Guidelines for Energy Auditing of P C Fired Boilers

Surender Kumar
Deputy Director,NPTI

Boiler Schematic

Water & Steam cycle Fuel System Air & flue gas Flow Path Ash/ rejects Handling System

Performance Parameters

Boiler Aspects For Study

Coal quality - composition and calorific value Coal milling aspects Combustion and excess air

Reheaters
Heat recovery units Economisers, air-preheaters

etc.
Insulation aspects

Boiler Aspects For Study

Operation and maintenance features which affect the energy efficiency Boiler blow down aspects Soot blowing aspects Condition & status of boiler and their internals Feed water system aspects

Air and flue gas system aspect

Steps Involved In Boiler Energy Audit

Data collection

Observations and Analysis

Exploration for energy conservation measures Report preparation

Data Collection

Data Collection-boiler Specifications

Particulars Make Type Unit Details at Normal cont. rating, NCR XXXXXX Water Tube Single Drum 627.32 155 540 87.16 627.32 565.6 4350 106.2 822 420 540 241 280 4.23

Capacity
Main Steam pressure Main Steam temperature Boiler efficiency Super heater outlet flow Reheater outlet flow Calorific value GCV Coal consumption Total combustion air LTSH outlet temperature Reheater outlet temperature Water-economizer inlet temperature Water-economizer outlet temperature Oxygen content at Economizer outlet

tph
kg/cm2
0

% tph tph kcal/kg tph tph

0 0 0 0

C C C C

Data Collection-boiler Specifications

Unit
Make Type Year of Installation Main Steam Pressure Main Steam Temperature Main Steam Flow Steam pressure at LTSH outlet Steam temperature at reheater inlet Steam temperature at reheater outlet kg/cm2 oC tph kg/cm2 oC oC

Design/NCR

Actual

Steam pressure at reheater inlet

Steam pressure at reheater outlet Steam temperature at LTSH out Saturated steam temperature in drum Super heater platen outlet temperature Maximum pressure drop in reheater Super heater spray Reheater Spray Ambient temperature Coal consumption

kg/cm2
kg/cm2 oC oC oC Kg/cm2 tph tph oC tph

Data Collection- Economiser

Unit Feed water pressure at the inlet Feed water pressure at the outlet Feed water flow Feed water temperature at the inlet kg/cm2 kg/cm2 tph oC Design Actual

Feed water temperature at the outlet

Oxygen content in flue gas before/after economizer

oC
%

Excess air % in flue gas before/ after economizer

Flue gas inlet temperature Flue gas outlet temperature Flue gas quantity

%
oC oC tph

Data Collection: Air Pre Heater

Unit Air quantity at APH outlet (primary) Tempering air Air heater outlet (secondary) Total combustion air Air temperature at fan outlet Air outlet temperature of APH primary Air outlet temperature of APH secondary Oxygen content in flue gas before APH Excess air % in flue gas before and after APH Flue gas inlet temperature Flue gas outlet temperature Flue gas quantity tph tph tph tph oC oC oC % % oC oC tph Design Actual

Data Collection-flue gas temperature profile

Unit Super heater platen outlet
RH front inlet RH rear inlet SH finish inlet LTSH inlet Economizer inlet

Design oC
oC oC oC oC oC

Actual

APH inlet APH outlet ID Fan inlet

ID Fan outlet

oC oC oC
oC

Data Collection- coal parameters

Unit
Fixed Carbon Volatile Matter Moisture Ash Grindabiity index Coal calorific value-HHV Size of the coal to mill Total contract fuel fired % % % % HGI Kcal/kg mm tph

Design

Actual

Data Collection-boiler heat balance

Unit Ambient temperature Excess air Dry gas loss Hydrogen loss Moisture in fuel loss Moisture in air loss Unburnt combustible loss Radiation loss Un accounted loss Gross boiler efficiency on HHV oC % % % % % % % % % Design Actual

Data Collection- mills and burners performance

Unit Requirement at NCR Actual Remarks

No of coal burners Primary Air Fuel No of mills in operation Mill loading Air temperature at mill inlet after tempering Air fuel mixture temperature after leaving mills Total coal fired Air Fuel Ratio

No tph No % oC

oC

tph

Data Collection- coal mill specifications

Type of mill Capacity Fineness ______________ Make _________

__________tph at coal ________grind ___________% through ________mesh ____________kW ________ V No of mills :__________

Motor rating Motor voltage

Running /Standby

_________/________

Design coal parameter Moisture Ash Volatile matter Fixed carbon HGI _____% _____% _____% _____% _____%

Data Collection: Soot Blowers

Type Soot blowers for furnace Soot blowers super heaters Soot blowers for reheaters Number

Soot blowers for air preheaters

Medium of blow

Steam pressure before reduction

Steam pressure after reduction

Steam consumption

Data Collection: Case Example of 210/500 MW Unit

Data Collection: Boiler Specifications

Main Boiler Make Type Capacity Main Steam pressure Main Steam temperature CRH Pressure HRH Pressure CRH Temperature HRH Temperature Boiler efficiency Super heater outlet flow Reheater outlet flow Calorific value GCV Coal consumption NCR Natural Circulation, balanced draft, double pass, single drum, single re-heat, direct pulverized coal/oil firing, dry bottom type, tangential firing XXXXXX XXXX (210 MW) (500MW) tph 700 1681 kg/cm2 0C kg/cm2 kg/cm2 0C 0C % tph tph kcal/kg tph 154.9 540 37.2 38.7 333 540 87.3 645 571 3500 139 177.2 540 43.09 40.99 341.6 540 88.1 1524.27 1372.42 3750 299

Data Collection: Boiler Specification

Total combustion air LTSH outlet temperature Reheater outlet temperature Water -economizer inlet temperature Water-economizer outlet temperature tph 0C 0C 0C 0C 791 398 540 246 292 540 253 314 1853

Pressure drop in reheater

Super heater spray

Kg/cm2
tph

1.5
3.2

2.1
0

Reheater Spray
Ambient temperature

tph
oC

--27 28

Data Collection: Economiser

ECONOMISER Feed water pressure at the inlet Feed water pressure at the outlet Feed water flow Feed water temperature at the inlet Feed water temperature at the outlet Oxygen content in flue gas before economizer Excess air % in flue gas before economizer Flue gas inlet temperature Flue gas outlet temperature Flue gas quantityt APH I/L kg/cm2 kg/cm2 tph oC oC 169 167.3 659.4 246 292 3.54 % % % % oC oC tph 20 493 351 193.1 191.03 1524.27 253 314 3.59 20 356 136 2032

Data Collection: Air Pre Heater

Air Pre Heater Air quantity at APH outlet (primary) Tempering air Air heater outlet (secondary) Total combustion air Air outlet temperature of APH primary Air outlet temperature of APH secondary Oxygen content in flue gas before APH Flue gas inlet temperature Flue gas outlet temperature Flue gas quantity tph tph tph tph oC oC % oC oC tph 175 91 483 791 320 324 3.54 351 136 257 283 1263 1853 326 326 3.59 356 136 2032

Data Collection Flue Gas Temperature profile

Flue Gas Temperatures Super heater platen outlet RH front inlet RH rear inlet SH finish inlet LTSH inlet
0

Unit
0

210 MW
1165 1008 864 754 637 493 351 136

500 MW
1119 1034 905

C C C C C

788 561 356 136

Economizer inlet APH inlet APH outlet

C
0

C C

Data Collection: Heat Balance

Heat Balance Ambient temperature Excess air Dry gas loss Hydrogen loss Moisture in fuel loss Moisture in air loss Unburnt combustible loss Radiation loss Un accounted loss Total Losses Heat Credits Guaranteed efficiency oC % % % % % % % % % % % 0.12 1.2 0.11 1.11 13.14 0.44 87.28 0.16 0.60 0.29 0.40 11.50 0.20 88.10 210M 27 20 4.77 5.83 500MW 28 20 4.64 5.54

Data Collection: Recommended Boiler Water Parameters

Recommended FW limits Hardness pH at 25oC Oxygen maximum Total iron- maximum Total silica maximum Conductivity at 25oC Hydrazine residual Total solids maximum chlorides ppm ppm ppm Micor s/cm ppm ppb ppm Unit Feed water Nil 8.89.2 0.007 0.01 0.02 0.3 0.010.02 15 30 Boiler Water 9.19.6

Copper maximum

ppm

0.005

Permanganate consumption

ppm

Nil

Data Collection: Fuel Parameters

Fuel Parameters Ultimate Analysis Carbon Hydrogen Sulpuer Nitrogen Oxygen Total moisture Ash Gross calorific value Fuel Parameters Proximate Analysis Fixed Carbon Volatile matter Total moisture Ash

Unit
% % % % % % % Kcal/kg

110 MW
37.03 2.26 0.33 0.85 6.53 12.0 41.0 3500

500 MW

3750

% % % %

24.0 23.0 12.0 41.0

28 24 8 40

Measurements and Observations

Average GCV of coal Coal analysis ultimate and proximate Coal consumption details Performance parameters of coal mills Boiler efficiency Steam parameters of main steam, reheat, super heater, LTSH (flow, pressure and temperature) Air flow, temperature, pressures Flue gas Flow, temperature and pressure Flue gas analysis Coal consumption pattern

Measurements and Observations

Ambient temperature Boiler loading Motor electrical parameters (kW, kVA, Pf, A, V, Hz, THD) etc. Surface temperatures of insulation and boiler surfaces Other important Parameters Unit load of the plant Date & time of measurement Instruments used for measurement Frequency of the measurement

Measurements and Observations

Availability factor PLF Coal consumption (tons and kg/kWh) Oil consumption in ml/kWh Boiler efficiency Past performance trends on boiler loading, operation, PLF, efficiency Major constraints in achieving the high PLF, load or efficiency (Input from plant personnel) Major renovation and modifications carried out in the recent past

Coal quality and calorific values aspects

Operational failures leading to in efficient operation such as tube failures, constraints for efficient heaters operation

Measurements & Observations

Soot blowers operation Tripping

Performance of economiser, air preheaters, LP / HP heater from

past records Combustion control system practice followed

Mills performance
If plant has online and off line tools for performance evaluation of main equipment and BOP equipment then details of these tools

Plant side initiatives to improve the performance and efficiency of

the boiler

Instruments Required For Boiler Auditing

Instruments Required
Power Analyser: Used for measuring electrical

parameters such as kW, kVA, pf,V, A and Hz Temperature Indicator & Probe Stroboscope: To measure the speed of the driven

equipment and motor Sling hygrometer or digital hygrometer Anemometer Available On line instruments at the site ( Calibrated )

Instruments Required
Digital Manometer of suitable range and appropriate probes for measurement of pressure head and velocity head

Additional pressure gauges with appropriate range of measurement and calibrated before audit

Flue gas analyzers / orsat apparatus

Infrared pyrometers

Pressure gauges
Steam trap tester / Ultra sonic leak detectors

Pre audit Checks

Trials are conducted at least for two hours and measurements are to be taken every fifteen minutes

Ensure during Auditing:

Load on the boiler to be by and large constant and represent average loading and normal operation No soot blowers operated No intermittent blow down Preparedness for simultaneous data measurements and collection of various parameters. Demo exercise for one set of measurement and observation

Measurement Locations
Flue gas analysis at air preheaters inlet / out let Temperature of flue gas at air preheaters inlet / out let Fly ash sampling at the economiser outlet and ESP hoppers for unburnt carbon in fly ash

Sample of bottom ash from hopper or scrapper

Sample of raw coal from RC Feeder of the mill for proximate and ultimate analysis of fuel and gross calorific value. Pulverised coal samples from each mill for sieve analysis. Sample of mill rejects for GCV.

Data Analysis

Observations & Analysis

Operating efficiency of the boiler: Heat loss due to dry flue gas losses Heat loss due to moisture in fuel Heat loss due to hydrogen (moisture of burning hydrogen) Heat loss due to combustibles in refuse

Heat loss due to radiation

Un accounted losses as per the contract with the Boiler Supplier

Data Sheet Boiler Efficiency Evaluation

Data Sheet Boiler Efficiency Evaluation

Data Sheet Boiler Efficiency Evaluation

Computation of Boiler Losses

1. Dry flue gas loss: Theoretical Air Requirement

Actual Air Requirement

Dry Flue Gas Quantity (Wd), Kg/Kg of fuel

Dry flue Gas Loss Ldfg %

Computation of Boiler Losses 2. Loss due to unburnt carbon in ash:

Loss due to unburnt carbon in ash, Luca Calorific value of carbon in kcal / kg (C % FA FAsh) (C % BA BAsh) GCV of fuel, GCV

3. Loss due to moisture in fuel:

Loss due to moisture in fuel , Lmf M (0.45 ( FGT ABT ) 584 100 GCV

4. Loss due to hydrogen in fuel:

Loss due to hydrogen in fuel , Lhf 9 H2 (0.45 ( FGT ABT ) 584 100 GCV

Where H2 kg of H2 in 1 kg of fuel

Computation of Boiler Losses 5. Loss due to moisture in air:

Loss due to in moisture in air, Lma AAS humidity 0.45 ( FGT ABT) 100 GCV

Where AAS=Actual mass of air supplied Humidity = humidity of air in kg/kg of dry air

6. Loss due to CO in flue gas:

Loss due to carbon monoxide, Lco CO in ppm 106 fuel consumption in kg / h 28 5744 100 GCV

Loss due to carbonmonoxide, Lco

CO% C 5744 100 CO% CO2 % GCV

Efficiency evaluation of Boiler

Particulars Unit MW kcal/kg % % % % % % % % % % Design Value Actual value % Deviation Remark

Date & time of the test

Load Fuel GCV Loss due to hydrogen in fuel Loss due to Dry Flue gases, Ldfg Loss due to moisture in Air Loss due to unburnt carbon in ash, Luca Loss due to moisture in fuel, Lmf Loss due to carbon monoxide, Lco Radiation monoxidelosses Unaccounted losses & manufacturers margin Total losses Boiler Efficiency

BoilerHeat Balance

5.5% 4.2%

Heat loss due to dry flue gas

Dry Flue Gas Loss

Heat loss due to wet flue gas Heat loss due to moisture in fuel Heat loss due to moisture in air Heat loss due to unburnts in residue Heat loss due to radiation & other unaccounted loss

Heat 100% from Fuel

BOILER

1% 0.3% 1% 1%

87%

Boiler Efficiency (Heat in Steam)

Energy Audit- Coal Milling System

Energy Audit- Coal Milling System

Objectives of energy audit :
To evaluate specific energy consumption

(kWh/ton of coal)
To establish air to coal ratio of the mills (ton of

air per ton of coal)

To evaluate specific coal consumption of the

unit (kg /kWh)

Compare the actual consumption with

design/pg test values

Suggest ways to optimise energy consumption

Energy Audit- Coal Milling System

Overview of system includes mills, RC

feeders, PA fans, seal air fans,mill reject handling system and associated ducts, piping, valves and dampers, lubrication system, thermal insulation status of mills/pa fans ducts/piping etc. rejects,mill gearbox oil, fly ash and bottom ash

Samples of raw coal, pulverised coal, mill

Energy Audit- Coal Milling System

Raw Coal:

GCV, ash content, volatile matter, fixed carbon, total moisture,and HGI value of coal. Mill fineness (% passing through 200 mesh), Running hours of mill grinding elements with material composition of each part, Individual RCF coal integrator readings be compared with overall coal integrator readings. Ash content and gross calorific value of mill rejects, FlyAsh, Bottom Ash and Combustibles in fly ash and bottom ash & GCV. Viscosity, moisture, mechanical impurities and appearance of lubricating oil of mill gearboxes.

Pulverised Coal:

Mill Reject Coal:

Mill Gear Box Oil:

Energy Audit- Coal Milling System

Observations

Energy Audit- Coal Milling System

Coal fineness

Mill rejects

COMBUSTION CONTROL, EXCESS AIR AND COLD AIR INGRESS

While conducting the study, the following need to be verified: Present excess air and comparison with PG test or design value

Combustion control systems installed and status of operation,

calibration systems Monitoring and controlling mechanism for oxygen, excess air and reporting systems in place Effect of excess air on boiler performance Excess air with respect to boiler load variation

Cold air infiltration in to the system observe the present method of measurement, estimation, frequency of measurement for estimating the losses and control mechanisms initiated.

PERFORMANCE OF AIR PREHEATERS

Air leakage estimation in APH:
The following gives the air leakage in to the (APH) system if the Oxygen % is measured at the entry and exit of the APH

Alternatively, if the CO2% is measured in the exhaust gases then the air leakage is estimated by

PERFORMANCE OF AIR PREHEATERS

Gas side efficiency: The gas side efficiency is defined as the ratio of the temperature drop, corrected for leakage, to the temperature head and expressed as percentage.

Temperature drop is obtained by subtracting the corrected gas outlet temperature from the inlet. Temperature head is obtained by subtracting air inlet temperature from gas inlet temperature.

PERFORMANCE OF AIR PREHEATERS

Theoretical

Total air = PA+ SA+ Seal air

tph

EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES

Boilers:
Steam and water parameters ( flow, pressure and temperature )

Air and gas parameters ( flow, pressure and temperature )

Burners operation Primary and secondary air ratios and temperatures

Air infiltration in to boilers

Unburnt loss reduction Combustion control boiler excess air, O2 Measurement inaccuracy or unbalance

Dry flue gas loss

Insulation Air infiltration to flue gases Water quality, Blow down and its control

EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES

Stack Temperature

Boiler Soot Deposits, High Excess Air , Air inleakages before the combustion chamber, Low Feed Water Temperature , Passing dampers and poor air heater seals , Higher elevation burners in service, Improper combustion

Incomplete Combustion

Poor milling i.e. Course grinding, Poor air/fuel distribution to burners, Low combustion air temperature, Low primary air temperature, Primary air velocity being very high/very low, Lack of adequate fuel/air mixing..

EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES

Dry flue gas loss.

Air in-leakage through man holes, peep holes, bottom seals, air heater seal leakage, uneven distribution of secondary air, inaccurate samples/analysis.

Poor automatic boiler SADC, burner tilting, O2 control. Radiation and convection heat loss.

Casing radiation, sensible heat in refuse, bottom water seal operation, not much controllable but better maintenance of casing insulation can minimize the loss.

EXPLORATION OF ENERGY CONSERVATION OPPORTUNITIES

Blowdown. 1 % of blow down carries a 0.17% heat added, in the boiler, 0.25% heat is required to make up accounts to 0.42% so blow down to be adhered to the chemist requirement.

Scaling and soot losses.

Super heated steam with high enthalpy is used. 1% of steam may be required, contains 0.62% heat content, to make up the loss another 0.25% heat to be added to feed water resulting total heat loss of 0.87%. Frequency of soot blowing must be carefully planned. Auxiliary power consumption.

Saving Analysis with improvement in efficiency

Fuel Saving

S% = (new- asis)*100/ new

Annual energy savings Annual cost savings

as is = the actual system efficiency CMWh = Fuel costs in Rs/MWh where MWh1 refers to energy in the fuel PLF = plant load factor as a fraction

Case Study: 1. 2. Optimization of Excess Air Optimization of PA to SA

Optimization of Excess Air

Parameter Excess air at boiler exit % Excess air at APH exit FG temp. at APH exit 0c Dry Flue gas loss % Heat loss due to CO % %

Design 19.0 28.0 146.0 5.08 0

measured 23.6 55.6 167.6 8.89 0

Observation Excess Air and cold air Ingress also causes ID fan loading Excess FG temp. at APH Causes & Actions Worn out seals and heat Transfer elements-Attended Leakage through peep/port holes-Attended Soot formation on the heat transfer area- S B done Results 2.83% effciciency impr. in Reduction Coal consumption By 74490 T/A Rs.63.09 saving (Rs. 847 /T)

Heat loss due to moisture in air %

Heat loss due to moisture and H2 in fuel % Heat loss due to unburnt in ash Sensible heat loss in ash % %

0.12
5.95 0.90 0.56

0.18
5.78 0.09 0.59

Surface and unaccounted losses %

Design margin % Total heat losses %(corrected)

0.17
0.5 12.57

0.10

14.93

Thermal efficiency

87.43

85.07

Efficiency Evaluation of 500 MW unit

Optimization of PA to SA
Type Unit PAF A PAF B FD A FD B

Capacity

M3/ 55 sec Total design mm 1212 head wc Fan Speed rpm 1480 Fan Inlet regulation damper type control Fan motor kw 900 rating Operating parameters Air Flow M3/ 65.27 sec Power kw 920 consumptio n System % 78.6 Efficiency Ratio of PA 56.7 (40)

55 1212 1480 Inlet damper control 900

58.4 450 1480 Blade pitch control 400

58.4 450 1480 Blade pitch control 400

Observation (120MW unit) Higher PA to SA ratio Result Adjustment of ratio, power consumption reduced from 2090 kw to 1760 kw Saving of Rs. 3.22 M/A, cosidering 7500 hrs/year and Rs. 1.30 per kwh

56.34
907 67.0

24.8
78 66.5 43.3 (60}

68.0
185 77.5

BoilerHeat Balance

5.5% 4.2%

Heat loss due to dry flue gas

Dry Flue Gas Loss

Heat loss due to wet flue gas Heat loss due to moisture in fuel Heat loss due to moisture in air Heat loss due to unburnts in residue Heat loss due to radiation & other unaccounted loss

Heat 100% from Fuel

BOILER

1% 0.3% 1% 1%

87%

Boiler Efficiency (Heat in Steam)