:
 Catchment device for parts of the feed station or the complete station. Leak-
ages shall be easily removable
 Leak detection probes for catchment devices
 Emergency or eye showers in proximity of the plant

Figure 4-8 – Ammonia feed system for manual dilution

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4.6.2 Solid alkalization

4.6.2.1 Sodium hydroxide

Sodium hydroxide is fed as diluted caustic soda solution for the internal treatment of
boiler water in case of drum boilers and, under certain circumstances, even for shell
boilers. Sodium hydroxide can be supplied as concentrated liquid solution or in solid
crystalline form. The delivery form of the chemical will govern the differences in feed
station equipment.
Properties: Besides the safety data sheet information as regards health warning and
environmental protection, the following properties of caustic soda or sodium hydrox-
ide shall be taken into account when designing chemical feed stations:
 As solid : Corrosive to metals
 Aqueous solution: Corrosive to metals

The solidification point of caustic soda depends on its concentration (see Figure 4-9).
Examples: solidification temperature of NaOH 50 %: +12 °C
solidification temperature of NaOH 20 %: -25 °C
Concentration of delivery: 10 to 50 % aqueous solution
The chemical shall be stored in heated rooms or heated storage tanks (see Figure
4-9).
In case of a central caustic soda storage tank all lines shall be provided with trace-
heating systems and insulation.
As regards the required purity of the caustic soda solution in the concentration of de-
livery and of sodium hydroxide reference is made to chapter 5.2.3.

Sodium hydroxide as a solid is usually delivered in plastic bags. The supplier’s stor-
age instructions shall be observed

Usual application concentration: aqueous solution 0.5 to 2.0 %

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Figure 4-9 – Crystallization of caustic soda solution in dependence of concentration and temperature

4.6.2.2 Phosphate
Phosphate is fed as tri-sodium phosphate for the internal treatment of boiler water in
drum boilers and shell boilers. Phosphate can be supplied as concentrated liquid so-
lution or in solid crystalline form. The delivery form of the chemical will govern the
differences in feed system equipment.
Properties: Besides the safety data sheet information as regards health warning and
environmental protection, the following properties of tri-sodium phosphate shall be
taken into account when designing chemical feed stations:
 As solid: None
 Aqueous solution: None

Concentration of delivery: 10 to 15 % aqueous solution

Tri-sodium phosphate as solid agent is usually delivered in plastic bags. The supp-
lier’s storage instructions shall be observed. Die Lagervorschriften des Lieferanten
sind zu beachten.

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Usual application concentration: 0.5 to 5.0 % aqueous solution

As regards the required purity of the tri-sodium phosphate solution in the concentra-
tion to be delivered and of tri-sodium phosphate reference is made to chapter 5.2.4.

4.6.2.3 Lithium hydroxide

Lithium hydroxide is provided as aqueous solution for the internal treatment of boiler
water in drum boilers and shell boilers. Lithium hydroxide can be supplied as 10%
solution or in solid crystalline form. The delivery form of the chemical will govern the
differences in feed station equipment.
Properties: Besides the safety data sheet information as regards health warning and
environmental protection, the following properties of lithium hydroxide shall be taken
into account when designing chemical feed stations:
 As solid: As solid lithium hydroxide has acute toxicity, the production of a lithi-
um hydroxide solution from solid is not recommended
 Aqueous solution: None

Concentration of delivery: max. 10 % aqueous solution

Usual application concentration: 0.2 to 2.0 % aqueous solution

As regards the required purity of the lithium hydroxide in the concentration to be de-
livered reference is made to chapter 5.2.5.

Essential components of the feed system for boiler water treatment with liquid con-
centrate (see Figure 4-10)

A: Chemicals packaging and discharge

The internal treatment chemicals (NaOH, Na3PO4, LiOH) are delivered in
 Plastic canisters of various volumes
 Drums
 IBC
 Tank truck

B: Transfer unit
The transfer unit shall consist of at least the following plant parts and components:
 Suction lance with shut-off valve and level switch
 Storage of suction line with non-detachable inherently stable hose line at a
safe location on the feed system (quiver)

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 Suction line of transfer pump with shut-off valve and strainer

 Flushing connection on suction side with shut-off valve (blanked-off)
 Diaphragm pump with manually adjustable stroke length
 Flushing connection on discharge side with shut-off valve (blanked-off)
 Quantity/volume measurement, if not arranged in the feed tank
 Discharge line to feed tank with shut-off valve
 Idle-run protection (anti-siphon device)

Diaphragm pumps shall preferably be used. Magnetically coupled centrifugal pumps

are also used as transfer pump. For the pumps, it shall be ensured that dry-run pro-
tection is provided.

C: Feed tank
The feed tank shall have the following properties and consist of at least the following
plant parts and components:
 Be designed for atmospheric operation
 Be made of material to Table 4.1
 Be dimensioned for a certain volume acc. to plant owner’s or planner’s re-
quirements (as a rule, daily or weekly metering volume), standard dimensions
shall be preferred
 Dilution water supply with shut-off valve, drain valve (blanked-off), manual
control valve
 Level indicator in the tank as by-pass line with level switches Min-Min, Max,
Max-Max and local level indication with shut-off valves to the tank; alternative-
ly an analogue level indicator may be used (in such case, quantity measure-
ment in the transfer unit can be omitted)
 Overflow protection in the tank
 Agitator. Where possible, the agitator shall be arranged to avoid running dry
 Drain valve (blanked-off), extraction valve
 Vent/ventilation nozzle with 180° bend and insect protection on the tank

D: Metering pump unit

The metering pump unit shall have the following properties and consist of at least the
following plant parts and components:
 For availability purposes one operational and one standby pump each shall be
installed per feed point
 Calibration vessel with shut-off valve to suction side and to feed tank
 Suction line with shut-off valves, drain valve (blanked-off), strainer, and flush-
ing connection per pump

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 hydraulic diaphragm metering pump with manually adjustable stroke length,

suited for frequency inverter operation
 Discharge line with shut-off valves, pulsation damper, relief valves
 Local pressure gauge, isolatable
 On the pump discharge side all valves shall be designed as double isolation
valve set at a pressure equal to or higher than 64 bar, except for the shut-off
valve at the discharge line outlet to the process which may be a single valve

E: Feed point to boiler water

See chapter 4.2.

F:Additional equipment
In addition, the following EHS relevant items of equipment shall be provided:
 Catchment devices for parts of the feed station or the complete station. Leak-
ages shall be easily removable
 Leak detection probes for catchment devices
 Emergency or eye showers in proximity of the station

Figure 4-10 – Feed system for boiler water internal treatment chemicals

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Essential components of the feed system for boiler water treatment with manual me-
tering (see Figure 4-11)

A: Chemicals packaging and discharge

The internal treatment chemicals (NaOH, Na3PO4, LiOH) are delivered in
 Plastic canisters of various volumes
 Drums
 IBC
The following explanations refer to the combination of “Canister as transport and
storage tank – chemical feed tank“.
Where the chemical is delivered in transport canisters / small packages, the chemical
shall be extracted by means of a suction lance. Complete drainage of the container is
not possible.
The canister storage site shall be equipped to satisfy national rules and regulations.

B: Transfer unit
The transfer unit shall consist of at least the following plant parts and components:
 Suction line of transfer pump with shut-off valve and strainer
 Diaphragm pump
 Discharge line to feed tank

C: Feed tank
The feed tank shall have the following properties and consist of at least the following
plant parts and components:
 Be designed for atmospheric operation
 Be made of material to Table 4.1
 Be dimensioned for a certain volume acc. to plant owner’s or planner’s re-
quirements (as a rule, daily or weekly metering volume), standard dimensions
shall be preferred
 Dilution water supply with shut-off valve
 Level indicator on the tank with impressed scaling
 Level switches Min-Min, Min
 Manual mixer
 Vent/ventilation nozzle with 180° bend and insect protection on the tank
 Drain valve (blanked-off), extraction valve

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D: Metering pump unit

The metering pump unit shall have the following properties and consist of at least the
following plant parts and components:
 For availability purposes one operational and one standby pump each shall be
installed per feed point
 Suction line with shut-off valves,
 Hydraulic diaphragm metering pump with manually adjustable stroke length
and controllable drive
 Discharge line with shut-off valves, pulsation damper, relief valve, and con-
stant-pressure valve
 Local pressure gauge, isolatable.

E: Feed point in the WSC

See chapter 4.2.

F:Additional equipment
In addition, the following EHS relevant items of equipment shall be provided:
 Catchment devices for parts of the feed system or the complete system
o Leakages, if any, shall be easily removable
 Leak detection probes for catchment devices
 Emergency or eye showers in proximity of the plant

Figure 4-11 – Feed system for boiler water treatment with manual metering

Essential components of the feed system for boiler water treatment with solids (see
Figure 4-12)

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A: Chemicals packaging and discharge

Sodium hydroxide and tri-sodium phosphate are usually supplied in plastic bags or
drums. The supplier’s storage instructions shall be observed.

B: Transfer unit
Precautionary measures shall be taken for the safe transfer of solids into the feed
tank. The ergonomic design of the feeding device shall be taken into account. The
feeding device should not cause dust loading in the environment of the dilution tank.

C: Feed tank
The feed tank shall have the following properties and consist of at least the following
plant parts and components:
 Be desiged for atmospheric operation
 Be made of material to Table 4.1
 Bedimensioned for a certain volume acc. to plant owner’s or planner’s re-
quirements (as a rule, daily or weekly metering volume), standard dimensions
shall be preferred
 Dilution water supply with shut-off valve, drain valve (blanked-off), manual
control valve
 Level indicator in the tank as bypass line with level switches Min-Min, Max,
Max-Max and local level indication with shut-off valves to the tank; alternative-
ly an analogue level indicator may be used (in such case, quantity measure-
ment in the transfer unit can be omitted)
 Overflow protection in the tank
 Agitator. Where possible, the agitator shall be arranged to avoid running dry
 Drain valve (blanked-off), extraction valve
 Vent/ventilation nozzle with 180° bend and insect protection on the tank
 Perforated plate-type basket in the feed tank for receiving the filled-in solid.
This largely prevents the solid from sinking to the tank bottom. The basket
shall be arranged such that in case of a filled tank adequate dilution in the
basket is obtained

For all other units (D to F) of the chemical feed system for phosphate solution from
solids the description under “Feed system for boiler water internal treatment chemi-
cals applies”.

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Figure 4-12 – Feed system for internal boiler water treatment with solids

Essential components of the feed system for boiler water treatment with solids,
manual metering (see Figure 4-13)

A: Chemicals packaging and discharge

Sodium hydroxide and tri-sodium phosphate are usually supplied in plastic bags or
drums. The supplier’s storage instructions shall be observed.

B: Transfer unit
Precautionary measures shall be taken for the safe transfer of solids into the feed
tank. The ergonomic design of the feeding device shall be taken into account. The
feeding device should not cause dust loading in the environment of the dilution tank.

51
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C: Feed tank
The feed tank shall have the following properties and consist of at least the following
plant parts and components:
 Be designed for atmospheric operation
 Be made of material to Table 4.1
 Be dimensioned for a certain volume acc. to plant owner’s or planner’s re-
quirements (as a rule, daily or weekly metering volume), standard dimensions
shall be preferred
 Dilution water supply with shut-off valve,
 Level indicator in the tank as bypass line with impressed scaling
 Level switches Min-Min, Min
 Agitator. Where possible, the agitator shall be arranged to avoid running dry
 Vent/ventilation nozzle with 180° bend and insect protection on the tank
 Drain valve (blanked-off), extraction valve
 Perforated plate-type basket in the feed tank for receiving the filled-in solid.
This largely prevents the solid from sinking to the tank bottom. The basket
shall be arranged such that in case of filled tank adequate dilution in the bas-
ket is obtained.

D: Metering pump unit

The metering pump unit shall have the following properties and consist of at least the
following plant parts and components:
 Normally one operational pump is installed per pressure stage and one
standby pump shall be provided for availability purposes
 Suction line with flushing connection
 Hydraulic diaphragm metering pump with manual stroke length adjustment
and controllable drive
 Discharge line with shut-off valves, pulsation damper, relief valve and con-
stant-pressure valve
 Local pressure gauge, isolatable

E: Feed point in the WSC

See chapter 4.2.

F:Additional equipment
In addition, the following EHS relevant items of equipment shall be provided:
 Catchment devices for parts of the feed system or the complete system
o Leakages, if any, shall be easily removable

52
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 Leak detection probes for catchment devices

 Emergency or eye showers in proximity of the plant

Figure 4-13 – Feed system for boiler water treatment with solids, manual metering

4.6.3 Feed systems for oxygen scavengers

Oxygen scavengers used today (if required by the process) are, among others, car-
bohydrazide, DEHA, ascorbic acid and sodium sulfite. These chemicals are delivered

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as aqueous solution in various packaging forms. The feed systems required for feed-
ing these chemicals principally do not differ from the systems used for feeding am-
monia (see chapter 4.6.1). Where oxygen scavengers are already delivered as con-
centrate, the system parts B and C are omitted. As regards the purity of oxygen
scavengers as delivered concentrate, reference is made to chapter 5.2.

Where hydrazine is to be used as oxygen scavenger, specific EHS measures shall

be taken to prevent hydrazine solutions or vapours from being released to the envi-
ronment or persons from getting into contact with these chemicals. Hydrazine is car-
cinogenic, irritant, very poisonous, caustic and water-polluting. The use and handling
with hydrazine requires, e.g. in Germany, the specific approval by the supervisory
authorities (see also the safety data sheet of the chemicals supplier). The respective
national rules and regulations shall be observed.

4.6.4 Oxygen feed system

Oxygen is required for the internal treatment of the WSC in case of OT mode of op-
eration.
Properties: Besides the health warning information in the safety, data sheet the fol-
lowing properties of gaseous oxygen shall be taken into account when designing
chemical feed systems:
 Oxidizing
 Gas under pressure (danger of explosion when heated)

Delivery container: pressurized gas cylinder or set of cylinders with 200 to 300 bar
gauge pressure
Application concentration: gaseous oxygen
As regards the purity of oxygen, reference is made to section 5.2.7.

All parts of the oxygen feed system shall be free from oil and grease. When selecting
the parts care shall be taken that the parts have been cleaned and packed specifical-
ly for oxygen application.

Essential parts of oxygen feed system (see Figure 4-14)

A: Chemicals packaging and discharge

Oxygen is delivered as pressurized gas in bottles. The pressure in the gas bottles
usually is 200 bar (300 bar are also possible). No single cylinder exceeding a volume
of 50 litres shall be used to ease handling and exchange of the bottles. A group of 9
bottles in a bottle rack is common.
The connecting threads at the bottle valve are standardized and shall correspond to
DIN 477. Other connections are prohibited in Germany. Where systems are installed

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in foreign countries, the respective national standards for flange connecting threads
shall be considered.

B: Transfer unit
The transfer unit shall consist of at least the following components:
 Automatic switch-over from one pressurized gas bottle set to a second set
without interruption of gas supply
 Pressure monitoring with low-pressure switch per bottle set
 Pressure reduction unit per bottle set
 Flushing and relief valves per bottle set
 Safety valve
 Shut-off valves
 Pressure indicator

In any case, individual bottles shall be protected against fall.

C: Pressure reduction
The pressure reduction unit shall consist of at least the following components:
 Optional isolating valve in case of long lines
 Pressure reduction valve
 Pressure indicator

D: Feed system
The feed system shall consist of at least the following components:
 Flushing and relief valve with plug
 Strainer
 Mass flow controller incl. bypass
 Automatic shut-off valve
 Pressure indicator with local indication incl. shut-off
 Optional isolating valve in case of long lines
 Safety valve (optional to protect the units D and E)

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E: Oxygen feed point

See chapter 4.2.

F:Additional equipment
None

Figure 4-14 – Oxygen feed system

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4.6.5 Amines and other treatment chemicals

Besides the basic chemicals described above, numerous organic treatment chemi-
cals, among others amines, are offered and mainly used in industrial plants. The use
of such chemicals shall be carefully considered since these chemicals are subject to
thermal decomposition under boiler operating conditions (for more details see VGB
Feed Water Standard VGB-S-010-T-00; 2011-12, clause 5.3.1.7).
The configuration of a feed station for liquid organic treatment chemicals is similar to
that of ammonia feed systems. Here, care shall be taken that organic treatment
chemicals often have to be fed as undiluted products.
In addition, the chemicals’ compatibility with the construction materials of the feed
system (especially gasket materials, diaphragms, etc.) shall be checked.

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5 Requirements for the purity of feed chemicals and dilution

water
In this chapter, the typical purities of feed chemicals in as-received quality are de-
scribed. It is recommended to ask the supplier for an analysis certificate to be estab-
lished with indication of impurities critical for power plant operation (e.g. chloride, sul-
fate …). Feed chemicals of insufficient quality may lead to an increase in acid con-
ductivity in the system.
The plant owner is responsible for the orderly, appropriate and proper storage in ac-
cordance with the respective national and local rules and regulations.
5.1 Water quality
Deionized water to VGB-M 407 shall exclusively be used as water for start-up,
maintenance, shutdown, and operation.
5.2 Ammonia
The typical delivery quality of ammonia for feeding into the WSC meets the following
purity requirements:
Ammonia concentration 15 to 25 % aqueous solution
Chloride mg/kg <1
Sulfate mg/kg < 1.5
Sodium mg/kg <1
Iron mg/kg < 0.2

5.3 Caustic soda and sodium hydroxide

The typical delivery quality of caustic soda for feeding into the WSC shall meet the
following purity requirements:
Caustic soda concentration: 20 to 50 % solution
Chloride 0.2 % of caustic soda solution
Sulfate 0.1 % of caustic soda solution
Oxidants 0.001 % of caustic soda solution
Silckate (as SiO2) 0.1 % of caustic soda solution
Iron 0.001 % of caustic soda solution
Aluminium 0.005 % of caustic soda solution
Earth alkalines 0.01 % of caustic soda solution
If sodium hydroxide is used, the same purity requirements apply analogously.

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5.4 Tri-sodium phosphate (as solid)

Tri-sodium phosphate may be used as either anhydrous product or phosphate with
crystal water. The typical delivery quality of tri-sodium phosphate for feeding into the
WSC shall meet the following purity requirements:
Water-insoluble substances < 0.05 %
pH value 1 % solution 11 to 12
Na3PO4 content > 90 % anhydrous quality
> 44 % with crystal water

5.5 Lithium hydroxide solution

The typical delivery quality of lithium hydroxide for feeding into the WSC shall meet
the following purity requirements:
Lithium hydroxide concentration: 10 % solution
Chloride 0.05 % of caustic solution
Sulfate 0.05 % of caustic solution
CaO 0.03 % of caustic solution
Carbonates 0.1 % of caustic solution
Iron 0.03 % of caustic solution
Sum of Na and K 0.01 % of caustic solution
Sum of heavy metals 0.01 % of caustic solution

5.6 Oxygen scavengers

In the following, the typical purity requirements for oxygen scavengers are described.
The treatment chemicals are often delivered with supplier-specific trade names.
Sodium sulfite/bisulfate and ascorbic acid are not steam-volatile and will only be used
in small boiler plants (shell boilers and industrial drum boilers) operating at pressure
stages up to 4 MPa.

5.6.1 Hydrazine
Hydrazine is usually delivered as aqueous solution. A typical delivery quality of hy-
drazine solution to be fed into the WSC shall meet the following purity requirements:
Content (as N2H4) approx. 15 %
Appearance clear colourless to slightly yellow liquid
Chloride < 4.0 mg/kg
Iron < 2.0 mg/kg

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5.6.2 Carbohydrazide
Carbohydrazide that is also called 1.3diaminourea is usually delivered as aqueous
solution. A typical delivery quality of carbohydrazide solution to be fed into the WSC
shall meet the following purity requirements:
Content approx. 6 %
Appearance colourless liquid
pH value 7.5 to 9.5

5.6.3 DEHA
DEHA (diethyl hydoxylamine) is usually delivered as aqueous solution. A typical de-
livery quality of DEHA solution to be fed into the WSC shall meet the following purity
requirements rungen:
Content approx. 15 %
Appearance clear colourless to slightly yellow liquid
Density approx. 0.99 g/cm3

5.6.4 Sodium sulfite/sodium bisulfite

Sodium sulfite (Na2SO3) is delivered as solid or aqueous solution, sodium bisulfite
(NaHSO3) as aqueous solution. A typical delivery quality of sodium bisulfite solution
to be fed into the WSC shall meet the following purity requirements:
Content (as NaHSO3) approx. 40 %
Apperance clear colourless to slightly yellow liquid
Density approx. 1.35 g/cm3

5.6.5 Ascorbic acid

Ascorbic acid (vitamin C) is delivered as solid or aqueous solution. A typical delivery
quality of ascorbic acid (as solid) to be fed into the WSC shall meet the following puri-
ty requirements:
Apperance white to weakly yellow powder
Content > 98 %
pH value (2% solution in DI water) approx. 2.6
Copper < 5 mg/kg
Iron < 2 mg/kg

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5.7 Oxygen
Oxygen for feeding into the WSC shall have a minimum purity of 99.9 % (oxygen
quality 3.0).

5.8 Amines and other treatment chemicals

Organic treatment chemicals are primarily delivered as aqueous solutions or aque-
ous emulsions. Here, solutions of individual components or ready-to-feed mixtures of
various components are concerned, such as (cf. chapter 4.4.3):
- Organic filming amines for alkalization
- Filming amines
The treatment chemicals are often delivered with supplier-specific trade names.
In the following, the typical purity requirements for selected amines are shown:

5.8.1 2-Aminoethanol (Monoethanolamine)

2-Aminoethanol is delivered as liquid or aqueous solution.
A typical delivery quality of 2-aminoethanol to be fed into the WSC shall meet the fol-
lowing purity requirements:
Content > 98 %
Appearance Colourless liquid
Density approx. 1.013 g/cm3

5.8.2 Diethylaminoethanol
Diethylaminoethanol is delivered as liquid or aqueous solution. A typical delivery
quality of diethylaminoethanol to be fed into the WSC shall meet the following purity
requirements:

Content > 98 %
Apperance clear colourless to slightly yellow liquid
Density ca. 0.885 g/cm3
pH (10% solution in DI water) > 11.0

5.8.3 Oleylpropylendiamine
Oleylpropylendiamine is delivered as aqueous emulsion. A typical delivery quality of
oleylpropylendiamine to be fed into the WSC shall meet the following purity require-
ments:

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Content approx. 2 %
Appearance opaque emulsion
pH value approx. 10.7

Organic treatment chemicals may contain further substances, e.g. oxygen scaven-
gers (cf. chapter 5.6) or polyacrylates, e.g. sodium polyacrylates. The general re-
marks and recommendations as regards the purity of treatment chemicals should be
observed.

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6 Operation, maintenance and quality assurance

Chemical feed systems shall operate correctly and trouble-free thus ensuring feeding
of chemicals at any time. For this reason, it is indispensable that the plant owner
takes regular measures for maintaining, repairing and servicing the chemical feed
systems to ensure trouble-free operation.
In the following chapters, the necessary boundary conditions and measures for as-
suring the quality of chemical feed systems are considered.
6.1 Operation

6.1.1 First putting into operation with liquid fluids

The first putting-into-operation shall principally be made with DI water (see Chapter
5.1).

The feed system shall be put into operation in accordace with the supplier’s operating
manual.

Prior to first putting-into-operation:

 All pipe connections, bolting, flange connections etc. shall be checked and re-
tightened, if necessary.
 Check and adjust, if necessary, pulsation dampers acc. to separate instructions
for the correct pressure required for operation.
 Prior to first switch-on the following checks shall be made:
o Check of electrical connections including protective equipment.
o Check of piping connections between chemical feed system and complete
plant (P&I diagram)
 The functionability of all safety devices required shall be ensured.
 Where all checks have been made, first filling with DI water may be effected.
 Capacity calibration of the metering pump to verify the pump characteristics and
ensure the mechanical functions of the total system
 Finally, putting into operation with chemicals can be effected in due consideration
of the safety measures to be taken.

6.1.2 Normal operation

Normal operation of the power plant (and thus of the feed system) covers start-up
from standstill, load-following operation and shutdown. The feed system shall conse-
quently follow to meet the respective requirements.
During standstills, the chemical feed system shall be set to standby operation without
taking further measures. The chemicals shall be left in the feed system. Specific
preservation measures are not required.

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6.1.3 Shutdown
Feed systems shall be shut down if:

 the power plant is brought into an extended preservation condition.

 repairs or maintenance work have to be done on the feed system.

When taking the plant out of operation the following shall be observed:

 Drain and orderly dispose off the chemicals from the pipework.
 Flush the lines with DI water (water quality to chapter 5.1) and subsequently
drain the lines.
 Disconnect system from power supply.

6.1.4 Restart of the system

Where the system is put into operation again, the procedure shall principally be the
same as during first putting into operation.
The following should be considered additionally:
 Check all components for correct seat, leak tightness and stability.
 Clean the complete system.
 Check correct valve positions acc. to operating manual of the chemical feed
system.

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7 Quality assurance and technical documentation

7.1 Plant design and fabrication
The design of chemical feed systems requires the minimum data as per Table 7-1:

Table 7-1 – Minimum data for the design of a chemical feed system

Chemical
Parameter Unit

Concentration of delivery %
Concentration to be fed %
Location of installation (outdoor in- -
stallation, under protective roof, tur-
bine hall, explosion-protected ar-
ea?,...)
Temperature at location of installa- °C
tion (min, max)
Design temperature at feed point °C
(min, max)
Delivery rate (min., normal, max.) l/h
Back pressure bar
Design pressure bar
Feed tank volume l

Upon placing the order, the chemical feed system will be designed. The respective
test and inspection steps and the type of documentation required shall be laid down
in the quality plan. Upon finalization of the engineering stage, fabrication will be re-
leased upon submission and review of the documents established (at least P&I plan,
dimensional drawings with loading data and electrical wiring schemes.
The manufacturer shall inform the purchaser on the finalization of chemical feed sys-
tem fabrication and on the subsequent inspection to be performed in the manufactur-
ers’ works. At this point in time, the documentation shall be fully available to the ex-
tent required.
The purchaser shall decide on whether to attend or have a third party engaged in the
inspection.
Annex 11, chapter 11.2 shows an example for a quality assurance plan.

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7.2 Safeguarding of trouble-free operation

For the purpose of quality assurance, a plant-specific quality assurance (QA) plan
shall be established. The following scheme shows the main steps to establish such a
QA plan:

Evaluate Define requi-

Analyse process
risks red QA activi-
risiks
ties

• Leakage • Susceptibility to distur- • Measures to be taken

• Plant failure bance • Frequency
• Wrong concentration • Consequences • Responsibility
of chemicals • Availability of spare • Documentation
• Faulty operation parts
• Lack of chemicals

The inspection and maintenance intervals to be determined depend on the specific

feed system conditions and on the importance of the exact chemical feeding for the
respective operating condition. In any case, the defined QA measures shall be auto-
mated or be performed by qualified personnel and be documented.

Table 7-2 hereafter contains examples as to how the various technical departments
can be incorporated and how the tasks be clearly allocated to the respective person-
nel:
Table 7-2 – Responsibilities for the performance of quality assurance measures in the chemical feed
system

Quality assurance measures for

To be performed by
chemical feed system
Walkdowns Schichtpersonal
Correction of minor disturbances Chemical laboratory, mainte-
nance and servicing depart-
ment
Maintenance of chemical feed sys- Maintenance and servicing
tem department
Definition of QA plan Chemical laboratory / process
Evaluations engineering department

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The list hereafter shows how a QA plan may be set up. The intervals proposed are
general values for illustration only. This list shall be broken-down and adapted to the
plant-specific requirements.
The maintenance plan and the lubrication plan that are part of the technical docu-
mentation provide good indication for the establishment of a QA plan.

Daily:
 General inspection round, no specific maintenance
 Visual inspection for leak detection
 Anomalous noise and vibrations (motors, pumps and lines)

Additionally weekly:
 Check of local control loops, indication devices, lamp control
 Check of oil level in gearbox of metering pumps
 Check of filling level

Additionally monthly:
 Flow rate control acc. to functional description
 Check of level indicators and level switch points

Additionally every three months:

 Check of pulsation damper inlet pressure

Additionally yearly:
 Complete test of system, functional control and inspection of all valves and
units and assemblies
 Check whether replacement of wear parts and change of gear oil is required
(see operating manual)

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8 Applicable legal stipulations, directives and standards

8.1 European legal stipulations and directives
EC Treaty Article 95 Provisions with basic requirements for safe
(former 100a) products
Articl 137 Provisions with minimum requirements for the
(former 118a) safety and health of workers
ATEX 2014/34/EC Directive 94/9/EC of the European Parliament
and the Council of 23 March 1994 on the ap-
proximation of the laws of the Member States
concerning equipment and protective systems
intended for use in potentially explosive at-
mospheres
PED 2014/68/EU Directive of the European Parliament and the
Council on the approximation of the laws of
the Member States concerning pressure
equipment – Pressure Equipment Directive
EC Directive Safety 89/391/EEC Directive of the Council on the introduction of
at Workplace measures to encourage improvements in the
safety and health of workers at work – OSH
"Framework Directive"
EMC 2014/30/EC Directive of the European Parliament and of
the Council on the approximation of the laws
of the Member States relating to electromag-
netic compatibility
Macinery Directive 2006/42/EC Directive of the European Parliament and of
the Council on machinery, and amending Di-
rective 95/16/EC
Product Safety Di- 2001/95/EC Directive of the European Parliament and the
rective Council on general product safety
Note: It is assumed that the aforementioned European directives have been trans-
posed into the respective national law in the European Economic Area.

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8.2 National Law

The laws and ordinances mentioned hereafter only apply to the installation and oper-
ation of plants in Germany. Otherwise, the pertinent national laws shall apply.
AbwV (Waste Water Ordinance)
BetrSichV Verordnung über Sicherheit und Gesundheitsschutz bei der Bereit-
stellung von Arbeitsmitteln und deren Benutzung bei der Arbeit, über
Sicherheit beim Betrieb überwachungsbedürftiger Anlagen und über
die Organisation der betrieblichen Arbeitsschutzes
(Betriebsicherheitsverordnung) (Ordinance on Industrial Safety and
Health)
ProdSG Gesetz über die Bereitstellung von Produkten auf dem Markt
(Produktsicherheitsgesetz) (Product Safety Law)
WHG Gesetz zur Ordnung des Wasserhaushalts
(Wasserhaushaltsgesetz) (Water Conservation Act)

8.3 European Standards (EN ISO) and other Technical Rules

AD 2000 AD 2000 Rules
EN 287 Qualification test of welders. Fusion welding
Part 1 Steels
EN 473 Non-destructive testing. Qualification and certification of NDT
personnel. General principles
EN 1418 Welding personnel. Approval testing of welding operators for
fusion welding and resistance weld setters for fully mechanized
and automatic welding of metallic materials
EN ISO 3834 Quality requirements for fusion welding of metallic materials
Part 1 Criteria for the selection of the appropriate level of
quality requirements
Part 2 Comprehensive quality requirements
Part 3 Standard quality requirements
DEN ISO 5817 Welding. Fusion-welded joints in steel, nickel, titanium and
their alloys (beam welding excluded). Quality levels for imper-
fections
EN 10216 Seamless steel tubes for pressure purposes. Technical deliv-
ery conditions. Stainless steel tubes
Part 5 Stainless steel tubes
EN 10272 Stainless steel bars for pressure purposes

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EN 10297 Seamless circular steel tubes for mechanical and general en-
gineering purposes. Technical delivery conditions.
Part 2 Stainless steel tubes
EN ISO 12100 Safety of machinery. General principles for design. Risk as-
sessment and risk reduction
EN 12952 Water-tube boilers and auxiliary installations
Part 3 Design and calculation for pressure parts of the boiler
Part 12 Requirements for boiler feed water and boiler water
quality
EN 12953 Shell boilers
Part 3 Design and calculation for pressure parts of the boiler
Part 10 Requirements for boiler feed water and boiler water
quality
EN 13445 Unfired pressure vessels
EN 13480 Metallic industrial piping
EN 14121 Safety of machinery – Risk assessment
Part 1 Principles
EN ISO 15613 Specification and qualification of welding procedures for metal-
lic materials. Qualification based on pre-production welding
test
EN ISO 15614 Specification and qualification of welding procedures for metal-
lic materials. Welding procedure test
Part 1 Arc and gas welding of steels and arc welding of
nickel and nickel alloys
EN 17635 Non-destructive testing of welds. General rules for metallic ma-
terials
EN ISO 17637 Non-destructive testing of welds. Visual testing of fusion-
welded joints
DIN 19261 pH-Messung - Messverfahren mit Verwendung potentiometri-
scher Zellen - Begriffe
DIN 24289-2 Oszillierende Verdrängerpumpgen und –aggregate; Techni-
sche Festlegungen, Angaben für ein Datenblatt.
DlN EN 60051 Direct acting indicating analogue electrical measuring instru-
ments and their accessories. Definitions and general require-
ments common to all parts

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EN 60204 Safety of machinery. Electrical equipment of machines

Part 1 General requirements
EN 60529 Specification for degrees of protection provided by enclosures
(IP code)
EN 62424 Representation of process control engineering. Requests in
P&I diagrams and data exchange between P&I tools and PCE-
CAE tools
VDMA 24286- Verdrängerpumpen; Beschaffung, Prüfung, Lieferung und Ver-
10:1974-12 sand; Datenblatt für oszillierende Verdrängerpumpen, Dosier-
pumpen

8.4 US American Codes and Standards

ASME Boiler and Pressure Vessel Code
ASME Pressure Piping Code
ASTM D 1066 Standard Practice for Sampling Steam
ASTM 5128 Standard Test Method for On-Line pH-Messurement of Water
of Low Conductivity

8.5 VGB Standards, Guidelines and Instruction Sheets

VGB-B 105e KKS Power Plant Identification System – Guideline, – Key
Part, Index A, B, C, D, E; Book and/or CD-ROM.
New edition: VGB-S-811-01-2018-01-EN
VGB-M 407e Conception, Specification and Performance Verification for
Demineralization Plants
VGB-R 106e Tubes for Condensers and other Heat Exchangers for the
Operation of Steam Turbine Plants – Copper Alloys
VGB-R 107e Ordering and Designing of Valves in Thermal Power Plants
VGB-R 123 C I.1 Sammlung von VGB-Richtlinien und VGB-Empfehlungen für
die Leittechnik, Band I.1 Messtechnik 1987, Ringbuch
1.1 Justieren, Kalibrieren, Eichen
1.2 Auswahl von Mess- und Probenahmeleitungen für die
Wasser- und Dampfbereiche im Wärmekraftwerk
1.5 Entnahmestellen für verfahrenstechnische Messun-
gen an wasser- und dampfführenden Systemen
1.6 Temperaturmessungen mit Thermoelementen und
Widerstandsthermometern; Einsatzkriterien und Feh-
lergrenzenermittlung

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1.8 Hinweise zu Messeinrichtungen in Rauchgasreini-

gungsanlagen
1.9 Messanordnungen und Messeinrichtungen von Pro-
zessmessgrößen
VGB-R 170 B0–B6e Design standards for instrumentation and control equip-
ment, Parts B0 to B6
VGB-R 455e Cooling Water Guideline
VGB-S-006-00-2012- Sampling and Physico-Chemical Monitoring of Water and
09-EN Steam Cycles
VGB-S-010-T-00; Feed water, boiler water and steam quality for power plants/
2011-12.EN industrial plants
VGB-S-029-S- Maintenance-compatible documentation
00;2012-03-EN
VGB-S-104-O Online-Leitfaden zur Umsetzung der Betriebssicherheits-
verordnung in Kraftwerken – 2007 (Update 2017)
VGB-S-109-00-2012- Werkstoffspezifikation für drucktragende Komponenten in
08-DE-EN fossil befeuerten Kraftwerken, ISBN 978-3-86875-394-3
VGB-S-170-R- Selection of impulse pipes and sampling lines for water and
41;2012-07.EN steam sectors in thermal power stations
VGB-S-170-42-2014- Sampling Points for Process Measurements in Water and
08-EN Steam Carrying Systems – Type, Selection and Design
VGB-S-513-00-2014- Internal Cleaning of Water-Tube Steam Generating Plants
07-EN and Associated Pipework
VGB-S-891-00-2012- VGB abbreviation catalogue for power plant technology
06-DE-EN

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9 Literature
Authors (alphabetically)

Bernasconi, M.: Low-Level Oxygen Measurement in Power Plants: What Really

Matters, PowerPlant Chemistry, 13 (2011), No. 2, pp. 69 – 73.
BETZ Handbook of Industrial Water Conditioning, 9th Edition 1991, Chemical Feed
Systems, pp. 247 – 264.
Christophersen, D.: Boiler Water Treatment Chemicals Feed and Control – Perhaps
it is More Complicated than We Thought, Association of Water Technologies 2006
Annual Convention & Exposition, September 15, 2006, pp. 170 – 184.
Cohen, P.: The ASME Handbook on Water Technology for Thermal Power Systems,
1989, Chapter 27-20 – Chemical Feed Systems, pp. 1485 – 1492.
DREW Principles of Industrial Water Treatment, 11th Edition 1994, Chapter 17 – Sys-
tem Monitoring and Control, pp. 295 – 311.
DREW Grundlagen der industriellen Wasserbehandlung, 3. Überarbeitete Auflage
1993, Kapitel 15, Einspeisung und Kontrolle von Aufbereitungschemikalien, pp. 236 –
250.
GE Handbook of Industrial Water Treatment, Chapter 35 – Chemical Feed Systems
– 2012.
Spellissy, F.; Griffin, F.; Stack, E.: Analyzing the Influence of Increased Ammonia
Dosing to CGT Condensate Systems, PowerPlant Chemistry, 16 (2014), No. 4, pp.
232 – 239.
DOW Physical Properties of Caustic Soda: Freezing Point Form No. 102-00417-
1203.

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10 Examples for faulty installation of chemical feed systems

Figure 10-1 – Restricted space at location of installation:

 Manoeuvring of IBC containers or drums difficult or impossible.
 Restricted accessibility to feed pumps, i.e. maintenance and care is impaired / made more dif-
ficult
 Handling of leaking chemicals difficult or even impossible

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Bild 10-2 – Chemical feed system as outdoor installation (covered) close to the sea
 Inconsistent materials concept (contact corrosion)
 Valve bodies made of stainless austenitic steel / handwheel and lantern of the valves made of
cast steel without corrosion protection
 Flanges made of stainless austenitic steel / bolts and nuts made of carbon steel

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11 Annex
11.1 Examples for feed point design

Example for equipment of feed point for a system pressure equal to or exceeding 64 bar

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Example for feed point design for oxygen feeding

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11.2 Example for test and inspection sequence plan

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