In power generation, corrosion isn’t just costly — it’s catastrophic. That’s why operators rely on Steam Water Analysis Systems (SWAS) to keep water chemistry in check and plants running safely. By analyzing continuous, real-time data on critical chemical parameters like pH and conductivity, SWAS helps operators ensure that the water chemistry stays within safe and optimized limits.

A SWAS system acts like the early warning system for a steam cycle in power plants, and pH and conductivity are its most critical measurement points. Monitoring these parameters ensures the water chemistry remains in optimal ranges, helping protect expensive assets, avoid unplanned outages, and maximize operational efficiency.

Steam and condensate lines operate at volatile temperatures, and both pH and conductivity are temperature-dependent measurements. Sample conditioning systems cool the samples to safe and stable temperatures before analysis.

Managing Measurement Points and Accuracy in SWAS

In the effort to prevent corrosion, operators will often ensure redundancy in their measurements. This means implementing multiple points of measurement along the analysis line. Depending on plant size, this necessary aspect of corrosion prevention can force operators to walk up and down the line for multiple strenuous sensor calibrations, removals, and replacements.

Additionally, the demand for accuracy in steam water analysis is critical. If pH and conductivity monitoring are inaccurate or inconsistent, the buildup of salts and other suspended solids can result in serious damage to plant infrastructure. Faulty pH and conductivity measurements can cause corrosion and fouling in plant infrastructure. If inaccurate, the risk of needing full-scale blow-downs or even full replacements of equipment becomes much greater. This is extremely costly and must be avoided.

Keeping Process Media and Infrastructure Clean

In SWAS systems, measurement redundancy is essential. But with multiple transmitters, space quickly becomes a problem. With Memorail Modbus, operators have been able to considerably consolidate the available space on the measurement line. MemoRail is a compact, digital transmitter configurable with up to 2 sensor inputs. Up to 32 Modbus RTU devices can operate in parallel, giving SWAS engineers a massive advantage in space consolidation. Operators can wire each device to a controller in tandem. This significantly reduces the controller space required and the time spent moving between various controllers and transmitters.

While space consolidation is important, accuracy is the most critical factor in maintaining uptime and the overall health of steam water analysis systems. For pH measurements, the SE558 is ideal for the ultra-pure conditions required in steam water analysis systems. The sensor utilizes 3 ceramic junctions and a pressurized reference system to prevent junction fouling and contamination. This vastly extends sensor life and reliability in SWAS measurements. As with any Memosens sensor, the pre-calibration capabilities allow operators to store calibration data digitally, saving significant time on in-field calibrations and sensor swapping.

The SE625 offers an ideal solution for conductivity measurements in SWAS. The sensor is engineered for high-purity water and steam condensate applications. Excelling in accuracy in very low conductivity ranges, the SE625 is the ideal choice for detecting trace contamination in ultrapure boiler feedwater and condensate. This is extremely important for SWAS, where even trace contaminants can lead to corrosion and fouling within process infrastructure.

Water temperature in SWAS is also dangerously high. Consequently, steam water analysis systems typically require sample cooling before the media can be measured. Operators cool the process media before it reaches the pH and conductivity measurement stage to avoid any damage or inaccuracy from volatile temperatures. M4 Knick provides full sample conditioning panels to meet these needs. Operators can tailor M4 Knick’s solutions to their needs, whether they require a full panel or individual components such as coolers, resin columns, or pressure and temperature valves.

Optimize Your SWAS Workflow with M4 Knick

Accurate pH and conductivity measurements are fundamental to maintaining water chemistry integrity in steam water analysis systems. These parameters serve as early indicators of contamination, corrosion risk, and system inefficiencies. Therefore, their reliability is critical to plant safety and performance. However, without proper sample conditioning, high temperatures and pressures can compromise both sensor function and data accuracy. By integrating robust sample conditioning systems and accurate, reliable sensors, operators ensure that the process media remains under optimal conditions.

For more useful information on M4 Knick’s solutions, consider scheduling a training to become more familiar with how these solutions can benefit your team and your process.