c2) United States Patent Booher (10) Patent No. 5) Date of Patent US 6,928,937 B2 Aug. 16, 2005 (51) SOOTBLOWING CONTROL BASED ON BOILER THERMAL EFFICIENCY OPTIMIZATION (75) Inventor: Joe H. Booher, Cansl Winchester, OH us) (73) Assignee: Diamond Power International, Ine., Lancaster, OH (US) (7) Notice: Subject to any disclaimer, the tem ofthis patent is extended or adjusted under 35 US.C. 154) by 0 days Appl. No. Filed: 10/739,888 Dee. 18, 2003 Prior Publication Data [Us 2000159270 AL Avg, 19, 204 Related U.S. Application Data (60) Provisional application No. 60436519, fled on Dec. 25, ne Im. CW? 1238 7/00 O34; 110/341; 110343 1108341, 348, 186, 188, 190, 122/379, 300, 302 5) References Cited US. PATENT DOCUMENTS. BAGRISH A 12/1964 Canter’. 3257.03 A * 6/1966. Kocke, I 122392 327437 A * 1001966 opachin ea 122392 $088.38 A 41978. Ber Sw A OOS Klatt 4718376 A 1/1988. Lerouel ta A191 Archer ea A 992 Caner eta ‘903 Late ea ‘OTHER PUBLICATIONS LeVer, et al, “A, Siag Deposition Monitor For Use in Coal-Fired Boilers”, Sensors Expo Proceedings, 1986. LeVert, ct a. “Slag Deposition Monitor For Boiler Perfor mance’ Enhancement", ISA’ Proceedings, 1987, Paper 87-1048. Frank, et al, “The Elects of Soot Blowing On Boiler Tube "Thermal Stress", American Power Conference, 1988. Alder, et al, “Optimization of Automated Sootblowing ‘Through On-Line Boiler Heat Balance Modeling”, Power- Gen Conference, 1991 CComte7, etal, “Thermal Modeling of Absorbed Heat Flux ‘Meters inthe Furnace Walls of a Coal Fire Uslty Boiler, pp. 39-46 Farell, et al, “On-Line Monitoring of Furnace Wall and Superheater Corrosion in Power Generation Boilers", 39 Corrosion Scieace Symposium, U.K., 1998 Farell, et al, “Performance Mapping of Industial Plan ‘Using an Electra! Resistance and Thermal Seanner", Euro- Cort 2000 Conference, London, U.K, 2000, Energy Technologies, ne, Knoxville, TN. “Boller Sensors Increasing Boiler Efficiency", pp. 1-7. Batell, Columbus, OH; CEGB, Nottingham, England; “Slag. Monitoring or Usility Boilers", CS-S692 EPRI Research Project 1893-5, Ape, 1988. reels etal, “On-Line Controllable Perameters Monitoring, For Heat Rate Improvement,” Richmond, Virginia (May 11, 1988), * cited by examiner Primary Examiner—Keowetb Rinebar (74) Attorney, Agent, or Firm—Brinks Hofer Gilson & Lione 6 ABSTRACT ‘The present invention provides a process for the control of 4 cleaning system for a boiler which incorporates factors related o the overall operation and ellcieney ofthe boiler Curtent values of plant data parameters associated with the boiler furnace are compated with respective seipoiat values The process thea determines ifthe furnace isto be cleaned, based on this comparison, 8 Claims, 2 Drawing SheetsU.S. Patent Aug. 16, 2005 Sheet 1 of 2 US 6,928,937 B2 a RETRIEVE CURRENT, SETPOINT VALUES OF KEY VALUES FOR PARAMETERS i=14,2...N FOR i=1,2..N 14 ois (CURRENT VALUE};| {SETPOINT VALUE}i| 1g VALUE), WAIT FOR 20 . IGHT PREDETERMINED =OiX (Factor), TIME PERIOD FOR i=1,2...N 7 OVERALL, PERMISSIVE VALUE eee ‘WEIGHT’ [ax (PacTOR i 22: DETERMINE LOCAL AREAS 2g] OF FURNACE TO CLEAN Fig. 1US 6,928,937 B2 Sheet 2 of 2 Aug. 16, 2005 HIE U.S. Patent BAISSINYAd WSLSAS TIV43A0_ u ooze Xe ‘g6zz 41933 LHORE L ‘ooze X< zee, 1934 1437 U 00E. Xe 7689 ‘avo SUSLSWVUVd JAISSINYAd WNOLLVUSdO Bz Es BAISSIN Sd SLWe LV3H TWESAO WOBHO SLVY LV3H TVESAO, MOTs AVUdS LV3HSY MOT AVES LVBHUAENS WLOL MOTS AvudS LVSHYSINS HLNOS. MO AVedS LVSHYSdNS HILSON SS BUNLWYIGWAL WV3LS NIV HLNOS: BUNLVYSIWSL WVALS NIVW ISON ¢OLOVS LHOISMUS 6,928,937 B2 1 SOOTBLOWING CONTROL BASED ON BOILER THERMAL EFFICIENCY OPTIMIZATION RELATED APPLICATION ‘The application elaims the benefit ofthe filing date under 35 US.C.§119(e) of Provisional US. patent application See. No. 601436,519, filed Dee. 26, 2002, which is hereby incorporated by reference BACKGROUND ‘This invention relates wo a system for controlling cleaning ‘equipment of large scale boiler or other combustion device In the operation of large scale combustion deviees, such 8 uly boilers, combustion products cause slag and ash ‘encristations to build on beat transfer surfaces, degrading the thermal performance of the system. In order to restore the thermal performance, various systems for cleaning the internal heat transfer surfaces are presently in use. ‘One type of cleaning system is referee 0 in the industry as soahlowers, Sootblowers are used fo project a stream of | ' blowing medium, sich as steam, ‘exchanger surfces within the combustion device. One type fof sootblower is known as along relrcting type and incomporates 3 lance tube, which is periodically inserted into and withdrawn from the interior ofthe boiler. Nozzles at the disial end of the Lance tube project «stream ofthe cleaning tedium agains the desired surfaces within the boiler. Wall blower units are mounted 4 the outside wall of the boiler and project a steam of cleaning uid through a wall port agains surfaces within the boiler. Some of these devices use 4 Tanoe which i not inserted into the boiler and is ‘capable of articulating to aim is steam of Bid in a desired ‘manner within the bole interior. Irrespective of the cleaning mechanisms used, it i nee ‘essary To contol theie operation s0 that they ate not operated needlessly. The introduction of the steam, ar, of wale into the boiler for leaning often has undesiable thermal eff- ciency effets. Moreover, thir use for suefices which do not need to be cleaned can cause physical damage to these interior boiler components. Accordingly, some mechanism i necessary t0 control the operation of boiler cleaning devices. A boiler may have dozens or more individually ‘contolled sooiblowers or other cleaning devices Tis known to use various boiler operating parameters to activate the cleaning cycles of the boiler cleaning systems. One approach uses infrared cameras which evaluate the internal surfaces of the boiler. Since the walls which are ‘costed with ash have a dlfeeat reflectivity Facto than other surfaces, this dillerence may be used as a means of mea ‘suring the development of slag and ash enerustaions a8 a input for initiating a cleaning cycle, Heat ux sensors are also used which are placed within the heat transfer surfaces ‘of the boiler and evaluate the difference in temperature between the wall surface and the process heat transfer uid (ypically water). degeadation in heat transfer is measur able as difference in the temperature reading from these ‘wo thermocouples. Again, this output may be used as part ‘of a boiler leaning control system. Boiler cleaning may also be initiated on timed cycle, based on certain assumptions regarding the development of slag and ash encrustations overtime, Tiler cleaning systems which base their contral deci sions on the characteristics of selective surfaces do. 201 s 2 ‘comprehend the full impact of cleaning operation on the boiler plant operation From the above, itis seen that there exists a need for a leaning system that coattols the timiag of the clesaing process lo optimize the overall boiler elliceney. SUMMARY OP THE INVENTION Tn overcoming the above mentioned and other drawbacks, the cleaning system in accordance with the present invention provides a methodology for the control of the cleaning System for a boiler which incorporates factors related to the ‘overall operation aod eliciency ofthe boiler. The operation of the system in accordance with this invention is expected to result in cleaning operations being delayed, even where surfaces to be cleaned are ordinarily consisered in need of| cleaning. In some implementations, the method includes receiving plant dats of parameters associated with the furnace and ‘comparing current values of the parameters with setpoint valucs. The metlod thea determines whether to clea the furnace based on the comparison between the current values and setpoint values of the parameters, ‘When comparing the cusrent values tothe seipoint values fof the parameters, the method may consider how the devia- ‘ion ofthe current values from the setpoint values affects the ‘heemal efficiency af the steam cycle of the furnace, ‘The comparison between the current values and the respective setpoint values may include determining, the difference between the curtent values and the respective setpoint values. The product of the difference and a eorre- sponding weight ctor may poi a espestve permissive a certain implementations, a postive permissive value inlcaes cleaning the furnace would ineresse the efiiency fof the thermal cycle, and a negative permissive value inlcates lesning the fumace would deerese the eficiency of the thermal eycle. In particular implementations, upon ding the permissive wales, a postive sum indicates that the furnace isto be cleaned ‘The parameters considered may include the superheat steam temperature andthe reheat steam temperature. Other parameters considered may include the amount of attem- peration spray flow being injected into the main steam and the relat steam fo contro the supeseat steam temperature and the rebeat temperate Funber advantages and features of the invention will become apparent Irom the following deailed description and fom the claims. [BRIEF DESCRIPTION OF THE DRAWINGS ‘The accompanying drawings, incorporated in and forming 4 part of the specification, illustrate several aspects of the ‘resent invention and, together withthe description, serve to explain the principles of the invention. The components in the figures are not necessarily to scale, emphasis instead being placed upoa ilistrating the principles of the inven- tion, Moreover, in the figures, lke reference numerals Sesignate corresponding parts throughout the views, In the deawings: FIG. 1 is a How diagram of a sequence of steps for determining whether or not to elean a boiler in aecordanee with the invention; and FIG. 2 depicts a page of a spreadsheet analysis of key parameters associated wit the cleaning of » furnace in sccordance with the process shown in FIG. 1US 6,928,937 B2 7 DETAILED DESCRIPTION The cleaning system utilizing this invention takes ‘curent values of plant data and makes a decision about ‘whether (0 clean the furnace at all, a8 well as which local areas in the furnace shoul be cleaned. The general decision ‘on whether to clean is based on a comparison othe curent ‘value of key parameters of the plant data to their setpoint values, including, in some implantations, cleanliness mea- sires. The key parameters selected for analysis are those which furmace cleaning will affect, including the ‘superbeat steam temperature, the ht reheat temperature, and the amount of attemperation spray How being injected 10 ‘contol these temperatures. Ia the comparison of the eureat ‘values ofthe parameters theie setpoint values, the systom ‘of the present invention considers how this evition affect the thermal efiieney ofthe steam eycle (ie the “heat eate™ ‘of the plant, For a typical electric generating boiler utilizing a steam ‘drum and operating at pressures below the critical point, ‘leaning the furnace reduces the gas temperature leaving the furnace and entering the superheat and reheat sections. Therefore, asthe Furnace is cleaned, there willbe less heat transfer inthe superbeat and rebeat sections. In some eases, this reduction in heat transfer is a positive factor for the thermodynamic balance of te boiler, while in some cases, itis actually © negative factor. Inthe negative instance, i ther the supecheat or reheat temperature is below design specifications, furnace cleaning would further reduce the temperature, hurting the efficiency of te boiler. In other cases, the uncontrolled superheat or reheat tem- perature may be above design specifications. In such eases, plant components exposed to these high temperatures may he damaged. Therefore, attemperator spray fw is typically injected into the superheaterorreheater lo lower the respec- tive steam temperatures, Steam atlemperaton spray flow, however, has an undesirable effect on boiler liiency, ‘especially when injected inthe reeater. Therefore, he ideal ‘condition i for the boiler to achieve its design steam, temperatures with litle of no attemperator spray fw. If altemperator spray flow is occuring snd it success ia holding the temperature atthe correct level through flow ‘modulation, thes furnace cleaning will educe the amouat of| atemperation spray flow since the furnace cleaning will lower the steam temperature in place of the attemperation spray flv, Referring now 10 FIG. 1, there is shown, in aecordance with the invention, a process 10 for determining when 10 ‘lean 4 furnace to optimize iis performance. After the process 10 ini ‘Values of the aforementioned key parameters (i. for 2... N, where identifies » key parameter, sich as the ‘perbeat ‘steam temperature, the reheat steam temperature, and the respective allemperation spray flow rates) Meanwhile, black 16 provides the respective setpoint values ‘of these parameters. The seipoiat values are typically the ‘design Values at whic the plant operates most elicently. An ‘operator can also select the setpoint values, for example, through a computer interface. The process 10 then proceeds to step 18 which determines the dtference(A,) between the cutent value and the setpoint ‘value ofeach parameter. Subsequently, step 20 multiples the difference (A,) with 4 respective weighting factor 10 deter- mine a permissive value for each parameter. The heat rate weighting factors for the key parameters are available as industry averages in the Electric Power Research Insitute (EPRI “Heat Rate Accounting Manual,” or unit specie tes in step 12, step 14 receives currents o 4 ‘weighting factors can be generated for improved accuracy. In general, with respect oa particular Key parameter, @ positive permissive value indicates that cleaning the furnace ‘would improve the efficiency ofthe plant, while « negative permissive value indicates that cleaning would hurt the plant etiieney, ‘Next, step 22 adkls the permissive values determined in step 20, The sum of the permissive values provides an ‘overall permissive value, The various inividis! permissive values could ether be positive or negative, The process 10 then proceeds to decision step 24 which determines whether ‘or no to clean the furace. In particular step 24 determines ‘whether the overall permissive value calculated in step 22 is positive or negative. If the overall permissive value is Degaive, the furnice is not cleaned, as indicated in o sep 26. At step 27, the process 10 waits for a time period pre-selected, for example, by the operator. Alter this time perio th process 10 retin to step 14 to rlrive a new sot fof curent values ofthe key parameters and then repeats the aforementioned steps 18, 20, 22, and 24 If the overall permissive value is positive, as determined in step 24, then the furnace isto be cleaned. If desired, the pracess 10 then proceeds to stop 28 which determines which local areas or regions of the furnace are tobe cleaned. Such etermination cin be made through the use of furnace cleanliness sensors distributed in various regions of the furnace. Examples of such sensors include heat Mux and emissivity sensors. ‘Alter the furnace has been cleaned, the process 10 termi es at step 30, Aer atime period selected by the operator, fr automatically by the system, the process 10 may again initiate at step 12 FIG. 2 shows an example ofthe application of the process 10 in sn Excel spreadsheet which performs the heal ra based calculations in accordance with the invention. Init the "Reading" (live current value) is compared to 4 “Set. point” value, and a “Weight Factor” is multiplied by the Giference to gel a “Permissive” value for that parameter, ‘The superheat (or main) steam temperature is measured at ‘so locations (identifled as North and South inthis paricu- lar example), providing an average superheat steam tem- perature of 997.2° F. The setpoint value for the superheat Steam temperature is 995° F_and the weight factor is 1.4 Hence, the permissive value is (1.4)x(997.2-995)=3.1 Similar analysis is made forthe reheat steam temperature, providing a permissive value of ~20.5 The total atemperation superheat spray Now injected into the two superheat regions is 237.1 Kiblhr and the total attemperation reheat spray flow is 36.1. Thus, employing the ‘weight factors and setpoint values shown in FIG. 2, the permissive values forthe atemperation superbeat spray flow land reheat spray How are $5.9 and 56.2, respectively. Then, upon adding the permissive values together, the ‘overall permissive value is 4.6, The overall decision as to ‘whether the optimization prooess wants the furnace to be cleaned is based on whether the overall permissive value is positive, asin the present example. Thus, the overall heat fale permissive is 1, indicating that the furnace i to be leaned, ‘As an example of ow this calculation and subsequent decisions ate of value to the customer, note how the eurtent reheat temperature is actually well below the setpoint value, that is, 980" F. vorsus 995° F. Thus, furnace cleaning aetually huis this parameter but helps the rest It not uncommon tohave boilers that have an excessive reheat lempratire but sirgele to make the setpoint superhea! temperature, o viceUS 6,928,937 B2 5 In some implementations, the optional Operational Per- missive Parameters in HG, 2 are used as configurable ‘comparisons of certain parameters (0 ensure that furnace ‘leaning doesn't occur outside acceptable ranges. If the ‘current value of one ofthese parameters is greater than its Setpoint vale, the permissive value for thit parameter is assigned “I”. Ifthe current value is less than the seipoint value, the permissive value is"=1". In the present example, the current values of the load and the two furnace exit gas temperatures (FEGT) are all above their setpoint values. “Ths, ther permissive values are all setto“1" indicating that furntce cleaning will improve the eliciency of the boiler ‘with respect to these parameters. Of course, adding these permissive values provides a positive number, and therefore the overall operational permissive value is set to “1”. Since both te overall heat rate permissive and the overall, ‘operational permissive are positive, them the overall system permissive Value is also set to "1" That is, based on the ‘current operational data of the furnace, the optimizatio process in accordance with the invention determines thatthe furnace is to be cleaned, since doing so will improve the ‘overall effcieney ofthe plan. tis therefore intended that the foregoing detailed descrip tion be regarded as lustrative rater than limiting, and that ithe understood that it isthe following elsims, including all ‘equivalents, that are intended to define the sprit and seope ‘of this invention, ‘What is claimed is 1. A method for determining when a furnace is to be ‘leaned, comprising: receiving current values of a plurality of parameters ‘associated with the performance of the fumace; ‘comparing the current values of the parameters with ‘espoctive setpoint values of the parameters, the com paring considering fiow the deviation of the current values from the setpoint values alfects the thermal cilicieney of the steam cycle of the furnace, the com paring including determining the difference between the current values of the plirlity of parameters with the respective setpoint values and further including elcrmining a permissive value for each ofthe plurality of parameters, each permissive value being the product fof 4 respective difference and a corresponding Weight factoe, and determining whether to clean the furnace based on the ‘comparison between the current Values and seipoint values of the parameters 2. The method of claim I wherein a postive permissive ‘vale indicates that cleaning the furnace would increase the 6 tliceney of the thermal eyele, and a negative permissive value indieates tbat cleaning the fumace would deerease the eliceney of the thermal eye. 3. The method of claim 1 further comprising adding the permissive values, wherein the determining wheter t clean Secidles to clean the furnace ifthe sim of the permissive values is positive, 4. The method of claim 1 wherein the plurality of param- ers includes a superheat steam temperature '. The method of claim 4 wherein the plurality of param= eters includes a ceheat temperature. ‘6. The method of elaim S wherein the plurality parameters includes an amount of atlemperation superheat spray flow being injected into the superbiat steam 16 coatrl te super beat steam temperature and an amount of attemperation heat spray flow being injected into the reheat sleam to control the reheat temperature 7. A method for determining, when a fumace is t0 be leaned, comprising: receiving current values of a plurality of parameters ‘ssocited withthe performance ofthe fumace; subiracting respective setpoint values from the current values of the plurality of parameters; ‘multiplying the dllference from the subtracting by a ‘weight factor to determine a permissive value for each parameter; Adding the permissive values to determine an overall permissive value; if the overall permissive value is positive determining that the fumace isto e cleaned and if the overall permissive value is negative, determining that the furnace isnot to be cleaned, 8. A method for determining when a fumace is to be cleaned, comprising: measuring wit at least one sensor a parameter selected from the group consisting of attemperaioe spray flow, reheat temperatre, and superheat temperature; determining the difference hetween the current value of the parameter with a respective setpoint value; etermining a permissive value for the parameter, the permissive value being the produet of the respective Aiference and a coresponding weigh factor, and ‘optimizing the cleaning of the furnace with a controller on the basis ofthe ofthe permissive valueUNITED STATES PATENT AND TRADEMARK OFFICE CERTIFICATE OF CORRECTION PATENT'NO. : 6,928,937 B2 Page 1 of 1 DATED August 16, 2005 INVENTOR(S) : Joel H. Booher Itis certified that error appears in the above-identfied patent and that said Letters Patent is hereby corrected as shown below: Column 6, Line 48, after “the basis” delete “of the” (first occurrence) Signed and Sealed this ‘Twenty-fifth Day of April, 2006 igre JON W. DUDAS. Divector of the United Sates Patent and Trademark Ofce