43rd Electric Utility & Cogeneration Chemistry Workshop (EUC²W)

Instructor: Brad Buecker, SAMCO Technologies and Buecker & Associates, LLC

As combined cycle power plants have become a large part of the U.S. energy portfolio, operators face both similarities and differences in managing water/steam chemistry compared to conventional coal-fired units. Like their predecessors, heat recovery steam generators (HRSGs) demand high-purity makeup and steam. However, multi-pressure HRSG designs often require different chemistry regimes or control ranges for each evaporator circuit, adding complexity. At the same time, HRSG feedwater systems are generally less intricate than those of coal plants, which can simplify certain aspects of chemistry control.

This paper will explore the unique challenges and advantages of HRSG chemistry management, providing guidance on best practices to ensure reliability, efficiency and long-term equipment protection.

Instructor: Bill Boyd, Power Industry Technical Expert, Apex Water and Process

Film-forming agents (FFAs) and film-forming products (FFPs) have emerged as an important treatment approach to reduce on-line corrosion and provide surface protection during plant layup. This session will explore the chemistry, mechanisms and structures behind FFAs and FFPs, with a focus on practical applications and lessons learned from field use.

Attendees will learn product selection, application methods and strategies for achieving the steam purity required for a successful turbine roll. The session will also compare different commercial offerings and highlight best practices for long-term reliability.

Instructor: Claudine Fields, Program Manager, Workforce Readiness, Day & Zimmermann

The nuclear sector faces a critical challenge: experienced craft professionals are retiring, and too few young workers are entering the field. To close this gap, industry leaders must rethink how nuclear careers are presented to a new generation.

This session includes practical strategies to attract and retain talent by aligning nuclear craft roles with the values of today’s workforce: purpose-driven work, strong safety culture, competitive compensation, flexible outage schedules and clear career advancement through apprenticeship programs. Learn how to dispel outdated myths about construction roles and reintroduce nuclear craft work as a stable, rewarding career path that supports clean, secure energy for the future.

Instructor: Dan Dixon, P.E., Technical Leader II, EPRI

Under-deposit corrosion (UDC) remains one of the most serious chemistry-related tube failure mechanisms in HRSG high-pressure (HP) evaporators. It occurs when deposits on internal tube surfaces trap contaminants such as chlorides or sulfates, concentrating corrosive species and promoting localized attack of the base metal. Improper control of treatment chemicals, especially hydroxide or phosphate alkalizing agents, can further accelerate the process.

This session will review the mechanisms behind UDC formation, discuss how deposit loading and cycle-chemistry control interact to drive risk and examine diagnostic methods for early detection. Drawing on EPRI research, the instructor will outline current guidance for deposit sampling and chemical cleaning, highlighting where HRSG-specific updates to conventional drum-unit criteria are needed. Attendees will gain insights to strengthen their UDC prevention and cleaning strategies while minimizing outage impacts.

Instructor: Tais Soares, North America Business Development Manager – New Energies, Vallourec New Energies

Carbon capture and storage (CCS) is a cornerstone of decarbonization strategies, particularly in integrated hubs where emissions from power plants and industrial sources converge. Yet the long-term integrity of CO₂ injection wells presents major technical challenges. Impurities such as H₂S, O₂, CO, NO₂ and SO₂ can accelerate corrosion at the bottom hole, while dense-phase CO₂ injection can trigger extreme temperature drops, placing severe stress on well materials and connections.

This session presents a case study from a California CCUS hub, highlighting a comprehensive qualification program for tubular materials and threaded connections. Attendees will learn how martensitic 13Cr and corrosion-resistant alloy 25Cr (UNS S32760) performed under Stress Corrosion Cracking and Crevice Corrosion testing, and how Finite Element Analysis (FEA) and full-scale validation—pressure/temperature cycling, thermal shock and sealability—demonstrated the importance of rigorous testing protocols.

The presentation reveals insights on how utilities, EPCs and infrastructure developers can optimize tubular design to ensure safe, reliable CO₂ injection and long-term CCS success.

Instructor: Garrett Figley, Technical Market Development Lead, SWAN Analytical Instruments USA

Reliable water-steam chemistry monitoring depends on robust online analysis systems. Over the past decades, analyzers have advanced significantly: improving reliability, integrating automatic temperature compensation, enabling continuous flow monitoring, adding self-validation functions and reducing maintenance requirements. Modern analyzers now deliver not only process variables, but also diagnostic and status data for enhanced quality assurance.

This session will highlight the essential design features and capabilities that every plant should consider when selecting online analyzers. This includes which features are mandatory for specific analyzer types, how to ensure reliable measurements and how to reduce the risks of malfunction and costly downtime.

Instructor: Jo Anna Ordonez, VP, Utility Water Applications, Water Tech, Inc.

Microbial control in cooling water systems remains a persistent challenge for power plants. This session presents a case study on a next-generation oxidizing biocide applied at a Midwest coal-fired power plant. Formed by reacting sodium hypochlorite with a non-toxic mineral catalyst, Oxi-Plus delivers superior microbial control across a wide pH range, without the need for complex on-site generation or supplemental acid addition.

Field testing showed the biocide reduced sodium hypochlorite use by 88%, eliminated sulfuric acid handling, improved condenser vacuum by 1" Hg and cut annual CO₂ emissions by an estimated 1,827 metric tons. With extended stability, benign byproducts, and straightforward monitoring via ORP and chlorine residuals, it demonstrated both operational and environmental advantages.

Attendees will learn how novel oxidizing biocides can transform cooling water programs, offering utilities a safer, more sustainable and effective approach to microbial control.

Instructor: Brian Snyder, Continuous Improvement Process Owner, NiSource

Managing closed-loop coal combustion residual (CCR) wastewater presents complex operational challenges. At one NIPSCO generating station, operators encountered persistent issues such as fluctuating pH, inadequate clarification, dissolved solids saturation, competing chemical treatments, corrosion and scaling—all of which drove up maintenance costs.

This session will share lessons learned from moving beyond short-term fixes and finger-pointing to adopting a more strategic, integrated approach to CCR wastewater management. This includes the common pitfalls, effective treatment strategies and practical steps to improve system reliability and reduce costs.

Instructor: Scott Bryan, Technical Sales Manager, Cortec Corporation

Long-term layup of steam generators, cooling water systems and other water networks exposes water-touched metal to serious corrosion, especially from in-leakage of air at potentially numerous points in the system. Often, these systems must remain water-filled for rapid startup when needed. VPCIs have become a mature technology for protecting metals in many applications. 

This presentation explains how VPCIs function, where they perform best and how they can complement or replace traditional layup practices. Attendees will review application techniques for both wet and dry systems, considerations for water-filled standby conditions and verification methods to confirm protection effectiveness. Real-world examples will illustrate how utilities and industrial plants are using VPCIs to safeguard assets and enable faster, corrosion-free restarts.