Performance assessment using test instruments

Role of instrumentation & up-gradation for correct

assessment

Case studies on Boiler & AH Performance

Testing

- A.K.Arora
The Diagnostic Tests

Clean Airflow Tests

Dirty Airflow Tests
Iso kinetic Coal Sampling
PA Flow Calibration
Secondary Airflow Calibration
Furnace Exit HVT Traverse
Air In-Leakage survey
Insulation survey
Furnace temperature survey
Flue Gas Flow Measurement
Boiler Efficiency Tests
AH Performance Tests
Boiler Tuning & Optimization
 Test Locations in a 200 MW unit

HVT traverse
from four points
2X10X2 points

Sec air traverse on

each side
8X5X2 points
AH Inlet Test grid
6 X 4 X 2points

AH Outlet Test grid

HVTPri
traverse from 6 X 4 X 2points
air traverse
four
4 Xpoints – 2 on
8 in each mill
each side
HVS Sampling
6 X 3 X 2 points
Mill Discharge Pipes
2X4X6 Clean Air
ID Discharge Ports
2X4X6 Dirty Air
6 X 4 X 2 points

Coal samples from inlet chutes of all running feeder

 Clean Air Testing

Clean Air Pitots

Clean  Air:  Air  going  through  the  fuel  lines,  at  normal  operating
temperatures and pressures; Mill motor may or may not be running.

Clean air velocities are indicative of the ‘transport’ energy in the pipes.
 Purpose of Clean Air Testing

• Clean Air Testing is Performed to:

– Establish similar system resistance for each burner line on a
balanced air flow basis.

– Provide a correlation between fuel line “dirty air” and clean

air velocities

– Clean air balancing is an integral part of air to fuel ratio

balancing which incorporates air, as well as fuel balancing.

– To ensure the minimum fuel line velocity is maintained after

optimization of primary air flow to improve flame stability at
lower loads and reduced fuel line plugging.
Performing Clean Air Test

1. Install two test ports, 90° apart, per pipe preferably

in a vertical run between five and ten diameters
downstream or upstream of the nearest obstruction
(elbow, orifice plate, flange, isolation value)

Clean Air Test Taps
90º apart
Performing Clean Air Test

2. Traverse points on the Pitot tube are marked on an equal area

grid in accordance to ASME Performance Test Code for
traversing circular duct.
Performing Clean Air Test

3. A 10" vertically inclined

manometer is set up on
a level and stable
location. Clear tubing is
attached to the correct
taps on the Pitot tube
and the manometer.

4. Prior to inserting the

Pitot tube, ensure
the incline
manometer is level
and “zeroed”.
 Performing Clean Air Test

5. Insert the Pitot tube to FLOW

the first mark with the

pointer directed into the
flow and observe. Allow
the incline manometer
indication to stabilize,

Pressure
Static
then record and move
to the next point.
Total Pressure
Repeat this process for
all (12) traverse points Static Pressure

on both ports.
10” Incline
Manometer
 Performing Clean Air Test

6. After traversing both ports, static pressure & Temp is

measured using a digital or “U-tube” manometer
connected to the stainless tube by a single piece of
clear tubing.

Point where the  Point where the Temp. 
Static Pressure  Reading is Taken inside 
Reading is Taken  the Fuel Line.
inside the Fuel 
Line.
 Iso-kinetic Coal Sampling

• Dirty Air: Air and fuel mixture going through the mill discharge pipes
• Isokinetic: When the velocity of dirty air entering the collection nozzle
is equal to the velocity of the flow in the fuel line

24 m/s 30 m/s 19 m/s

24 m/s 24 m/s 24 m/s
Iso‐Kinetic  Super Iso‐Kinetic  Sub Iso‐Kinetic 
Sampling Sampling  Sampling 
The  particles  The  particles  are  The  gas  velocity  is 
flow  into  the  pulled  into  the  less  than  the 
sampler  at  the  sampler  at  an  sample  rate 
same rate as the  higher  rate  than  allowing  fines  to 
coal  is  flowing  the  pipe  velocity  escape.
through the pipe (more fines)
 Why Perform Dirty Airflow & Isokinetic
Coal Sampling?

To:

• Ascertain relative pipe-to-pipe fuel balance

• Quantify pulverizer air to fuel ratios
• Quantify individual fuel line velocity and airflow
• Ascertain pipe-to-pipe airflow balance
• Quantify fuel line temperature and static pressure
• Obtain representative fuel sample for coal fineness
analysis
 Three Steps to Isokinetic Sampling

• In all the isokinetic coal sampling process is a

three step process.

1. Determine static pressure and temperature in

fuel line.

2. Determine velocity pressure.

3. Finally extract an isokinetic coal sample

 Performing a Dirty Air Test

1. Install minimum two test ports, 90° apart, per pipe

in a vertical run between five and ten diameters
downstream or upstream of the nearest obstruction
(elbow, orifice plate, flange, isolation value)

Dirty Air Test Taps

Clean Air Test Taps
90º apart
Arrangement of test connections is based
on these guidelines below

No. 1 No. 2 No. 3

10 Diameter Upstream 5 Diameter Upstream 2 Diameter Upstream
5 Diameters Downstream 2 Diameters Downstream 1 Diameters Downstream

The  overall  length  “x” from  fuel  line  to  ball 

valve should be ±1/8” from pipe  to  pipe  for 
max.  productivity  of  test  team  (to  avoid 
difference in probe marking)
1 ¼” NPT Full Port Ball Valve  

½” Half  Coupling  with  ½” Plug  or 

minimum  drill  and  tap  pipe  with 
½” NPT plug
Static Pressure & Temperature Probe

1 ¼ Full Ported 
Ball Valve

Dustless Connector

Type “K”
Thermocouple Lead 
and Digital 
Thermometer
Static Tap and 
Connection 
Digital 
Manometer

Coal/Air Mixture
 Dirty Air Probe
1 ¼” Full Ported
Ball Valve

Dustless Connector
Dirty  air  velocities  must  be  Dirty Air Probe

measured  in  each  fuel  line  to 

establish  proper  sampling  rate  (∆P) 
for  the  isokinetic  sampler  and  to  Pointer
Denotes HP
determine airflow in each fuel line.   Side

LP Connector
HP Connector

Coal/Air Flow

Inclined Gauge Oil

M anometer
Sampling in Vertical Pipes only
 Use of Isokinetic Coal Sampler
1 ¼” Full Ported
Ball Valve

Pointer Denotes
Dustless
Sample Tip
Connector
Location
HP
Connection
Orifice
LP
Assembly
Connection

Reinforced
Tubing
To Air Supply

Filter Canister
Assembly
Coal
Flow Cyclone
Separator

Sample
Container

Test Cart
 Sieving Coal Samples

Determine sample weight in

each of the sample bags, record
on the data sheet and perform
fineness analysis on all coal
samples.

Place 50 grams of coal on

stacked 50, 100, 140 and 200
mesh sieves and shake for 20
minutes
Plotting Coal
Fineness
Results on a
Rosin and
Rammler Chart
S Type pitot or Forward/Reverse Probe
Primary Air or Secondary Air Duct Traverse
Digital Thermometer
10” Incline Manometer
Digital Manometer or U‐Tube

Storm Forward Reverse velocity probe

Duct
 Test Equipment

Flue Gas Analyser

Gas Sampler Conditioner
 High Volume Sampler

This sampler uses 2-3 ksc air through

an aspirator to create vacuum to pull
a large volume of flue gas & ash into
probe’s canister; A filter catches the
ash but allows gas to pass through.
Flyash Sieve / LOI Analysis

PLACE 20 GRAMS OF ASH ON 
STACKED 200 MEASH AND PAN AND 
SHAKE FOR 20 MINUTES.
DETERMINE UNBURNT OF RESIDUE 
ON 200 MESH SCREEN AND IN PAN
Higher Unburnt in the pan indicates 
Air distribution problems while 
higher Unburnt in the sieve would 
indicate milling system problems
 Furnace Exit HVT Test

Furnace High Velocity Traverse (HVT) is a

diagnostic test for the following.

1. Quantifies furnace exit gas temp (FEGT)

2. Ascertains furnace temperature profile
3. Quantifies furnace oxygen level
4. Ascertains furnace oxygen profile
HVT - High Velocity Thermocouple Probe
Furnace Temperature Mapping using IR Gun

Furnace Temperatures - 209 MW, Mills ABDE

HVT 1145

FF 1273

EF 1230

DE 1203

CD 1175

AB 1150

AA 1163

1000 1100 1200 1300

Boiler & Air Heater Tests
Tests to be conducted under defined operating regime (O2
level / PA Header Pressure / no. of mills) at nominal load
 Boiler Efficiency Testing

– Ambient Conditions (Wet and Dry Bulb 
Temperatures)

Flue Gas 
Raw Coal  Measurements 
Ultimate Analysis  (Temperature, 
& HHV Oxygen, CO)

Average Air 
Inlet 
Temperature

Flyash & Bottom 
Ash Analyses (UBC)
Test Locations - AH Inlet & Outlet

• Inlet Sampling plane to be as close to AH as possible; Outlet grid

to be a little away to reduce stratification
• AH hopper / Manhole air ingress can influence test data

FG
Expansion
Bellow
Economizer

APH
Sampling
APH Locations
FG
Equal Area Traverse Grid Sampling For Rectangular
Ducts

DEPTH

DEPTH /4

DEPTH /8

WIDTH /12 WIDTH /6

WIDTH

NOTE: IT IS IMPORTANT TO HAVE A SUFFICIENT NUMBER OF SAMPLING

POINTS FOR REPRESENTATIVE MEASUREMENTS. THE DIMENSIONS
ON THE SKETCH ABOVE MAY VARY DEPENDING ON THE NUMBER
OF TEST TAPS REQUIRED DUE TO SIZE OF DUCT BEING TESTED.
Pre Test Stabilisation Period

Prior to the test run, equipment must be operated at steady

state conditions to ensure that there is no net change in
energy stored in steam generator envelope.

Minimum Stabilisation Time - 1 hour

AH Inlet Test Grid Multi Point Sampling Probe
 Pre Test Checks

• Sootblowing completed at least one hour before start of the test

• Steam coil air preheaters’ steam supply kept isolated
• All FW heaters in service with normal levels, vent settings and with
normal drain cascading
• No sootblowing or mill change over during the test. In case oil guns
are used, the test shall be repeated
• Air heater gas outlet dampers are modulated to ensure minimum
opening of cold air dampers to mills
• Auxiliary steam flow control kept isolated or defined during the test.
• CBD / IBD blowdowns kept isolated for the test duration
• Bottom hopper deashing after completion of test and not during the
tests
Test Duration

Should be sufficient to take care of deviations in parameters

due to controls, fuel variations & other operating conditions.

When point by point traverse of Flue gas ducts is done, test

should be long enough for atleast two traverses.

In case of continuous Data Acquisition System & use of

composite sampling grids, shall be based on collection of
representative coal & ash samples.

Could be 1/2 to 2 hours in case of parametric optimisation

tests or 4 hours for Acceptance Tests.
Frequency of Observations

Parameter readings to be taken at a maximum interval of 15

minutes & a preferred interval of 2 minutes or less
Flyash Sampling

• Flyash is collected in several hoppers as Flue Gas goes

to stack; Heavier particles fall out first due to turns in
gas stream
• Relative distribution of ash to various hoppers is not
accurately known
• Preferred way to collect a) a representative sample b)
sample of the test period is to use High Volume
Sampler probes on both sides of boiler
 Bottom Ash Sampling

• Bottom ash samples are collected every 15 minutes from the

scrappers system during the test

• In case of impounded hoppers, incremental samples are

collected from bottom ash hoppers’ disposal line at slurry
discharge end

• Unburnt carbon is determined as LOI (Loss on Ignition)

Test Ports ID Discharge Traverse
Role of instrumentation & up-gradation
for correct assessment
Accurate process feedback

• Representative location
• Sufficient no. of sensors
• Periodic Calibration
• Upkeep & maintenance
• Availability of spares
• New tools & techniques
 Air Heaters

• Thermocouples for flue gas

temperatures at AH inlet as
well as exit are generally
clustered on one side.

• Thermocouples for SA
temperature measurement at
AH outlet are mounted too
close to air heaters and
need to be relocated
downstream to avoid duct
stratification.
 Air Heaters

• Thermocouples for PA
temperature measurement at
AH outlet are mounted in a
row and need to be relocated
across the gas duct.

A grid survey is needed for representative values.

Effect of location on process feedback
Typical temp profile at Air heater Outlet
3 112 115 123 127 131 136 3 136 135 121 121 110 105
2 112 114 122 126 131 136 2 133 134 121 120 110 103
1 110 114 120 124 130 135 1 133 132 119 120 109 102
A B C D E F A B C D E F

Avg value: 123 C (110 – 136) Avg value: 120 C (102 – 136)

Temp profile at AH outlet-R Tem p profile at AH outlet-R

S3 130-140 130-140
S3
Temperatu 120-130 Tem peratu 120-130
S2 S2
re re
110-120 110-120
S1 S1
1 2 3 4 5 6 1 2 3 4 5 6 100-110
100-110
Sampling ports Sampling ports
Effect of air ingress, stratification, duct design

Variation of Oxygen in Flue gas and its temperature

in common ducts after Air heaters
 Effect of Accuracy on Heat Rate
Probable reasons: MS Temp (0-600 degC)
Accuracy Change in Effect on
• Drifting (%) Temp HR
• Calibration (degC) (Kcal/Kwh)
• Improper mounting 0 - -
• Pri/secondary instru. 0.2 1.2 0.768
• Process condition 0.4 2.4 1.536
• Process layout 0.6 3.6 2.304
• Representative location 0.8 4.8 3.072
• Insufficient sensors 1.0 6 3.840
 Impact of air-in-leakage on O2 reading

Gases 1% dilution 5% dilution

CO2 -0.7% -5.2%

H2O -1.3% -5.6%

SO2 0 0

O2 +5.7% +19.5%

N2 0 +0.3%

CO -1.0% -5%
 O2 Stratification at APH Inlet FG Duct

7
7-8
6
% 6-7
5

5-6
4
S3
S2 3 4-5
E F
S1 C D
A B
3-4
Probe
 Temperature Stratification in APH Outlet
FG Duct (Trisector Air heater)

170

160
Temp C

150

140 160.0-170.0

130 S3 150.0-160.0
A B
S2

C 140.0-150.0
D E
S1

Probes F
130.0-140.0
Flue Gas Temperature at AH outlet

Flue gas temperature as measured in common ducts leading

to ESPs in 500 MW units is more representative than weighted
averages of temperatures measured at individual AH exits.
Flue Gas Temperatures C
T3 T4 T9 T 11 T 14
PAPH A Outlet 142.7 133.2 145.7 139.1 139.9
SAPH A Outlet 132.5 133.1 139.8 138.1 137.0
Eqv. Temp A side 135.9 133.1 141.7 138.5 138.0

Grid Average Left 141.8 146.5 147.3 144.1 143.6

PAPH B Outlet 142.2 134.5 143.9 137.9 149.5

SAPH B Outlet 135.9 132.4 139.6 136.2 143.2
Eqv. Temp B side 138.0 133.1 141.0 136.7 145.3

Grid Average Right 144.0 147.5 149.9 148.4 150.4

 Flue Gas Composition at AH outlet

Flue Gas Oxygen plotted probe wise to show the variation in

values across the duct; A minimum of two zirconia probes
are required to get complete duct coverage

Variation of FG O2 in left and right FG ducts at ESP inlet in

Tests 3,4,9
7

6
O2 %

4
T3 T4 T9

3
A B C D E A B C D E
 It’s worthwhile to re-look at all the
instrumentation around Air heaters for air
temperatures / Flue gas composition &
temperature measurement.

The unit operation, equipment efficiency

assessments and maintenance decisions are
based on the same.
Optimised Boiler

~ Design

1
.

THANKS