January 8, 2012 BOILER FAILURE TROUBLE SHOOTING REPORT By K.K.

Parthiban, Venus Energy Audit System Agenda for visit The FBC boiler was commissioned on 24.06.2007. The following are the problems faced. 1. Right from commissioning, the boiler could not be run on 100% under bed firing. If the over bed firing damper was closed, there was accumulation of husk near the feeder head end resulting in jamming of drag chain. So all the time, about 30-40% fuel was fired from over bed. Boiler is designed for 100% rice husk / 100% Indian coal / Rice husk- coal mix as well. 2. Within a period of 7-8 months of commissioning, various failures in the economizer, super heater & water wall occurred. Bursting of Radiant Super Heater Coils (Mainly Bends), Economizer leakage, Water wall leakage, Erosion of ID Fan Impeller & Bed Coil leakages were experienced. 3. There was no provision for secondary air in the furnace. 4. In November 2010, the following modifications were carried out. a. Modification in the drag chain feeder. b. Provision of secondary air system. c. Changing of all T-22 bends in Radiant Super Heater. d. Replacement of one Super Heater Coil. e. Replacement of PA Fan with higher capacity Fan & Motor to suit Secondary air System. f. All the 78 outer bed coils were replaced. g. The above modification job was taken up in Nov2010 & Boiler was restarted in Dec2010. Immediately after starting, bearing failures of PA Fan started. Four bearings were replaced in presence of manufacturer, but the PA Fan could not run. Impeller of PA Fan was also damaged. New Impeller was changed. Since June 2011, boiler is in operation with under bed feeding. However, the steam generation does not go beyond 18 TPH Flow. Beyond this load, the steam pressure starts falling & furnace temperature rises to the tune of 900 1000 C. Again in Jan11, Economizer leaked. Since Jan 2011, 6-7 times radiant superheater Tubes & bends leaked in both T-22 & T-11. All 32 bends of T-22 were changed in Dec 2010 (With original thickness of 4.5 mm), within 4-5 months, thicknesses of most of the tubes have come down to 3.8 3.9 mm. 5. Further the boiler did not achieve the designed steam generation of 25 TPH till date even after the modification of underbed feed system. About the boiler The FBC boiler parameters are 25 TPH, 65 kg/cm2, 485 deg C and feed water temperature is 105 deg C. The feed water is preheated at process plant and comes to deaerator. The process condensate does not come to boiler. The boiler is provided with Trema cyclone. There is no ESP. The FD fan

and ID fan are with VFD drive. The PA fan is with IGV control damper. The Turbine is an extraction cum condensing turbine of 3 MW capacity. Most of the time, rice husk is used. During rainy days, coal is mixed up to 20 percent and fed through bunker & drag chain feeder. DIAGNOSIS OF VARIOUS PROBLEMS The boiler was inspected as per the plan. All the inspection doors of entire boiler were opened and shown to undersigned. The report below covers the diagnosis of each of the problems. RADIANT SUPERHEATER FAILURE Failed tubes Three failed bends and two straight portion of the radiant SH tubes were available for inspection. The tubes had failed by localized swelling. SH Tubes can fail by external erosion, long term overheating and short term overheating. Long term overheating / short time overheating can occur due to increased metal temperatures. Metal temperatures can be high due to inadequate steam velocity / high gas side temperature & high steam temperature. The failure pattern shows the entire tube is not overheated. The failures are of localized swelling type only. Such a thing can occur only due to carryover of water (with dissolved solids / suspended solids) from boiler steam drum. Carryover marks in steam drum The steam drum was inspected. The following are the observations & comments. The steam drum surface appeared red. The reddishness was due to fine iron dust found in the boiler water / metal surface. The reddish surface comes due to contamination of feed water from pre boiler system. Sometimes it is generated due to boiler water as well, when there is a deviation of boiler water chemistry. The steam space should appear grey, if there is no foaming / priming. Priming is due to high pressure drop in boiler due to which drum level swells and there is carryover of water. Foaming is due to oil content / corrosion particulates from pre-boiler system and / or boiler water system. The baffle box was found tack welded to steam drum instead of complete seal welding. This leads to carryover of circulating water directly to demister. Otherwise all the circulating water is expected to pass through the cyclone separators inside the steam drum. It was seen that the blow down piping and chemical dosing lines were interchanged at site to suit convenience of layout. The blow down pipe is to be arranged below the cyclone to remove high TDS water. The chemical dosing line is located after that so that water to downcomer will be with the right pH.

Carryover instances It was also informed that there had been occasions of boiler water contamination due to oil mix up from process. It was learnt that the oil had come up to turbine due to foaming. It is learnt that that the water is checked physically, at every hour, for presence of oil. There is no organized testing of oil content. It is important to note that oil is not permitted in feed water.

There is no online oil detection system available in the market. Hence we need to remove the possibility of oil mix up permanently in a fool proof manner. Present pre-boiler feed water system At present the treated water with very low TDS and silica (~ 0.009 ppm) is the output from DM plant. This water is stored in an overhead treated water storage tank. The water goes to autoclaves for cooling the oil product through carbon steel limbert coils. It is learnt that the coils cool the oil product once or twice in a day for a period of 1 hr or so. This is a batch cooling process. It is possible that the use of un-deaerated water and air contamination leads to break down of the steel from autoclave. This is seen by the rise in silica & TDS increase in feedwater after the use in process. It is also seen that pH drops when the water returns from autoclave. Organics generally reduce pH on heating. It is learnt that the present DM water storage tank is rubber lined (!) to protect the tank from pH and O2 attack. It is necessary to check the condition of rubber lining. The piping used for boiler make up has to be rubber lined if the DM water is not adjusted for pH at DM plant outlet itself. Ensure the pH is always above 8.5 at DM water storage tank itself. In the case of high pressure boiler with large quantity of makeup, the piping should be of SS material. For room temperature piping HDPE piping can be used up to level control station. It is learnt that the turbine condensate is about 3 TPH only. It means almost 15 TPH is the makeup water. Since there is no process condensate from the plant at all, there is no contamination from process. It is advised to check turbine condensate separately through cation column and with online conductivity meter. In case of condenser leak, there will be low pH in boiler. It causes steel to fracture immediately. Inspection of deaerator & storage tank The deaerator tower is seen with marks of contaminated make up water. See the photograph in annexure. The tank below also shows the dirt mark above the water level. BFP strainer check It is learnt that the strainers at BFP suction are cleaned roughly in two month frequency. It is advised to check whether the iron / oil is present in the choked material in the strainers. Presence of particulate iron content can be checked by a magnet. Presence of particulate iron implies that there is contamination of pre-boiler system. As such the abrupt rise in silica in boiler water confirms that there is contamination. High blow down rate & rise in silica in boiler water At present there is rise in chloride content, silica content in boiler water. In order to maintain boiler water silica at < 3 ppm, the boiler water TDS is maintained at 10 ppm only. Note this is inclusive of the silica, chloride and dosing chemical as well. This is high blow down rate for the boiler with a

good quality feed water. Hence to rule out silica pick up from autoclave, it is advised to stop using this water for autoclave. It is advised to check the colloidal silica in DM water plant outlet water. It is advised to measure the blow down rate from the boiler. This can be done by steel bucket measurement. Chloride contamination is alarming. See the water analysis reports enclosed.

Unused tubes thickness measurement The plant has Modisonic thickness measurement with which the RSH tube bend thicknesses are measured done at every opportunity. It is learnt that wherever the thickness is less than 3.5 mm, the tube bends are replaced. A new bend thickness was measured in my presence. The parent tube thickness was 5 mm and the bend thickness measured 4.1 mm. There is thickness reduction of 18% in the new bend itself. The past readings of thickness measurement were reviewed. The thickness measured at a location is not consistent with previous measurement data. There were some readings in which the thickness had increased between two observations. The measurement error can be there if the tube is not cleaned well and if the probe is not positioned perpendicular to tube axis. This was physically explained with the instrument. Metal temperature & strength of tube bends Originally supplied RSH tubes are of 44.5 dia x 4.5 thickness. With 18% thinning, it can measure 3.69 mm at the bend. When the steam temperature goes high the metal temperature will go high. We can check at what steam temperature the tube would start yielding. See the annexure for a calculation made. Unless & until the steam temperature touches 569 deg C, the metal would not yield at bend. With this, we can say that the tube can weaken, if only there is scale inside the tube. Overbed feeding and high gas temperature at RSH inlet There is no doubt that the gas temperature at RSH has gone up in operation. The RSH clamps are already burnt due to high gas temperature. However for the superheater to fail, there has to be deposit inside. Since all the failed tubes show localized bulging, the failure can be due to carryover only. To avoid burning of SH clamps over feeding must be stopped fully. The boiler maker has not considered the residence time required for burning of fuel in suspension. The height available from fuel feed point to SH is 2.58 m. The furnace volume above bed coil outlet header is 56.38 m3. The residence time will be 0.75 sec. Recommended minimum residence time is 2.5 sec. This is the reason that the steam temperature is uncontrollable, when the over bed feeding is used. Limitation of underbed feeding? The boiler manufacturer has rightly addressed the problem of smaller PA line size and PA fan capacity. They have provided a higher PA head (900 mmWC as against 700 mmWC earlier) & flow of 4.67 m3/s (though 4.07 m3/s is adequate). During inspection by undersigned, it was found that the

PA fan inlet damper was locked at 900 mmWC (as per draft gauge at panel). For husk to go in, there has to be good suction at venturi. This can be achieved only with higher PA flow. In annexure, a photograph is attached, showing the high suction available at a drag chain feeder with high PA pressure. Bed coil heating surface & low bed temperature The boiler is to be working for rice husk & coal. Rice husk contains more volatile matter and is a light weight fuel. About 25% of the heat is released above the bed coil. Coal burns practically inside the bed itself. The bed coil heating surface is generally selected for rice husk with a bed temperature of 850 deg C. This will be 335 m of plain bed coil. We need to select this bed heating surface and operate the boiler on coal with higher bed temperature (925 to 950 deg C) and if required with excess air as well to the tune of 40%. It is seen that the bed coil is studded in 4 x 3 pattern. This is about 35% extra heating surface as compared to plain bed coil (in worn out condition). Overall the present heating surface is about 563 m long plain tube (equivalent). At a bed height of 700 mm itself, 513 m long bed coil gets immersed. The bed coil heating surface is to be reduced for improving the bed temperature. This can be done by covering part of the bed coils with plastic refractory. When the heat transfer is retarded, more inbed combustion takes place. The detail on plastic refractory is given in drawing no VENUS-JVL-2-002. Refractory above the bed and at waterwall The waterwall refractory is required if the boiler is operated purely on coal. With some overbed feeding of husk we can remove refractory party so that the waterwall will take some heat transfer and produce steam. This will reduce the present SH temperature excursion problem. But with overbed feeding the burning of SH clamps cannot be avoided. Stones in fuel & its separation Foreign material is a limitation in underbed feed system. Some customers provide a bar screen at the fuel inlet hopper above the drag chain feeder. A typical photo can be seen in annexure. Drawing number VENUS-JVL-2-001 shows a screen arrangement at feeder, which can be used if there is stone ingress despite the screen in the husk handling plant. Summary& action plan 1. Radiant Superheater tubes are failing due to carryover phenomenon. 2. The incomplete welding of baffle box inside steam drum shall be welded. At the time of visit, it was welded partly. For complete welding, cyclone separators shall be removed to create access to complete remaining welding. 3. The DM water tank rubber lining condition shall be checked. If not available FRP lining / rubber lining shall be done. 4. The DM water pH shall be boosted at DM plant outlet itself. Morpholine must be added at DM plant outlet itself. 5. The autoclave cooling arrangement by boiler feed water shall be dispensed with completely. It

may be used in low pressure boiler. 6. The blow down piping & HP chemical dosing pipes are to be interchanged to improve boiler water chemistry. 7. The PA header pressure shall be increased to 1100 mmWC and above, as required, to avoid PA line choking. 8. Refractory height can be reduced as the overbed feeding would be required at times. 9. Bed coil shall be applied with plastic refractory as per drawing enclosed. At present this refractory has to be applied insitu. When new bed coils are procured, the refractory shall be applied before tube fitment to position. The plastic refractory information is attached in annexure. 10. Superheaters are not weakened yet. Replacement of bends can be planned after the drum returns normal with recommended water chemistry. The water chemistry for 66 kg/cm2 cycle is enclosed in annexure.

WATERWALL FAILURE In the year 2009, there had been two failures in waterwall. The tubes were not available to seen the type of failure. In general, if boiler water is contaminated with oil / grease, there will localized swelling and burst of tubes where there is high radiation heat transfer. At the time of inspection, the boiler tubes are seen free of hardness / silica scales. Some fin weld failures are possible during commissioning. This is due to weld quality.

BED TUBE FAILURES Two failed tubes were inspected. They exhibit external erosion in a localized fashion. On inspection, it is seen that some coils are eroded externally and locally. Stone ingress & localized erosion With overbed feeding, the stones do not get spread. They fall locally near the fuel feed point. Since the overbed feed opening is on right side waterwall, the right side bed coils will suffer erosion as the amount of stones increase. There is a phenomenon of char in case the husk falls in excess of requirement. The husk will char locally over the bed tubes. But only on high accumulation, there will be erosion by air / flue gas from below the charred zone. It would have been a proper choice to use open bottom FBC which removes stones automatically out of the fluidized bed.

Erosion with under bed feeding system There are 100 nb / 125 nb and 150 nb fuel feed lines available. The number off and diameter are so chosen, to meet the pneumatic conveying requirement. With 14 to 16 m/s velocity in PA lines, a 150 nb causes more erosion at bed coils above the fuel feed point.

The small stones that accumulate around the fuel feed point over a period, lead to tilting the PA flow upwards, thus directing to bed coil erosion. Bed coil replacement is warranted every two years. The plastic refractory helps to protect the bed coil from erosion. As it is required to cover part of the bed coils, there will be some improvement in life.

Bed tubes failure with oil film Oil films insulate the metal from heat transfer and that is the reason alkali boil out is done in the boiler. The bed coil failure in this case will be again swelling of the tube locally.

Summary& action plan 1. Bed coil shall be applied with plastic refractory as per drawing enclosed. 2. Bed coil replacement will be required every two years. 3. Adjust the PA header pressure as required to have trouble free feeding. Always keep optimum PA pressure. 4. Incorporate bar screen system as shown in the drawing can be adopted to prevent stone ingress. 5. Use more fresh sand to ensure stones come out of the system.

ECONOMISER TUBE FAILURES Failed tubes were not available for inspection. It was informed that there had been erosion of bends. Plant personnel informed that there had been pinhole failures at weld joints. Corrosion products from pre boiler system Pinhole failures at weld joint are encountered in case the water is contaminated with corrosion products from pre-boiler system. This mechanism is known as under deposit corrosion. The water chemistry under a deposit is different and it leads to high / low pH situation under the deposit. Gas flow distribution device and ash accumulation at economiser inlet duct During inspection, ash accumulations were seen on the economiser inlet duct and on the gas baffles. In many installations, this defect is seen in many boilers. When ash accumulates on the flat portion of the gas baffles, the gas flows preferentially over the economiser tubes. See the photo enclosed in annexure. Gas baffles at economiser end tubes & at bends Generally there is non-uniform gap between the tube and the casing. This leads to excess gas flow along the bends. The staggered pitch causes more erosion at the end tubes and at the bends. A typical erosion pattern in staggered pitched economiser can be seen in annexure. My observations on economiser inspection are:

The gas baffles are in excess than what is required. At some places there are no gas baffles. Gas baffles shall be perforated. Cable trays can be used as baffles. Or else gas baffles shall be made from 4 thk plates with 10 mm holes at 30 mm square pitch. These baffles are required to cover the first tube only as shown in the sketch.

Summary& action plan 1. The flow splitters at Economiser inlet duct shall be modified as per suggestion. The inner baffle shall be removed fully. The horizontal portion of the top baffle shall be removed. 2. Perforated baffles shall be installed as shown in the sketch.

BOILER RATED CAPACITY PROBLEM The design of fluidized bed was checked. It is seen that the bed cross sectional area is just adequate to meet the fluidization velocity requirement. At the moment, the underbed feeding system is underutilized. Excess bed coil heating surface As explained already excess bed coils force the bed temperature to be on the lower side. Since there was refractory lining between the bed & radiant SH, the temperature rise on steam was more than the pressure. The overbed feeding made it worse. The bed coil heating surface shall be adjusted as recommended. PA header pressure The PA pressure has to be adjusted to ensure that the required rice husk is carried in the venturi system. Adequacy of FD & ID fans The data on fans given at proposal stage was made available. The ID fan and FD fan sizing is found to be OK. Gas velocities in flue path The gas side velocities are seen to be the optimum at 25 TPH load. The calculations are attached with this report. With the 420 tubes available, the gas side entry velocity is seen to be 15.47 m/s at the bottom APH block. Adjustment of refractory at waterwall The refractory height at waterwall is adjusted at many sites to meet the DESH spray requirement as per minimum load of the boiler. There are cases where the refractory height is increased to reduce the waterwall pickup. There are also cases where the refractory height is decreased.

Erosion of ID fan impeller With rice husk as the fuel, the ID fan impeller life is always less. With eroded ID fan, the boiler loading would be difficult. Spare impeller is always required. It is recommended to have an electrostatic precipitator. Bag filters have maintenance issues. APH plugging The condensation of flue gas in the ducts above the APH is a serious problem. See photograph in annexure. The insulation mattresses can be removable type so that the flue gas condensation can be prevented. During rainy season the condensation can be very high plugging the APH tubes. Generally the air inside tubes design is not prone for plugging. APH tubes fail due to condensation of flue gas moisture at cold ends. This failure is yet to begin / has begun. APH pressure test is advised at the earliest opportunity. FD fan alone is run for this test, with compartment dampers in closed condition. The tubes are checked from flue gas side. The test shall be done annually. At least first 10 rows of tubes at cold end would need change every two years. APH tube erosion at bottom block entry The flue gas duct between Economiser hopper and APH hopper shall be modified to prevent the erosion of the APH tubes. The ferrules are to be replaced regularly. On one boiler 125 mm long additional tubes were fitted as in annexure. This helps in easy identification of eroded tubes. Uninterrupted operation This can be achieved if each and every problem is addressed. Annual maintenance is to be done properly without fail. Essential spares are to be replaced on time to avoid down time. These include spares such as Air nozzles, mixing nozzle, coal nozzles, fuel piping, bed coils, APH tubes, APH ferrules, furnace refractory. ID fan life will be much less with rice husk, since ESP is not provided. It has to be replaced promptly. Thorough inspection is a must and thickness survey is important to assess the remnant life of SH, boiler bank and economiser coils. In line economiser would avoid sudden failures of economiser tubes. Insulation work shall be attended regularly. Safety valve It was seen that the main steam line safety valve is gagged. This is against the safety of power plant. Repair or replacement should be carried out. All Safety valve exhaust elbow trays are filled with ash. They shall be cleaned. All safety valves are to be popped manually once in a month. Ash leakage from roof panel There is no sealing of SH coils with the roof panel at the moment. This is not OK. The air ingress will cause tube failures due to erosion. There will be secondary burning at free board. The oxygen measured will be different from actual. Monitoring boiler efficiency In boiler major losses are excess air loss, unburnt loss in ash, stack heat loss and blow down losses.

Oxygen measurement is to be made available at economiser outlet. This oxygen has to be between 4 to 4.5%. Unburnt loss depends on bed material size, bed height and bed temperature. Bed material size is to be controlled to 2.5 mm maximum by the proper screen. Bulk density of bed ash should not exceed 1300 kg/m3. The bed height & bed temperature is decided by the load. Refractory application will improve the bed temperature. Stack temperature would go high if only free board burning is present.

K.K.Parthiban.

ANNEXURE - Photographs and comments

Photo 1 & 2: The failed tubes indicate short term overheating with localized swelling. If there was high metal temperature then the entire tube would be in swollen condition.

Photo 3: The tube could have deposits inside just before failure. After the failure, the deposit is generally blown out. Yet under microscope, we may find some deposits around the failed portion.

Photo 4: Carryover marks seen inside the drum. The water level shows dusty water. The reddish marks in steam space are the indication of carryover. Here carryover is seen due to left out welding of baffle box with steam drum and also due to water quality itself. Foaming is present to dust.

Photo 5: The entire drum is uniformly red indicating there is foaming. The feed water quality needs to be corrected.

Photo 6: The close view of the manhole door shows suspended matter in boiler water.

Photo 7 & 8: The recent failures in straight portion of the RSH are seen with localized swelling only. There is no overheating of tubes.

Photo 9 & 10: Internal view of the failed tubes show deposits near the failed tubes. There is boiler water carryover.

Photo 11: The chemical dosing piping and blow down piping routings were found interchanged. This can also force a low pH regime and drain of the chemicals. The piping can be interchanged inside the steam drum itself.

Photo 12: The deaerator tower was inspected for marks of dirt. We could see that there is extra iron oxide coating in the tower. This can come from DM water tank to deaerator piping system. It is advisable to use SS piping. Also the pH must be boosted at DM plant itself. The Autoclave heat recovery system shall be dispensed with.

Photo 13 & 14: The storage tank of the deaerator is seen with reddish dust in the shell wall. The pre boiler system corrosion / pH swings have to be eliminated.

Photo 15: One of the best steam drum with magnetite layer. It is a layer of the steel itself under the right boiler water and feedwater chemistry.

Photo 16: Typical overheating due to high metal temperature over a period taken from another plant. The failed portion of the tube shows multiple cracks. The failed tubes at JVL agro do not show this. The overheating due to design defect or free board combustion can not be the reason.

Photo 17: Burning of SH clamps seen due to free board combustion of rice husk. This is due to inadequate free board. If this is to be avoided, the overbed feeding has to be stopped.

Photo 18: At present the refractory is up to nose panel. The refractory can be reduced to avoid high main steam temperature. Rice husk being a high volatile matter fuel, free board combustion takes place. For coal, refractory needs to be there.

Photo 19: The free board height is only 2.586 metre. This not OK for overbed feeding. The residence time for the gas is hardly 0.75 secs whereas requirement is 2.5 secs minimum. Usually water wall height is increased and the refractory is also extended to obtain the steam temperature.

Photo 20: The gas velocity at full load itself is OK. At 18 TPH load, there is no possibility of SH tube erosion. Moreover erosion leads to thinning over and it is not localized.

Photo 21: The TDS is seen to increase from nil to 3 ppm in feed water as it comes to deaerator. The boiler water TDS is only 16 ppm and it may be inclusive of the chemicals as well. The chloride level is high in boiler water. This can come from pre boiler system. It can also come from chemicals contamination. It is learnt that in order to limit silica in saturated steam, the boiler water silica is kept at 1.04 ppm and the low TDS is incidental. Normally boiler water TDS will be from 50 to 100 ppm. This can be an indication of foaming in boiler drum. If silica rise in boiler water is abnormal it is advisable to check silica in feed water before after autoclaves. Also check for colloidal silica in DM water in outside laboratory. Autoclave return water pH is 7.5, which implies there is contamination.

Photo 22: The bed coils show erosion. This is near the over bed fuel feed point. It is possible that stones had accumulated at this area. Otherwise the bed was not seen with heavy stones at time of boiler inspection.

Photo 23: The stud pattern is 4 x 3 for the bed coils. The bed heating surface gets multiplied by 1.5 times due to this. In reality there will be at least 1.35 times increase in heating surface accounting the worn out studs.

Photo 24: The bed was inspected with the bed material. It was seen that the bed height is much less than desired. This is due to high bed heating surface than what is required. If we increase the operating bed height, there will be reduction in steam temperature.

Photo 25: 800 mm expanded bed height is ideal for husk. The expanded bed height has to be 900 mm for coal so that entire available bed coils would be immersed. As the coal burns fully inside the bed, the operating height has to be more.

Photo 26: Bed coils being applied with phoscast to protect against erosion. The coils are kept upside down for application purpose. This picture is from a different site. The refractory like this can be applied to make part of the bed coil ineffective. The exact length / detail of application will be given separately.

Photo 27: Typical phoscast applied bed coil in service. We need to adopt this to camouflage heating surface so that the heating surface will be adjusted for a good bed temperature.

CI

CASTWEL INDUSTRIES
C-18/6, M.I.D.C. AREA, NAGPUR - 440 028 PH.No.07104- 236566, 235993

DATASHEET PHOSCAST-90 XR
PROPERTIES
MAXIMUM SERVICE TEMPERATURE (C) BULK DENSITY CURED AND THEN DRIED AT 110 C (gm/cc) (Min) COLD CCRUSHING STRENGTH (Kg/cm2) (Min) AFTER DRYING AT 110 C AFTER HEATING AT 1300 C PERMANENT LINEAR CHANGE (%) (Max.) AFTER HEATING AT 1300 C

VALUES
1650

TEST PROCEDURE
-------------

2.7

BIS: 10570 Reaffirmed 2009 BIS: 10570 Reaffirmed 2009

650 875

() 0.60

BIS: 10570 Reaffirmed 2009 IS: 1528 -PART I Reaffirmed 2009

REFRACTORINESS CHEMICAL ANALYSIS (%) Al2O3 (Min.) Fe2O3 (Max) ABRASION LOSS (cc) (Max.) AFTER DRYING AT 110 C AFTER HEATING AT 1000 C MAXIMUM GRAIN SIZE (95 % PASSING THROUGH) INSTALLATION: RAMMING

+ 1785C

90 0.3

BIS: 1527 - 1973

5 3.5 5 MM

ASTM C-704 IS: 1528 -PART 14 Reaffirmed 2009

NOTE: ABOVE PROPERTIES ARE ON SAMPLES PREPARED AS PER STANDARD

TEST METHOD & ARE SUBJECT TO REASONABLE VARIATIONS. The above is the specification of the plastic refractory used for erosion protection and for reducing heat transfer to bed coils.

Photo 28: The present overbed feed chute is about 400 mm wide and with 25 mm opening for air. This can push more air than required. It is necessary to keep the air as minimum as possible. The refractory slope can be increased to the extent possible. We need to look at the way of dropping the husk in to the bed than pushing it with air.

Photo 29: Deflector plates used at another plant to prevent husk directly flying to SH area. This can be tried here.

Photo 30: Stones in husk can cause bed coil failure. Stones can be controlled to an extent by a screen.

Photo 31: This is an arrangement of static screen used for lignite. This helps in filtering the cakes that form due to high moisture lignite. Similar concept can be used in for removing the stones at the fuel feed hopper above drag chain feeder. .

Photo 32: The effect of high PA header pressure in another boiler no 1 can be seen here. The feeder was operating at 1300 mmWC at this time. The PA fan head was increased by CVL to 900 mmWC for this purpose. With air box pressure at 450 mmWC, the PA header pressure has to be 1350 mmWC maximum.

Photo 33: The feeder is seen to be under positive pressure in another boiler with less PA header pressure. Due to puffing, the husk chutes would be jammed and carrying capacity of fuel lines comes down.

Photo 34 & 35: There are two gas baffles at economiser inlet duct. There is no proper gas distribution even though it is supposed to work that way. This happens due to ash settling on horizontal portion of the baffles. It is advised to remove the bottom baffle fully as the ash settling will be disturbed by increased gas flow. The top baffle horizontal portion should be removed.

Photo 36 & 37: We can see that the flue gas flows only at two sides. Due to this preferential erosion will be seen at economiser side portions and at rear portion. The polishing of coils was noted in the gas flow area.

Photo 38: The gas baffle is not seen at top of economiser. It is advisable to have perforated gas baffle so that ash.

Photo 39: Gas baffle not installed on the other side as well. Perforated baffle shall be erected as per sketch enclosed in this report.

Photo 40: Staggered pitch leads to erosion at the end coils. Inline pitch is any time welcome from erosion point of view. This is from another 36 TPH boiler from the same boiler manufacturer.

Photo 41: Gas baffle modification is suggested to prevent preferential erosion of economiser.

Photo 42: At the lower bank also, the gas baffles are missing. We may note that the gap between casing and the tube is more.

Photo 43: We can see the use of perforated gas baffle used by German boiler engineers in a CFBC boiler where the ash load is higher due to recirculation.

Photo 44: Soot blower shall not be used in economiser. In FBC boiler this does not make a difference except that it temporarily removes the ash that settle over tubes. Unnecessary operation of soot blower can lead to erosion of economiser tubes. The gas baffle is required here as well at the marked location.

Photo 45: Note the gas baffle is not provided here at the marked location at the lower economiser bank.

Photo 46: Gas baffles are required at bends. Generally this is installed while fitting the casing plate. Now the casing has to be opened to fit the baffle.

Photo 47: This the bottom of economizer bank where we can see more gap between casing and end tubes. Here also baffle is required for protection.

Photo 48: The sketch shows the arrangement of gas baffles required. The gas baffle shall be from 4 mm MS plate with 10 dia holes drilled at 30 m square pitch. Cable tray can also be used as gas baffles.

Photo 49: The gas velocity is safe at economiser. But the staggered pitch has inherent defect of accelerating the erosion along the end coils near casing and at bends. It is advised to install the baffles properly without a compromise.

Photo 50: Under deposit corrosion failures in economiser at other plants. This occurs close to welds. When the feedwater is contaminated with suspended corrosion products, this will happen.

Photo 51 & 52: The Upper APH block is seen blocked with rusted plates and ash. The casing plate above the APH gets rusted due to condensation of flue gas. The APH casing has to be insulated very well. In fact it can be insulated like the way the 12 TPH boiler flue duct is plastered.

Photo 53: The Top inspection doors of APH are seen peeling off due to flue gas condensation. Insulation is a must. At least loose mattress can be placed temporarily. It is possible to have proper insulation boxes inside the inspection doors.

Photo 54: The APH design gas velocity is very much safe.

Photo 55: Ash blocks seen below the cold block of APH. Regular inspection is required in this area. When some tubes are blocked the other tubes erode faster.

Photo 56: We can see the corroded duct fall down to the bottom APH block as well and choke the tubes. It is necessary to do regular pressure test at every shut down. This is done by running the FD fan alone with compartment dampers in closed condition. Leaky tubes can be identified. When tubes begin to leak, we must note that the tubes are corroded due to condensation. Cold blocks generally suffer corrosion. Hot block suffers erosion at the gas inlet.

Photo 57: Door corrodes in flue path. Insulated box can be fitted so that the corrosion can be minimized. The condensing water & the rust lead to choking of APH tubes.

Photo 58: The above sketch shows how the door can be in a flue path to prevent corrosion of casing also.

Photo 59: Many ferrules have been eroded already at the APH inlet at the bottom block. A permanent arrangement is required for inspection and replacement. The erosion rate can be more due to inlet duct arrangement for which a modification is suggested below.

Photo 60: Instead of fitting ferrules this method of adding 125 mm long tubes to APH tubes also a good idea. Here the eroded tubes would be easily visible. The tube bits are to be tack welded to main tube at three places.

Photo 61: Impingement marks seen in economiser hopper. This is due to gas flow pattern from economizer outlet duct. This can cause more gas flow at the tubes along the rear side. The economiser outlet duct shall be modified as shown.

Photo 62: Modification recommended at economiser hopper outlet duct.

TUBE THK. CALCULATION FOR YIELD CONDITION WP X D t = --------------- + C 2f + WP Where , WP = Working Pressure of Boiler in kg/cm 2 D = External dia of tube in mm f t C = Permissible stress for the mtrl. at the working metal temp in kg/cm2. = Minimum thk. of tubes to be calculated in mm = 0.75 mm , for Working pressure 70 kg/cm2 = 0 mm , for Working pressure > 70 kg/cm 2 Total coil length Length of coil to failed portion m m 33 29.8 4.5 3.69

Tube thickness as per original supply min. reqd thk of tube at bend after 18% thinning

CHECKING YIELD TEMPERATURE FOR RSH - AT THE FAILED PORTION Size SL. Steam in Steam out At bend Metal Design Yield Yield Stress Value(f) No. OD Thk Temp. Temp. Temp. temp Pr. Stress Thk. 2 o o o o 2 2 kg/cm mm mm mm C C C C kg/cm kg/cm T1 T2 T1 T1+ 50 s Y = S x 1.5 01 44.5 4.5 335.0 485.0 470.5 520.5 68.0 683.6 1025.4 1.43 02 44.5 4.5 335.0 490.0 475.0 525.0 68.0 652.6 978.9 1.49 03 44.5 44 5 45 4.5 335 0 335.0 495 0 495.0 479 5 479.5 529 5 529.5 68 0 68.0 622 7 622.7 934 1 934.1 1 56 1.56 04 44.5 4.5 335.0 500.0 484.0 534.0 68.0 592.8 889.2 1.64 05 44.5 4.5 335.0 505.0 488.5 538.5 68.0 562.9 844.4 1.72 06 44.5 4.5 335.0 510.0 493.0 543.0 68.0 532.9 799.4 1.82 07 44.5 4.5 335.0 515.0 497.5 547.5 68.0 503.0 754.5 1.92 08 44.5 4.5 335.0 520.0 502.1 552.1 68.0 475.1 712.7 2.03 09 44.5 4.5 335.0 525.0 506.6 556.6 68.0 450.9 676.3 2.13 10 44.5 4.5 335.0 530.0 511.1 561.1 68.0 426.6 639.9 2.25 11 44.5 4.5 335.0 535.0 515.6 565.6 68.0 402.4 603.6 2.37 12 44.5 4.5 335.0 540.0 520.1 570.1 68.0 378.2 567.3 2.52 13 44.5 4.5 335.0 545.0 524.6 574.6 68.0 354.0 530.9 2.68 14 44.5 4.5 335.0 550.0 529.2 579.2 68.0 332.9 499.4 2.84 15 44.5 4.5 335.0 555.0 533.7 583.7 68.0 312.8 469.2 3.01 16 44 5 44.5 4.5 45 335.0 335 0 560.0 560 0 538.2 538 2 588.2 588 2 68.0 68 0 292.6 292 6 438.9 438 9 3.20 3 20 17 44.5 4.5 335.0 565.0 542.7 592.7 68.0 272.4 408.6 3.42 18 44.5 4.5 335.0 566.0 543.6 593.6 68.0 268.4 402.5 3.47 19 44.5 4.5 335.0 567.0 544.5 594.5 68.0 264.3 396.5 3.51 20 44.5 4.5 335.0 568.0 545.4 595.4 68.0 260.3 390.4 3.56 21 44.5 4.5 335.0 569.0 546.3 596.3 68.0 256.2 384.4 3.62 from the above we can see that if the SSH outlet reaches 569 deg C, the tube will start yielding only if the thickness i 3.62 mm. Th new b d may b 3 69 mm even if consider 18% thinning. Th tube can not hi k is 3 62 The bend be 3.69 id hi i The b fail by overheating under normal circumstance.

EWS 604 UNDER FED FLUIDISED BED SIZING PROJECT : JVL agro - rice husk firing- 100% INPUTS FOR FLUIDISED BED SIZING Vf, Fluidisation velocity Tb, Design bed temperature Steam generated nett Main steam temperature Main steam pressure Fuel burnt rate Wet air required, kg /kg of fuel fired Flue gas produced, kg /kg of fuel fired Flue gas molecular weight Te, Boiler exit temperature Tca, Combustion air temperature Ta, Ambient temperature Assumed carbon loss Ts, Saturation temperature Constituents of fuel H, Hydrgen M, Moisture A, Ash GCV, Gross calorific value of fuel = 3.42 % = 15 % = 18.48 % = 2956.52 kcal /kg = 2.75 m/s = 850 Deg C = 25000 kg/h = 485 Deg C = 65 kg/cm2 a = 7,614 kg/h = 4.908 kg/kg = 5.678 kg/kg = 28.73 = 160 Deg C = 150 Deg C = 40 Deg C = 2.67 % = 284.9 deg C Date & time : 1/2/12 7:38 AM

UNDERBED FLUIDISED BED SIZING Calculations for bed cross sectional area Wet flue gas produced per kg of fuel = 5.678 kg/kg Fuel firing rate = 7,614 kg/h Wet flue gas flow rate = 5.678 x 7,614 kg/h = 43232.292 kg/h Molecular wt of flue gas = 28.73 from air & gas calc K, altitude correction factor = 0.977 Flue Gas volume flow rate at 0 deg C = 43232.292 x 22.4 / 28.73 x 0.977 = 34,500.56 Nm3 /hr Flue Gas volume flow rate at 0 deg C = 9.58 Nm3 / sec Design bed temperature = 850 Deg C Gas flow at bed temperature = ( 9.58x ( 273 + 850 ) / 273 )m3 /sec = 39.41 m3 /sec Vf, Fluidisation velocity = 2.75 m/s Vf, Fluidisation velocity with free board burning = 2.475 m/s Therefore, bed cross sectional area = 39.41 / 2.75 Bed cross sectional area required = 14.33 m2 bed width 4680 mm bed length 3065 mm Bed cross sectional area available = 14.34 m2 Calculations for bed heat transfer area Unburnt carbon loss

Design by: Name: Sign:

Approved by: Name: Sign:

EWS 604 HL1, % design Unburnt carbon loss Calculations for Heat loss though ash A, Ash content in fuel C, Specific heat of ash Ta, Ambient temperature Tb, Design bed temperature HL2, % Heat lost through ash =4 %

= 0.1848 kg/kg = 0.22 kcal/kg Deg C = 40 deg C = 900 deg C = A x C x (Tb-Ta) x 100 / GCV = 0.1848x 0.22x (900-40) x 100 / 2956.52 % HL2, % Heat lost through ash = 1.18 % Calculations for Heat loss through moisture in air Ww, weight of water in air = 0.02825 kg/kg Wd, Dry air required per kg of fuel = 4.773 kg/kg from combustion calc Cp1, specific heat of water vapor at bed temp = 0.5685 kcal/kg C Cp2, specific heat of water vapor at ambient temp = 0.3592 kcal/kg C Tca, Combustion air temperature = 150 deg C Tb, Design bed temperature = 900 deg C HL3, % Heat lost through moisture in air = Ww x Wd x {(Cp1 x Tb) -(Cp2 x Tca)}x 100 / GCV = 0.02825x4.773x[(0.5685x900)-(0.3592x150]x100 /295 HL3, % Heat lost through moisture in air = 2.09 % Calculations for Heat loss through moisture & hydrogen in fuel H, hydrogen in fuel = 0.0342 kg/kg M, moisture in fuel = 0.15 kg/kg Cpb, Specific heat of water vapor at bed temp = 0.5685 kcal/kg L, latent heat of water = 595.4 kcal/kg Ta, Ambient temperature = 40 deg C Tb, Design bed temperature = 850 deg C HL4, % Heat lost through moisture & H2 in fuel ={M+(8.94 x H)} x [595.4+(Cpb x Tb) -Ta] x 100 / GCV HL4, % Heat lost through moisture & H2 in fuel ={ 0.15+ (8.94 x 0.0342)}x [ 595.4+(0.5685x 850) 40]x100/2956.52 % HL4, % Heat lost through moisture & H2 in fuel = 16.01 % Calculations for Heat loss through dry flue gas Qfgd, Dry flue gas produced per kg of fuel = 5.087 kg/kg Cpb, specific heat of flue gas at bed temp = 0.285560088607609 kcal/kg deg C Cpa, specific heat of flue gas at Tca = 0.242252054910967 kcal/kg deg C Tb, Design bed temperature = 850 deg C Tca, Combustion air temperature = 150 deg C HL5, % Heat lost through dry flue gas =Qfgd x{ (Cp1 x Tb) - (Cp2 x Tca)} x 100 / GCV =5.087x { ( 0.285560088607609 x 850) HL5, % Heat lost through dry flue gas = 35.51 % Calculation for Heat loss through radiation to waterwall Ab, Bed cross sectional area = 14.33 m2 e, Emissivity of waterwall surface = 0.9 S, Steafan boltzmann constant = 4.9 x 10 ^ -8 Tb, bed temperature = 850 Deg C

Design by: Name: Sign:

Approved by: Name: Sign:

EWS 604 Ts, saturation temperature = 284.948697777768 Deg C Radiation heat loss to waterwall =Ab x e x S x {( Tb + 273 )^4 - ( Ts + 273 )^4} = 14.33x0.9x4.9 x 10^-8x{( 850+273)^4-(284.948697777 = 943,844 kcal/h Fuel heat input in the bed = 7,614x 2956.52= 22510943.28 kcal/h HL6, % Radiation loss to waterwall = 100x 943,844/ 22510943.28 HL6, % Radiation loss to waterwall = 4.19 % Bed heat balance & HTA required HL1, Unburnt carbon loss = 4 % HL2, Total Heat loss through the ash = 1.18 % HL3, Heat lost through moisture in air = 2.09 % HL4, Heat lost through moisture & H2 in fuel = 16.01 % HL5, Heat lost through dry flue gas = 35.51 % HL6, % Radiation loss to waterwall = 4.19 % Total losses = 4+1.18+2.09+16.01+35.51+4.19 = 62.98 % Therefore, % heat to be transferred to Bed coil = 100 - 62.98 % % Heat transferred to Bed coil = 37.02 % Fuel heat input in the bed = 22510943.28 kcal/h Actual heat to be transferred to Bed coil = 37.02 x 22510943.28/ 100 = 8,333,551 kcal/h Tb, bed temperature = 850 Deg C Ts, Saturation temperature = 284.95 Deg C Temperature difference = (850 - 284.95)= 565.05 deg C Heat transfer coeff = 220 kcal / kg m2 Deg C Bed coil area required = 8,333,551/ ( 220 x 565.05) Bed Coil HT area required, if plain = 67.04 m2 free board combustion = 20 % Bed Coil HTA reqd a/c free board combustion = 53.632 m2 Plain Bed Coil length required = 334.74 m Checking the available bed HT area Bed coil length per coil- type 1- studded length = 2339 mm No off bed coils- type 1 = 78 No Bed coil plain length per coil- type 1 = 1267 mm No off bed coils- type 1 = 0 No Bed coil length plain per coil- type 2 = 1267 mm No off bed coils-type 2 = 78 No Total eff length of bed coil = 513.1269 m Summary of results Bed cross sectional area required = 14.33 m2 Bed cross sectional area available = 14.34 m2 Bed Coil length required = 334.7 m Bed Coil length available = 513.1 m

Design by: Name: Sign:

Approved by: Name: Sign:

ENWS-251-00

WO / Prop.Nr Client JVL agro Prepared By Name Sign Rev Nr. Revision Details

Document no
WXXX-XX-DCS-XXX-XX

BED COIL STUD EFFECTIVENESS Approved By Name Sign Rev by Checked

Date

Date

Source : HEAT TRANSFER by YUNUS A. CENGEL FUNDAMENTALS Fin efficiency Efficiency of a fin is defined as the ratio of the actual heat transferred by fin to heat transferred by fin, if the entire fin area were at base temperature. Fin effectiveness Effectiveness of a fin is defined as the ratio of the heat transfer rate from a surface with the fin to the heat transfer rate without the fin. Fin efficiency and fin effectiveness are related by Effectiveness, E = Qfin Qwithout fin = Af * Ab Where, Af Ab INPUTS Stud Diameter Stud Length HTA Coefficient Conductivity of fin D L h K = = = = 0.01 0.018 220 36 m m Kcal/kgm2C kcal/mhrC = Surface Area of fin = Cross sectional Area of the fin = Efficiency of the fin

CALCULATION Fin Efficiency Calculation By Formulae Fin Effic= a Where P = Perimeter of the fin = tanh aLc aLc (hP/KA)^(1/2)

Sheet 1 of 2

ENWS-251-00

= = = = Corrected Length, Lc = = = Fin Efficiency = = Fin Efficiency, = Effectiveness Calculation E = =

A a

Cross sectional area of the fin (hP/KA)^(1/2) ((220x3.14x0.01)/(36x3.14 / 4 x 0.01^2))^(1/2) 49.44 L+(D/4) (0.018+(0.01/4)) 0.021 tanh aLc aLc 0.767 1.014 0.76

Af * Efficiency Ab * D * (L+(D/4)) * X * D^2/4 3.14 * 0.01 * (0.018 +( 0.01 / 4)) x 0.7 (3.14 x 0.01 ^2 )/ 4 6.21 6.21

Fin Effectiveness, E = RESULT SUMMARY Fin Effectiveness, E =

Sheet 2 of 2

ENWS-252-00 WO / Prop.Nr Document no Client JVL agro BED COIL STUD CONTRIBUTION AND HEAT FLUX Prepared By Approved By K.K.Parthiban Name Name Sign Rev Nr. Revision Details Sign Rev by Checked

Date

Date

CALCULATIONS Tube OD mm Stud pitch mm mm mm mm2 mm2

TYPE 1 50.8 16 10 16 78.54 502.65 4 3 7.00 549.78 3518.58 50.8 36 5745.34 5745 34 5195.57 5195.57 549.78 6.21 3414.13 8609.69 1.50 1.35

Stud diameter Stud length Stud dot area / stud Stud annular area / stud No of studs in plane A No of studs in plane B No of studs per set Stud dot area per set Stud annular area per set Tube OD Tube length per set of studs Tube annular area Tube annular area-dot area

Nos. mm2 mm2 mm mm mm2 mm2 mm2 mm2 mm2 mm2 Nr Nr

STUD EFFECTIVENESS FACTOR Tube annular area-dot area Dot area Stud effectiveness Additional area due to stud Net total plain tube + stud area Ratio of studded / plain tube area Ratio of studded / plain tube area ( corrected for oxidation)

Sheet 1 of 1

RSH HEAT BALANCE CUSTOMER JVL agro

Inlet gas temperature T1 Outlet gas temperature T2 Sp heat calculation at diff temperatures a 28.9 25.48 25 48 22.26 32.24 25.78 b -0.001571 0.0152 0 0152 0.05981 0.001923 0.05795 c 8.081E-06 7 155E 06 -7.155E-06 -3.501E-05 0.00001055 -3.812E-05

Deg C Deg C

= 900 = 722.7 @ T2 995.7 kJ / kmol -K 32.5113107 34.8161886 34 8161886 54.4763193 41.0653725 54.1893244 @ T1 1173 33.5391786 35.5823497 35 5823497 56.3005582 43.2095268 55.2044007 = = = = = = = = = = = = = = @ T2 995.7 KJ/kg-K 1.1605794 1.08803989 1 08803989 3.02394223 0.93309186 0.84587553 @ T1 1173 1.197271931 1.111983178 1 111983178 3.125204451 0.981811561 0.861720504

N2 O2 H2O Co2 SO2

d -2.873E-09 1.312E-09 1 312E 09 7.469E-09 -3.595E-09 8.612E-09

At deg K molar mass 28.013 31.999 31 999 18.015 44.01 64.063

g p p Actual gas composition & specific heat vol % wt% N2 66.82 65.1568528 O2 3.41 3.79826089 H2O 16.1 10.0961117 Co2 13.66 20.9264748 SO2 0.01 0.02229982 total 100 100 Mole wt 28.73 Sp heats

g p g Average specific heat kcal/kg -K @ T2 0.75619701 0.04132659 0.30530059 0.19526323 0.00018863 Cp 2 0.31007 kg/cm2g deg C kg/cm2g deg C kcal/kg kcal/kg kg/h g kcal/h = = = = = = = = = = @ T1 0.78010471 0.04223602 0.31552413 0.20545855 0.00019216 Cp 1 0.32088 Gas flow rate Molecular weight Gas density Gas flow rate Heat available Nm3/h kg/m3 kg/h kcal/h

Loss to ambient assumed % Net heat available kcal/h

( p p ) (Cp 1 + Cp2 )/ 2 0.315475 25029.8507 28.73 28.73 / 22.3 =1.2883 25029.8507462686 x 1.2883 =3 32245x0.315475x(1173-995.7) 1803582.72 1 1785547 149.42 0.8 08 403.75 37.00

RSH inlet pressure RSH inlet steam temperature RSH outlet pressure RSH outlet steam temperature RSH inlet enthalpy RSH outlet enthalpy Steam flow heat to be added to steam

heat lost by gas / heat gain by steam kcal/h

66.5 Heat transfer area m2 330 Effectiveness factor 65 LMTD deg C 485 HTC as per heat transfer kcal/h/C/m2 708.13 807.34 18000 18000 x ( 807.34 -708.13) 1785780 1.00

Photo 63: The PA outlet duct is seen with a bend immediate to discharge. This is not good. While installing the new PA fan, manufacturer had proposed horizontal discharge duct. This was right. Later Somehow vertical discharge fan has come. Due to this the immediate bend has come in the layout. It is advised to enlarge the duct first to 575 sq. The expansion bellow immediate to fan can be removed as there is another expansion bellow nearby. The bend should be of 575 square. This can help to improve the fan performance.

Photo 64: The IGV at PA fan inlet can be removed in case the power consumption is high. Instead a multi flap damper can be provided near the support. This may improve the performance of the fan further.

Photo 65: The Top inspection doors of APH are seen peeling off due to flue gas condensation. Insulation is a must. At least loose mattress can be placed temporarily. It is possible to have proper insulation boxes inside the inspection doors.

Photo 66: The roof panel, risers, SH headers shall be insulated and applied with POP. This is required to avoid secondary combustion at SH and to avoid SH failures due to erosion at air ingress point. The above photo shows a typical application which was successful.

Photo 67: It is seen that the safety valve in main steam line is gagged. This can result in a major accident. It is advised to remove the gag immediately for the safety of the boiler and the power plant.

Photo 68: Water level gauge is important to counter check the level transmitter working. There are alternates such as 2 out of 3 level transmitters.

GAS VELOCITY CALCULATION PROJECT : JVL agro - rice husk firing- 100%

Date & time:

1/2/12 9:14 AM

GAS PATH VELOCITY Gas flow in (from fansizing) Nm3/s = 9.58 Calculation for RSH gas velocity tube inlet gas temp = 780 deg C Flue Gas volume flow rate at inlet = 9.58x (273 +780)/273) = 36.951 m3/s No of tubes across the bank = 32 Tube OD = 44.5 bank width = 3383 bank height = 2757 Total tube area = 3.925968 Free Gas flow area = 5.400963 Inlet gas velocity = 6.84 m/s Calculation for SSH outlet gas velocity tube inlet gas temp = 680 deg C Flue Gas volume flow rate at outlet = 9.58x (273 +680)/273) = 33.442 m3/s Gas flow area = 5.400963 m2 outlet gas velocity = 6.19 m/s Calculation for SSH average gas velocity Average gas velocity = (6.84+6.19) /2 m/s = 6.52 m/s Calculation for CSH gas velocity tube inlet gas temp = 680 deg C Flue Gas volume flow rate at inlet = 9.58x (273 +680)/273) = 33.442 m3/s No of tubes across the bank = 32 Tube OD = 44.5 bank width = 3383 bank height = 2300 Total tube area = 3.2752 Free Gas flow area = 4.5057 Inlet gas velocity = 7.42 m/s Calculation for CSH outlet gas velocity tube inlet gas temp = 525 deg C Flue Gas volume flow rate at outlet = 9.58x (273 +525)/273) = 28.003 m3/s Gas flow area = 4.5057 m2 outlet gas velocity = 6.22 m/s Calculation for CSH average gas velocity Average gas velocity = (7.42+6.22) /2 m/s = 6.82 m/s Calculation for bank inlet gas velocity tube inlet gas temp = 525 deg C

m3/s

m3/s

m3/s

m3/s

Flue Gas volume flow rate at inlet = 9.58x (273 +525)/273) m3/s = 28.003 m3/s No of tubes across the bank = 21 Tube OD = 50.8 bank width = 3099 bank height = 1610 Total tube area = 1.717548 Free Gas flow area = 3.271842 Inlet gas velocity = 8.56 m/s Calculation for boiler bank outlet gas velocity tube inlet gas temp = 400 deg C Flue Gas volume flow rate at outlet = 9.58x (273 +400)/273) m3/s = 23.617 m3/s Gas flow area = 3.271842 m2 outlet gas velocity = 7.22 m/s Calculation for boiler -bank average gas velocity Average gas velocity = (8.56+7.22) /2 m/s = 7.89 m/s Calculation for Economiser inlet gas velocity Eco inlet gas temp = 400 deg C Flue Gas volume flow rate at inlet = 9.58x (273 +400) / 273 m3/s Flue Gas volume flow rate at inlet = 23.617 m3/s No of tubes across the bank = 11 tube OD = 51 tube length = 3380 Casing width = 1300 Casing length = 3380 Gas flow area = ((1300x3380)-(11x3380x51))/10^6 m2 = 2.4978 m2

RSH HEAT BALANCE CUSTOMER JVL agro

Inlet gas temperature T1 Outlet gas temperature T2 Sp heat calculation at diff temperatures a 28.9 25.48 25 48 22.26 32.24 25.78 b -0.001571 0.0152 0 0152 0.05981 0.001923 0.05795 c 8.081E-06 7 155E 06 -7.155E-06 -3.501E-05 0.00001055 -3.812E-05

Deg C Deg C

= 900 = 722.7 @ T2 995.7 kJ / kmol -K 32.5113107 34.8161886 34 8161886 54.4763193 41.0653725 54.1893244 @ T1 1173 33.5391786 35.5823497 35 5823497 56.3005582 43.2095268 55.2044007 = = = = = = = = = = = = = = @ T2 995.7 KJ/kg-K 1.1605794 1.08803989 1 08803989 3.02394223 0.93309186 0.84587553 @ T1 1173 1.197271931 1.111983178 1 111983178 3.125204451 0.981811561 0.861720504

N2 O2 H2O Co2 SO2

d -2.873E-09 1.312E-09 1 312E 09 7.469E-09 -3.595E-09 8.612E-09

At deg K molar mass 28.013 31.999 31 999 18.015 44.01 64.063

g p p Actual gas composition & specific heat vol % wt% N2 66.82 65.1568528 O2 3.41 3.79826089 H2O 16.1 10.0961117 Co2 13.66 20.9264748 SO2 0.01 0.02229982 total 100 100 Mole wt 28.73 Sp heats

g p g Average specific heat kcal/kg -K @ T2 0.75619701 0.04132659 0.30530059 0.19526323 0.00018863 Cp 2 0.31007 kg/cm2g deg C kg/cm2g deg C kcal/kg kcal/kg kg/h g kcal/h = = = = = = = = = = @ T1 0.78010471 0.04223602 0.31552413 0.20545855 0.00019216 Cp 1 0.32088 Gas flow rate Molecular weight Gas density Gas flow rate Heat available Nm3/h kg/m3 kg/h kcal/h

Loss to ambient assumed % Net heat available kcal/h

( p p ) (Cp 1 + Cp2 )/ 2 0.315475 25029.8507 28.73 28.73 / 22.3 =1.2883 25029.8507462686 x 1.2883 =3 32245x0.315475x(1173-995.7) 1803582.72 1 1785547 149.42 0.8 08 403.75 37.00

RSH inlet pressure RSH inlet steam temperature RSH outlet pressure RSH outlet steam temperature RSH inlet enthalpy RSH outlet enthalpy Steam flow heat to be added to steam

heat lost by gas / heat gain by steam kcal/h

66.5 Heat transfer area m2 330 Effectiveness factor 65 LMTD deg C 485 HTC as per heat transfer kcal/h/C/m2 708.13 807.34 18000 18000 x ( 807.34 -708.13) 1785780 1.00

FEED WATER / BOILER WATER SPECIFICATIONS

FEED WATER SPECIFICATION :

Drum Operating pressure bar (g) Hardness, max ppm pH at 25 deg C Oxygen, max ppm Total Iron, max ppm Total Copper, max ppm SiO2, max ppm Conductivity at 25 deg C after cation exchanger in H+ form and after CO2 removal max s / cm Hydrazine residual ppm

Up to 20 1.0 8.8 to 9.2 0.02 0.05 0.01 1.0 10.0

21 -40 0.5 8.8 to 9.2 0.02 0.02 0.01 0.3 5.0

41 - 60 Nil 8.8 to 9.2 0.02 0.02 0.01 0.3 2.0

61-100 Nil 8.8 to 9.2 0.007 0.01 0.01 0.02 0.5

101 & Above 8.8 to 9.2 0.007 0.01 0.005 0.02 0.3

Remarks Note 4 Note 1

Note 4 Note 4

0.02 to 0.04

0.01 to 0.02

0.01 to 0.02

BOILER WATER SPECIFICATION : Drum operating pressure bar (g) PH at 25 deg C Phosphate residual, ppm TDS, max ppm Specific electrical conductivity at 25 deg C, max s / cm Silica, max ppm Up to 20 10 10.5 20 -40 500 1000 21 -40 10 10.5 20 -40 200 400 41- 60 9.8 10.2 15 -25 150 300 61 to 100 9.8 to 10.2 15-25 Not more than 100 Not more than 200 101 & Above 9.4 to 9.7 5-10 Not more than 50 Not more than 100 Remarks

Note 7 Note 5

25.0

15.0

10.0

To be controlled on the basis of silica in boiler water and drum Pr. And boiler water pH relationship to maintain less than 0.02 ppm in steam leaving the drum Note 2

Sodium sulphite as Na2SO3, ppm

20 -40

5 - 10

Notes : All the measurements of feed water shall be made at high pressure heater outlet or economiser inlet.

Morpholine or any other volatile amine may be used to elevate the pH. The concentration of volatile chemical in feed water shall not exceed 1 ppm. (Expressed as ammonia) Sodium sulphite shall be dosed in the feed water, after the tapping point for desuperheater spray so that it does not get contaminated. The phosphate and pH shall be maintained in accordance with coordinated phosphate pH curve, to prevent the presence of free hydroxide in boiler water. If the feed water is used for desuperheating spray, for all pressures 4.1 4.2 4.3 Hardness shall be nil. SiO2 shall not exceed 0.02 ppm. Conductivity at 25 deg C measured after cation exchanger in H+ form after CO2 removal not to exceed 2 micromho / cm.

5 6

Total alkalinity in boiler water shall not exceed 20% TDS. Presence of oil or organic matter is not allowed in feed water which will induce foaminess and cause carry over of impurities in to steam. The phosphate and pH are recommended in accordance with co-ordinated phosphate curve to prevent presence of free hydroxide in boiler water. If the recommended pH is consistently obtained phosphate residual can be maintained near lower limits.

Silica in boiler water Vs Drum Pressure

10 9 8 7 6 5 4 3 2 1 0 60 70 80 90 100 110 120 130 140 150 160 170 Drum Pressure - bar(g) Boiler water Silica - ppm

the above curve is for Boiler water pH = 10 , for drum pressures of 60 to 98 bar(g)

Phosphate Curve

10.8

10.4

10

C 5 2 t a e u l a v H P

9.6
Series1

9.2

8.8

8.4

8 0 5 10 15 20 PPM PO4 25 30 35 40 45

Photo 11: Poorly insulated steam drum. It was not right to take a branch connection from the stub of steam outlet as it weakens the steam outlet area. Boiler regulations do not allow such a thing. There is no method of calculations for ensuring safety here.

Photo 12: The duct flow area at ID fan inlet / outlet has to be minimum 0.5 m2. Awkward ducting provides resistance, which puts a limit to boiler draft performance & steam generation. The inspection door at ID fan casing shall be flush to casing. There should not be any box as it affects the fan performance.

Photo 13: The feedwater tank is not insulated. Having put a feed water preheater, the insulation is a must so that the heat can be recovered.

Photo 11: Sonic horns are usable for removing accumulations in boiler bank. Using this along with fire side additive would help the boiler bank clean.

Photo 12: Inspection doors like this can be installed at boiler bank sides. It will help in cleaning the boiler bank quickly.

Photo 13: Removable insulation pads shall be used for covering all the four box headers. This work and with insulation of FW preheater and APH will improve the steam generation.

Photo 14: Air blasters can help to prevent ash build up in boiler bank. Different sizes are available in the market depending on the area and depth to be covered. It is advised to contact suppliers.