Supporting Boiler Integrity with a Custom-Built Steam and Water Analysis System
This project, completed by Swan Analytical Australia, is one we are proud to share. Our team successfully delivered a customised steam and water analysis system that met the client’s operational requirements while overcoming the significant challenges created by the COVID-19 pandemic, including lockdowns, travel restrictions and border closures.
Reliable Monitoring for an Ageing Power Generation Fleet
With many of Australia’s thermal power stations operating with ageing infrastructure and fewer specialist power plant personnel, maintaining boiler integrity is increasingly important.
Swan Analytical Australia supplies customised steam and water analysis system (SWAS) packages to help power stations continuously monitor critical water and steam chemistry parameters. Reliable monitoring allows plant operators and chemists to identify changes in water quality, protect valuable equipment and maintain confidence in boiler operation.
Each SWAS package is designed and built to meet the specific requirements of the client and the facility. Our systems are developed with reference to recognised international standards, helping ensure that critical analytical measurements are accurate, reliable and available with minimal operator intervention.
The result is a practical monitoring system that gives plant chemists and operators greater confidence in the condition of their steam and water cycles.
Monitoring a Wide Range of Parameters
Swan offers a comprehensive range of analysers for pure water, ultrapure water, steam and cooling water applications.
Available measurement parameters include:
pH;
specific, cation and degassed cation conductivity;
oxidation-reduction potential (ORP);
dissolved oxygen;
silica;
sodium;
phosphate;
chlorine;
chlorine dioxide;
bromine;
iodine;
ozone; and
turbidity.
The Swan analysers are integrated with Sentry sample-conditioning equipment. Established in 1924, Sentry Equipment is internationally recognised for its steam and water sampling systems.
Effective sample conditioning is essential because high-temperature and high-pressure samples must be safely reduced to stable conditions before they can be accurately measured. The Sentry panels provide properly conditioned samples at approximately 25 °C, supporting consistent analyser performance and helping protect both personnel and analytical equipment.
Engineered for Long-Term Operation
Swan Analytical Australia’s SWAS packages are designed for dependable, long-term service. The expected operating life of a well-designed and properly maintained system can exceed 15 years, with some Swan systems remaining in service for almost 20 years.
The systems are built using high-quality analysers, sample-conditioning equipment and carefully selected components. Their layouts are designed to improve instrument accessibility, simplify routine maintenance and reduce the level of operator interaction required during normal operation.
Swan Analytical Instruments are highly regarded within the Australian power generation industry and are installed at many of the country’s major power stations.
One observation shared with our team was that Swan systems frequently replace analysers from other manufacturers, rather than the other way around.
Supporting Boiler Compliance and Reducing Costs
Accurate and reliable chemistry data can play an important role in demonstrating boiler integrity and supporting risk-based inspection programs.
For this client, confidence in the performance of the Swan SWAS contributed to a significant extension of the interval between boiler compliance inspections. The client reported that inspections previously conducted every 12 months could be extended to every four years, delivering substantial cost savings.
The client provided the following feedback:
“I was on site two weeks ago and sat in the new SWAS containers for a long time, just looking and smiling. I am very, very satisfied. The feedback from the operators was that they are very happy too.
Previously, our boiler compliance inspections were conducted every 12 months, costing more than $2 million for each inspection. With the accuracy and reliability of the Swan Analytical SWAS, our boiler compliance inspections can now be extended to every four years, saving millions of dollars.
This is our second Swan Analytical SWAS installation across two different sites. It is another great job from Swan Analytical Australia.”
A Complete SWAS Solution
This project demonstrates the value of combining reliable online analysers, effective sample conditioning and a practical system design within one complete monitoring package.
By delivering accurate, continuous chemistry measurements, the customised Swan SWAS helps the client protect boiler integrity, improve operator confidence and support more efficient compliance and maintenance planning.
Despite the logistical challenges created by the COVID-19 pandemic, Swan Analytical Australia successfully delivered a system designed to provide dependable service for many years.
