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BOILER PERFORMANCE TESTS

Boiler Efficiency

Care shall be taken to maintain the losses to practical minimum and as far as possible,
the original design values for input, such as C.V. of fuel, % excess Feed water
temperature etc., shall be maintained.
The following sources of loss from the boiler shall be taken
into account:
a. Heat leaving through flue gas going to stack,
b. unburnt fuel (specially liquid fuels),
c, heat contained in moisture formed by burning hydrogen and
d. radiation and convection losses etc.
The following two acceptable methods, as described in
ASME Codes shall be use to calculate the Boiler Efficiency:

a. Input – Output Method :

Heat Absorbed by Working Fluid (i.e., output)


ηb = ------------------------------------------------------- × 100
(Heat in Fuel + Heat Credits) (i.e. Input)

b. Heat Loss Method :

Heat Losses
ηb = 100 - { [ ---------------------------------- ] × 100 }
(Heat in Fuel + Heat Credits )

III.6.2.2 Data Collection and Efficiency Calculations

The unit operating parameters shall be fixed for performance test, based on
guaranteed values (Steam Pressure & temperature, rate of blow down, Air to fuel
ratio, fuel heating value, % excess air, feed water temperature etc.). If there is an
unavoidable deviation, it shall be considered in the calculation.
With the assistance of Operations staff, E&S staff will
measure the following data needed for the Boiler efficiency (ηb)
calculations:

a. Steam pressure at S/H outlet


b. Steam Temperature at S/H outlet
c. Steam Drum Pressure
d. Water Temp. entering Economizer
e. Saturated steam flow to Auxiliaries
f. Superheater (S/H) steam flow
g. Feed Water (F.W.) flow to Economizer
h. F. W. flow to Desuperheater
i. Fuel flow rate
j. F. D. fan power

Laboratory shall provide the fuel heating (calorific) value & relative
density of fuel and the flue gas analysis (%by volume of CO2, CO, O2 and N2).
The steam-water specific enthalpies for the following shall
be obtained from standard ‘Steam Tables / Chart’:
a. Drum saturated liquid
b. Drum saturated steam
c. S/H Steam
d. Economizer feed water
Mass / Heat balance calculations for the Unit shall be made to
ensure all the values are OK and also their reproducibility shall be checked.
The input and output energies and efficiency shall be computed using
equation (1) above for Input –Output method, as indicated below (per Hour basis ):
a. Input Energy (Million BTU)
= [Mf ×35.3147 × C. V. ×10-6] + FD Fan power × 3.412

b. Output Energy (Million BTU)


= [(MS/Hst × hS/Hst + Msat × hsat - MFW × hFW) / 1.055] × 10-3

c. Efficiency = Output Energy / Input Energy

Where :

1. FD Fan Power = Forced Draft Fan Power , MW


2. C.V. = Calorific value, BTU/SCft
3. hFW = Feed Water Enthalpy, KJ/Kg
4. hsat = Saturated Steam Enthalpy, KJ/Kg
5. hS/Hst = Super Heated Steam Enthalpy, KJ/Kg
6. Mf = Fuel Flow Rate, Nm3/hr
7. MFW = Feed Water Flow Rate, m3/hr
8. MS/Hst = Super Heated Steam Flow rate, Ton/hr
9. MSat = Saturated Steam Flow Rate, Ton/hr
Using the ASME test form for abbreviated efficiency test, heat loss through the
following sources shall be computed:
a. dry gas
b. moisture in fuel
c. moisture from combustion of H2
d. combustion refuse
e. radiation / convection
f. H2O in Air

Utilising the data computed, the Boiler efficiency shall


again be calculated using equation (2) above. This mode of calculation is
preferable, as any error in the computation of losses will not affect the efficiency
calculated significantly.

The calculated Boiler efficiency shall be compared with the acceptable / guaranteed
values, given in Page 11. In case of deviations, the same shall be discussed with
recommendations. These values shall be plotted over time to monitor the ‘Boiler
Performance’ with time.

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