Real-Time TOC Analysis: Safeguarding Power Generation Equipment from Organic Water Contamination

Organic contamination in pure power plant waters poses significant operational and economic challenges, particularly in cogeneration systems where steam is utilized for both power generation and industrial heating. In such systems, the steam that condenses and returns to the boiler may become contaminated by organic compounds during industrial processes. This contamination is not always detectable through traditional conductivity measurements, as many organic compounds are non-conductive. Nonetheless, their presence can significantly compromise the efficiency and safety of power generation infrastructure.

The consequences of organic contamination are multifaceted. Organic substances can clog ion exchange resins, resulting in increased maintenance and replacement costs. More critically, they can degrade into acids under high temperatures, which lowers the pH of the water and accelerates corrosion in boilers and turbines. Organic residues may also deposit onto heat exchange surfaces, reducing thermal efficiency and causing foaming in boilers, which leads to the undesirable carryover of contaminants into the steam phase. Each of these issues can threaten the reliability and longevity of expensive equipment.

Sources of organic contamination in cogeneration plants vary widely. The most direct source is the return of condensate from production processes, where it may pick up organic matter through leaks or exposure to plant materials. Additional sources include makeup water, which is mainly derived from surface water, or reclaimed sources that vary seasonally in their organic content. Even ion exchange resins, while essential to purification, can degrade and release organic compounds. Other contributors include lubricants, leaking condensers, and certain chemical additives.

Given that traditional monitoring methods, such as conductivity or resistivity, are insufficient for detecting non-ionic organics, power plants are increasingly relying on Total Organic Carbon (TOC) measurements. TOC sensors work by oxidizing organic compounds into carbon dioxide using ultraviolet light and then measuring the conductivity of the resulting carbonic acid. This technique enables accurate detection and quantification of organic contamination, even at trace levels, allowing for real-time monitoring and rapid response.

Steam used in evaporation can pick up organics that, if returned to the boiler untreated, may damage the system. Early detection through TOC measurement enables corrective actions to be taken before significant damage occurs. Devices like METTLER TOLEDO Thornton's 450TOC and 4000TOCe analyzers provide fast, continuous monitoring and are designed to integrate into process systems with minimal disruption.

Recommended TOC Monitoring Approach:

For comprehensive organic contamination monitoring in cogeneration systems, consider implementing a dual-strategy approach using METTLER TOLEDO Thornton's proven UV oxidation technology. 

Deploy the 4000TOCe online analyzer at critical fixed monitoring points such as condensate return lines and makeup water inlets for continuous, real-time surveillance. This provides operators with immediate alerts when contamination levels exceed safe thresholds, enabling them to take rapid corrective action.

Complement this fixed monitoring with the portable 450TOC analyzer for diagnostic troubleshooting and multi-point system profiling. Utilize the portable unit to identify contamination sources, verify treatment effectiveness, and conduct regular water quality audits throughout the plant. Both analyzers deliver results in approximately 60 seconds from sample inlet to final measurement, ensuring operators can respond quickly to contamination events before significant equipment damage occurs.

This combined approach provides both the continuous protection required for critical process streams and the flexibility to investigate emerging issues throughout the water/steam cycle, offering comprehensive coverage against organic contamination risks.

Ultimately, the ability to detect and respond to organic contamination in pure water systems is essential to maintaining the performance, efficiency, and safety of cogeneration and power generation facilities. Investing in TOC monitoring safeguards equipment and helps avoid costly downtime while ensuring compliance with increasingly stringent water quality standards.

Alliance Technical Sales, Inc.
312 Park Avenue Unit 145
Clarendon Hills, IL 60514-0145
Phone: 630-321-9646
https://alliancets.com

On-line, Continuous TOC Measurement For Pure Water Systems - Real-time Measurement For Full Visibility of TOC Excursions

The Mettler Toledo 6000TOCi is a continuous measurement Total Organic Carbon sensor with ISM capabilities designed to measure the concentration of organic substances in pure and ultra-pure water applications. 

Monitoring Total Organic Carbon is critical for determining and controlling organics pollution in pure and ultrapure waters. This technology is relied upon in pharmaceuticals, microelectronics, and power generation sectors. 

The 6000TOCi sensor is a continuous-flowing, continuous-measurement instrument that detects any TOC change, regardless of duration. The continuous design also allows rapid detection, recognizing differences 60 seconds after the sample enters the sensor. The sensor provides continuous, real-time measurements in pure and ultrapure waters by utilizing advanced UV oxidation technology with swift response times. 

 The 6000TOCi sensor measures conductivity before and after oxidation of organic material with ultraviolet light to provide continuous, real-time TOC determination. 

The 6000TOCi's flexibility allows it to be installed anywhere on a water system, with the option of displaying results at the point of measurement or in a more convenient location for operators. 

The METTLER TOLEDO Thornton 6000TOCi Total Organic Carbon sensor has a response time of less than one minute. It provides continuous monitoring, a significant advantage over batch measurement systems that take six minutes or longer to give only a snapshot of water quality. 

The M800 Transmitter is a multiparameter, multi-channel instrument with a large, color touchscreen display that displays measurement and setup information for the 6000TOCi sensor. The M800 can control and monitor the operation of up to four 6000TOCi sensors. The 6000TOCi sensor and M800 transmitter form a TOC measurement system with design flexibility for full integration into water systems when used together. The separate components allow for close positioning of the sensor to the sample point for the quickest response while also allowing integration of the transmitter into the local control system.

For more information, contact Alliance Technical Sales by visiting https://alliancets.com or by calling 630-321-9646.

New 2020 Mettler Toledo Process Analytics Catalog

Mettler Toledo Process Analytics, which includes the well-known Thornton and Ingold brands, has published their 2020 product catalog.

Ingold has a long track record of innovative high-quality solutions for demanding process analytics applications. Their products include systems for the measurement parameters of pH/ORP, dissolved oxygen (DO), dissolved CO2, conductivity and turbidity.

Thornton is the market leader in critical ultrapure and pure water analytics, where accuracy and reliability are essential. Their products include analytical instruments and sensors for the measurement of resistivity, conductivity, TOC, bioburden, pH, dissolved oxygen (DO), sodium, silica and ozone.

For more information, and to download the 2020 MT Process Analytics catalog, visit this Alliance Technical Sales webpage.

Alliance Technical Sales, Inc.
630-321-9646
https://alliancets.com

Continuous, Real-time Measurement for Full Visibility of Total Organic Carbon (TOC) in Pure and Ultra-Pure Water Systems

At-line batch method of monitoring total organic carbon (TOC), which takes measurements at set intervals, is the equivalent of taking snapshots of information. The gaps between measurement intervals could easily miss a critical event, whereas on-line, continuous TOC monitoring done by the Mettler Toledo 6000TOCi total organic carbon analyzer captures any-and-all excursions in real-time.

Monitoring total organic carbon levels is critical to meeting internal water quality specifications and global pharmacopeia regulatory requirements. Missing an increase in TOC levels can put you at risk of contaminating your water system, which in turn could affect production and potentially lead to an out-of-spec event or product recall.

Most TOC analyzers on the market offer at-line batch or non-continuous methods of total organic carbon measurement, which limits TOC data collection to every 6-12 minutes. But much can happen in six minutes.  When you are subject to an audit or have a quality problem, how are you sure that you did not experience a problematic TOC excursion between batch samples?

The 6000TOCi analyzer’s true continuous measurement along with its comprehensive record keeping and advanced diagnostics provide audit-ready TOC compliance and complete control of your water system.

DOWNLOAD THE 6000TOCi TOTAL ORGANIC CARBON ANALYZER CATALOG HERE

Alliance Technical Sales
https://alliancets.com
630-321-9646

Process Analytics Product Guide

Ingold and Thornton brands provide wide ranging solutions
for process analytic challenges.
Image courtesy Mettler Toledo

Mettler Toledo is well known and regarded in the field of process analytical instrumentation. The company's line of sensors, transmitters, and analyzers delivers solid performance along with ease of use and reduced maintenance.

The full range of the company's Ingold and Thornton brand capabilities and applications for liquid, gas, and pure water analytics is illustrated in a newly available brochure. The document is useful as an overview of all potential intersections of your own work and the products and capabilities of Mettler Toledo.

Request a full copy of the brochure from a fluid analytics specialist. Share your measurement and analytical challenges with experienced professionals, leveraging your own process knowledge and experience with their product application expertise to develop effective solutions.

Mettler Toledo Process Analytics Product Guide from Alliance Technical Sales, Inc.

TOC Measurement in Water Systems

TOC analyzer for continuous on-line measurement
Image courtesy Mettler Toledo Thornton

Total Organic Carbon, referred to as TOC, is a measurement providing one of several facets to indicate the purity of a water sample or stream. Organic contamination in water for use in power generation, semiconductor manufacturing, and pharmaceutical production poses a number of operational risks or quality failures that can substantially impact process output. The elevated presence of carbon compounds in certain purified water sources can be an indicator that water treatment processes are not performing properly and need attention.

The measurement technology involves oxidation of carbon compounds in the presence of UV light and measuring sample conductivity. Processing of the raw measurement yields a value for TOC. Analytical instruments benefit from having features and attributes that lessen the need for human involvement and deliver rapid and accurate results. Mettler Toledo provides an advanced solution for TOC measurement with it 5000TOCi analyzer.

• Fast continuous measurement
• Reagent and chemical free
• Reliable operation
• ISM Intelligent Sensor Management

More detail is provided in the document below. Share your process analytic challenges with fluid process specialists. Leverage your own knowledge and experience with their product application expertise to develop effective solutions.

TOC Total Organic Carbon Analyzer from Alliance Technical Sales, Inc.

Digital Sensor Technology For In-line Process Analytics

Digital sensor technology opens new
avenues for accuracy and efficiency
Courtesy Mettler Toledo

In-line process analytics deliver wide ranging data used to control production processes and assure the suitability and performance of end products. Strict adherence to established procedures and standards contribute to the accuracy and value of the measurements derived from instruments and equipment monitoring various process steps from start to completion.

Digital sensor technology, with an onboard microprocessor, provides a wealth of functionality not previously available that enhances accuracy and efficiency. Mettler Toledo is at the forefront of digital sensor technology for inline process analytics with their line of ISM (Intelligent Sensor Management) compatible sensors. The digital sensors interface with companion transmitters and software tools to deliver customers top flight process analytics performance.

• Simplified workflow.
• Increased measurement effectiveness and process confidence.
• Sensors are easily removed from the process for calibration, negating need for personnel to bring calibration gases or buffer solutions to the measurement point.
• Diagnostic functions provide easy to read tools, notifying operators of when and what to do to maintain proper performance.
• Each sensor stores its own set of calibration data, which is automatically uploaded to the companion transmitter.
• Self configuration executed when new sensor connected to transmitter.
• Supporting software facilitates the range of tasks necessary to maintain top flight operational status for every ISM sensor.
• Sensor output is a digital signal, not prone to degradation in the same manner as analog signals.
• Sensor learns from and adapts to process conditions to provide better overall performance.

There is much more to learn regarding how ISM sensors can dovetail into your process operation and deliver substantial increases in efficiency and accuracy. The document below provides the next layer of information. Reach out to an inline process measurement specialist, sharing your process measurement challenges. The combination of your process knowledge and their product application expertise will yield an effective solution.

Intelligent Sensor Management For Inline Process Analytics from Alliance Technical Sales, Inc.