Reviving Abandoned SWAS Infrastructure at a Power Plant

A thermal power plant in Southern India relied on a sophisticated Steam and Water Analysis System (SWAS) to maintain operational efficiency and long-term asset uptime. In high-pressure environments within power plants, effective SWAS operation is the primary defense against corrosion and breakdowns. By monitoring essential parameters including pH, conductivity, and dissolved oxygen, the power plant ensures boiler safety and turbine reliability.

Despite a significant initial capital investment in a system, the facility found itself unable to utilise the asset, leaving the plant’s critical infrastructure vulnerable.

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PROBLEM

The power plant faced significant operational issues when a SWAS from an alternative manufacturer proved completely non-functional after installation. The total absence of real-time data regarding water chemistry left the power plant exposed to substantial risks.

The core challenges included:

Lack of OEM Support: The Original Equipment Manufacturer (OEM) failed to provide any commissioning assistance, leaving the system abandoned and practically useless.
Hardware Failures: Multiple critical wet panel components and sensors were found to be faulty or non-functional upon arrival.
Asset Protection Risks: The loss of monitoring capability increased the probability of costly downtime and internal damage to boilers and turbines.
Financial Loss: The plant faced the daunting prospect of a full-scale system replacement to restore vital safety functions .

SOLUTION

Forbes Marshall was engaged to conduct a comprehensive technical assessment and develop a recovery strategy. Prioritising restoration over replacement, Forbes Marshall focused on reviving the existing infrastructure to ensure a rapid and cost-effective return to service.

The engineering intervention included:

Component Replacement: All defective sensors and components were replaced with compatible, high-performance SWAN spares and electrodes.
Wet Panel Correction: Forbes Marshall engineers corrected the underlying faults within the wet panel functionality to ensure reliable sample handling.
Complete Recommissioning: The entire Steam and Water Analysis System was recommissioned to meet stringent operational standards.
Technical Handholding: Forbes Marshall provided end-to-end support and structured training to plant staff to ensure long-term system stability.

BENEFITS

The project successfully transformed an underperforming asset into a reliable monitoring system for the plant.

Key results from the intervention includes:

Significant Capital Cost Avoidance: By restoring the existing system, the plant avoided the massive expenditure and extended downtime associated with a total system replacement.
Enhanced Asset Protection: Real-time chemistry monitoring was fully restored, immediately reducing the risk of corrosion-related failures in boilers and turbines.
Operational Reliability: The integration of SWAN analysers and components re-established monitoring and provided the plant with accurate, actionable data.
Independent Capability: The project proved that specialized technical expertise can revive critical infrastructure regardless of the original manufacturer.