Showing posts with label Performance Boiler. Show all posts
Showing posts with label Performance Boiler. Show all posts

Performance Testing of Boiler


Performance testing of boiler and heat balance are last stages of its execution. The last action of performance testing of boiler is implemented by running over of power plant and also finalized economical funds by the user. The guarantee time period of steam boiler begins after that. Consequently, it truly is very crucial in which the performance testing methods are performed impartially to prevent costly legal combat. Therefore, performance testing of boiler should be done in accordance with Code ASME PTC 4 (American Society of Mechanical Engineers Performance Test Code) or DIN 1942 for German Code or BS 2885 for British Code.

Performance testing of boiler is ideally performed at a new steam boiler prior to the normal use and also dissects controls in. However this can be commonly impossible for several factors. Once of purchase it can be common to determine the actual time frame restriction prior to performance testing of boiler might be done and the way in which it might be executed. In small scale of power plant it can be feasible to in-take steam as long as complete testing.

Whether performance testing of boiler is important to be performed? In case it isn't obligatory according to contractual conditions, Performance testing is usually eliminated due to the fact that it need a lot of preparation works such as equipment, tools, manpower, materials and the others. In addition, it can be important in which the power plant be given to the provider to permit for setting of steam boiler approximately seven days. This results in a specific impairment of boiler accessibility, which in turn the power plant would possibly not manage to pay for. Furthermore, the power plant users can simply decide whether a steam boiler is reaching performance requirements. A performance testing of boiler is commonly needed exclusively if there may be a worry of decreased or limited performance.

Major performance (%) = net output / total input

It can be primary rating of performance when the output of steam could be calculated. The following formula can be taken by replacing input = loss + output;

Major performance (%) = 100 - (heat losses / fuel input)

Performance assessment acts 2 functions:
  1. Popularity of a repaired or new steam boiler to verify no matter if the guaranteed performance continues to be supplied
  2. A program rating in a working power plant to evaluate no matter if training correction is required

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Performance Assessment of Boiler

A procedure of performance assessment of boiler must be integrated in the system of power plant. In addition to checking performance of equipment and tool, the personnel who operate the power plant could assess the influences of the incorporated plant control method. A system of efficient performance assessment of boiler can present appropriate performance of equipment that, any time provided as required, provides safe, inexpensive and efficient operation of boiler. Utilizing preventive maintenance programs which identify bad performance increases plant productivity and also provide the life of boiler is longer. Actual-period assessment and checking of important operating information allows the personnel create prepared and appropriate decisions.

Actual performance assessment of boiler and power plant is remarkable to determine considered performance programs for the reason that the considered performance of boiler or power plant's equipment could be compared specifically while using predicted performance within same working conditions. Therefore, real changes in performance of power plant and boiler equipment are effortlessly observed. Performance assessment for each unit is carried out based on Code ASME PTC (American Society of Mechanical Engineers Power Test Code).

The conclusion of essential characteristics of performance assessment of boiler as follow:
-          Showing final results at boiler system
-          Dedication of predicted boiler performance
-          Actual performance calculations

The following are performance assessment that shows to assistance personnel read the information:
-          Degeneration of plant parts show
-          Controlled variables show
-          Total plant performance show

Every class of shows is developed intended for a certain class of personnel. Such as, plant operations is involved in total present comparative to past performance of boiler or plant although the operators are involved with supervising controlled variables, permitting the best economical operation.

Stats are utilized in the performance assessment data, providing a assurance period per performance indication. Not necessarily understanding the correctness of provided calculation could result in mistaken results and next faulty selections on improvements and maintenance of equipment. It is consequently important to give quantitative indicator of the precision final result.

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Boiler Rating


Boiler rating is a rating that shows performance and productivity of boiler. There are 3 forms unit to show boiler rating which are generally applied; Boiler horsepower (BOHP), kW rating, and ‘From and at’ rating.

  1. Boiler horsepower (BoHP)
Boiler horsepower (BoHP) is one of unit to show boiler rating, BoHP is commonly applied exclusively in the New Zealand, Australia, and USA. At New Zealand, BoHP rating is formula of area of heat transfer and applies to heating surface of 17 ft2 in the boiler, seeing that shown in the following equation:

Boiler Horsepower (BoHP) = area of heat transfer (ft2) x (1/17)

Boiler horsepower (BoHP) isn't normally acknowledged conversion component of 1 horsepower = 746 Watts and also the frequently recognized 550 ft lbf/s doesn't use.

  1. kW rating
Several boiler makers can express boiler rating in form of kW. kW rating isn't the rate of evaporation and also this rating be more responsive to similar aspect of ‘from and at’ rating. To determine the exact evaporation by way of mass, it can be earliest important to recognize the steam pressure which is generated and the feedwater temperature, to be able to determine the amount of energy is put in to each one kg of water. Boiler rating with kW form can be calculated by using following equation:

Boiler rating (kW) = Steam output (kg/h) / ((3600 s/h) / (added energy in kJ/kg))

  1. “From and at” rating
This rating is commonly applied as a datum simply by steam boiler makers to provide boiler rating that indicates the quantity of steam in kilo gram per hour (kg/h) that boiler may generate at atmospheric pressure, “from and at 100°C”. Each one kilogram of steam could subsequently has obtained heat 2.257 kJ.

Steam boiler is frequently run by using temperature of feedwater  under 100°C. Therefore boiler is needed to provide enthalpy to deliver water upward to boiling stage. A lot of steam boilers operate at pressures greater compared to atmospheric pressure, due to the fact that steam at an increased pressure provides extra heat energy compared to steam at temperature of 100°C. The following requires more enthalpy of water in saturation temperature. When the pressure of steam boiler increases, the temperature of saturation will be enhanced, requiring extremely enthalpy previous to feedwater is delivered around boiling temperature.

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Boiler Efficiency Calculation


According to PTC (Power Test Code) 1.4 ASME (American Standard of Mechanical Engineering) there are two methods for boiler efficiency calculation namely: input output method and heat loss method. The following below is further explanation of the boiler efficiency calculation methods:
  1. Input-output method
η = Output / Input

Output is defined as the heat that is absorbed by working fluid. Input is defined as the chemical heat of fuel plus the heat that is added to working fluid, air, gas and other fluid circuit in which the fluid circuit across thin layer.

  1. Heat Loss Method
Heat loss method is the method that is used to calculate the percentage amount of heat which is not useful. This method is very effective used in an attempt to find potential savings of boiler with heat balance.

There are several factors act as the source of heat loss combustion. These factors will be used to calculate boiler efficiency based on heat loss method. The source of heat loss can be seen as following below:
Heat loss due to dry flue gas is the heat loss which is contained in dry flue gas such as CO2, O2 and N2. These gases are one of causes of heat loss in combustion process. The high temperature of flue gas coming out from boiler affect amount of heat loss.

The weight and heat loss of dry flue gas of combustion of coal can be calculated as following formula:
Wdfg = mCO2 + mSO2 + mO2 + mN2
Eloss dfg = Wdfg x Cp x (To - Ts)

Where:
Wdfg          = weight of dry flue gas (kg/kg coal)
Eloss dfg        = heat loss in dry flue gas (kJ/kg)
To              = temperature of dry flue gas coming out from boiler
Ts              = temperature of surrounding air

There are two sources of steam contained in flue gas. It is steam from burning H2 and steam from fuel moisture coupled with steam present in combustion air.

-          The calculation formula of heat due to steam from burning H2 is:
WH2O = 9 x H2
Eloss H2 = WH2O x (hg - hf)

Where:
WH2O = weight of water content (kg/kg coal)
Eloss-H2O = amount of heat loss due to steam from burning process of hydrogen (kJ/kg)
Hg = enthalpy of steam at the temperature of flue gas coming out from boiler
hf = enthalpy of water at surrounding air temperature.

hg and hf can be seen in Table 1 below.
Table 1: Saturated Water and Saturated Steam
-          Steam from fuel moisture and combustion air
Calculation of heat loss due to steam from fuel moisture and combustion air: can be seen in the following formula:
Eloss-H2O = (WH2O-coal + WH2O-air) x (Hg - Hf)

Where:
Eloss-H2O = amount of heat loss due to steam from fuel moisture and combustion air

  1. Heat loss due to unburned carbon
The calculation is assumed level of excess air is provided about more 20% and combustion that occurs only produces unburned carbon about 1% of carbon content in fuel. Calculation of heat loss due to unburned carbon can be seen as following formula:

Eloss-UC = WUC x HHVcarbon

Where:
WUC = weight of unburned carbon (kg/kg)
HHVcarbon = highest heating value (kJ/kg)
Eloss-UC = amount of heat loss due to unburned carbon

  1. Heat loss due to radiation
The amount of heat loss due to radiation depends on the rate of heat which is released in combustion furnace. Based on the ABMA chart (American Boiler Manufacturers Association), at big heat release rate, the amount of heat loss due to radiation tends to constant. The heat radiation that occurs is estimated 0.2% calorific value of fuel.

  1. Uncountable heat loss
There are several sources that can cause heat loss in combustion, where the value is too complicated to be calculated certainly. This heat loss is called as uncountable heat loss. The amount of uncountable heat loss is about 0.3% of calorific value of fuel.
  1. Heat losses in the boiler if the heat is used only for warming fluid only.

Total heat loss that may occur in boiler system can be calculated as formula below, so boiler efficiency calculation can be determined.

Eloss total = Eloss-dfg + Eloss-H2 + Eloss-H2O + Eloss-UC + Eradiation + Euncountable
READ MORE - Boiler Efficiency Calculation

Feedwater Regulator

Feedwater is the water to be supplied into steam boiler. Requirement of feedwater is regulated by ABMA (American Boiler Manufacturing Association). Water treatment is one of step in this requirement. Temperature of feedwater influence efficiency of steam boiler, higher temperature will increase the efficiency, so feedwater heater is required in the feedwater system.

Amount of feedwater is maintained to keep steam boiler on the range of NOWL (Normal Operation Water Level). Maintain water level is totally important to keep steam boiler safe from both short term overheating or long term overheating and also damage turbine generator.

There are three types of feedwater regulators commonly used in the power plant system. The type of feedwater regulator is generally used based on function, size, and the principal working. The following below are the feedwater regulator type:

1.      Thermostatic Expansion Regulator.
This type is feedwater regulator which uses inclined tube and connects it between feedwater control valve and boiler. If the water level in the boiler indicates low level, the tube will get expansion, so the feedwater control valve will supply the feedwater.

2.      Hydraulic Regulator
This type is feedwater regulator which consist tube, fin, and jacket. This regulator use tube which be connected between water column in the steam drum and feedwater control valve. When water level show low level which means that amount of steam steam is higher than water, the steam will enter the tube, at the certain temperature and pressure, the valve will open to supply feedwater into steam boiler.

3.      Float Regulator
This type is feedwater regulator which uses floating equipment like a ball and connects it to the boiler. The floating ball will move up and down parallel with water level in the boiler. A connecting system must be set up between this equipment and the feedwater control to maintain the steam boiler water level in the range NOWL.
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How to Run Steam Boiler Perfectly

Steam boiler needs requirements condition to perform it perfectly and efficiently. How to run steam boiler perfectly is a question that must be considered. The regulation must be fulfilled as follow:

1.      Feedwater will be supplied to steam boiler must be treated in water treatment system. Requirement of contents consist of PH, oxygen, silica, hardness, etc must be met.
2.      All personnel involved in work on steam boiler should has good capability such engineer, designer, drafter, fabricator, erector, etc.
3.      Circulation of water and steam must be constant.
4.      Perform maintenance program, check equipments daily or weekly, clean surface boiler tubes from soot and ash with soot blower.
5.       Design good combustion process by choose high quality fuel, enough excess air and well circulation of flue gas.
6.      Perfect firing should be performed in the furnace, before flue gas escape from furnace to give highest efficiency.
7.      Steam boiler should be equipped with safety gauges such as safety valve, relieve valve, venting valve, water level, and so on.
8.      All structures for support steam boiler must have enough strength to resist all of boiler loads.
9.      Chemical injection should be supplied to remove hardness.
10.  Before running steam boiler, all of equipment should be tested by hydrostatic test, air leakage test, etc.
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Properties of Steam

Boiler output which is required to generate turbine generator is steam. Engineer or designer of steam boiler must have good understand about properties of steam. The properties of steam should be known are specific volume, specific entropy and enthalpy.

Specific volume of steam is volume (expressed as m3) divided by unit mass (expressed as kg) of steam at certain pressure. Specific volume will different if steam is produced at different pressure. Specific entropy of steam is the amount of energy (expressed as Joule) which be divided by unit mass (expressed by kg) at certain temperature (expressed as C). Enthalpy is measure energy (expressed as Joule) which is divided unit mass (expressed by kg).

The properties of steam can be seen in the steam table of ASME International Steam Tables for Industrial Use and the calculation properties of steam can be performed based on code International Association for the Properties of Water and Steam (IAPWS). At saturation condition by means that steam and water are mixed, steam will has different properties based on temperature and pressure. If the mixture heated exceeds saturation temperature, the steam will be superheated, but on contrary if the mixture cooled under saturation temperature, the water will be sub cooled.
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Outlet Temperature in Superheater

Superheater is one of pressure parts in steam boiler. Superheater has some classifications. Outlet temperature in steam boiler is temperature of steam when leaves superheater that will be distributed to steam turbine. Outlet temperature in superheater is usually higher than outlet temperature in another pressure parts.

Based on use classification, process heating boiler has outlet temperature in superheater not exceed 350 C and the steam temperature is generally not adjusted. This condition is difference with power boiler, steam outlet temperature leaves superheater is usually above 400 C and need to adjust it.

Adjust steam outlet temperature in power boiler can be performed by using desuperheater or attemperator. The function is decrease outlet temperature if the temperature is higher than expected. One of methods to decrease steam temperature is using spray desuperheater. It spray water flow from feed water piping, so steam flow receive low temperature from water then decrease temperature it self. Location of spray desuperheater is usually between primary superheater and secondary superheater. Another way to adjust steam outlet temperature is maintain steam temperature control constant until load generally 70%. – 100% maximum continuous rating.

Steam temperature control can be executed by control excess air, burner management system, and flue gas circulation to gain maximum efficiency. Flue gas circulation should be controlled to give certain temperature when pass through both primary superheater and secondary superheater also ensure they had received enough heat transfer to generate expected steam outlet temperature.
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Optimizing Heat Transfer in Steam Boiler

Heat transfer within steam boiler can be performed by three ways and by their combination; radiation, conduction, and convection. Optimizing heat transfer should be done to maximize efficiency of steam boiler. The followings are the ways to optimize heat transfer:

1.      Control excess air
Composition of excess air should be controlled, if excess air is too much will effect temperature of flue gas low because of cooling from excess air, but on contrary if amount of excess air is too low will cause flame temperature is high.

2.      Keep clean boiler tubes
Tubes receive heat from combustion furnace by radiation and heat is distributed to all of surface metal tubes by conduction. The presence of soot, ash and scale will obstruct heat transfer because they are poor conductor. Any deposit on outside surface tubes can be cleaned by soot blower, while any scale in inner side tubes can be prevented if water treatment is undertaken well.

3.      Keep optimum flue gas and feedwater
Feedwater should be treated free from sludge and scale to ensure water can receive good heat transfer and can flow with a certain velocity. Optimum flue gas can be taken by doing routine maintenance and choose optimum fuel.
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Combustion of Coal in Steam Boiler

Coal as one of fuels for combustion process contains fix carbon, ash, volatile matter and moisture. Coal can be classified based on them. In the combustion system of boiler, coal needs oxygen and heat (certain temperature) to perform firing. Coal can be fired by two methods; underfeed stoker firing and overfeed stoker firing, for more details see here.

When we discuss overfeed stoker firing in which approximately 8 inch coal bed is arranged above stoker grate, air should be distributed from bottom the grate and a layer of ash are passed first. Oxidizing zone occur when oxygen content in air pass through the first layer of burning coal which contain fix carbon. When burning process, heat temperature will increase and drying raw coal from moisture and volatile matter.

Over fire air as excess air is needed to perform complete combustion because distributed air from bottom grate can not burn volatile matter and carbon monoxide perfectly. Composition of air combustion should be controlled, does not be over and less regarding to efficiency of combustion. At firing which has low rate, level of over fire air should be minimized to eliminate possibility of cooling on volatile matter, so the combustion will be incomplete. At firing which has high rate, amount excess air is determined by the ability to totally mix over fire air, carbon monoxide and volatile matter to perform complete combustion.
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Water Level Indication in Steam Boiler

Steam boiler use water level indication to detect the water level in steam drum. Steam drum usually uses gauge glass as its indicator. A lot of rules determine to use and arrange two gauge glasses especially for steam boiler which has maximum allowable working pressure above 400 psi or above 28 bar to reduce possibility of breakage which can cause the operator in danger. Gauge glass is a tool consisting prismatic glass which is design to resist high pressure (see figure 1) and allow the operator to see water level in the normal condition, under normal and above normal water level.

Fig. 1: Water Level Gauge Glass in Steam Boiler
Source: Book - The Boiler House - The steam and condensate lopp - spirax sarco
Water level can be designed for remote or direct viewing. Sometimes water level is difficult to be seen clearly because there are steam and many bubbles at the water surface and high pressure / temperature make more water fluctuation.

Water level indicator has two types for direct viewing and remote viewing. Each type has kind of product type:

1.      Water level indicator for direct viewing
  • Tubular gauge glass
  • Reflex type gauge glass
  • Transparent gauge
  • Bicolor gauge
  • Port type bicolor gauge
  • Multiple gauge

2.      Water level indicator remote viewing
  • Manometric gauge
  • Electronic gauge
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Design Water Level in Steam Boiler

Steam boiler has a important function to produce steam with the best quality and efficient. Combustion process give heat transfer to water inside water wall tubes then water will be evaporated continuously to generate steam. In the process of steam release, steam boiler needs a certain amount of water surface area. Tolerance of height water level slightly exceeding normal water level should be considered if at any time the increase in load which allow the rise elevation of water level but still within safety limit.

Engineer who design steam boiler should make sure that steam can be produced in calculated area of normal water level and steam can be distributed with the correct velocity. Specific the lowest height of steam which can be generated above normal water level should be determined. The normal water level should be maintained, so supply of feedwater must be maintained, do not be shortage.

If steam boiler is performed with insufficient feedwater or under normal even low water level then steam boiler will has high possibility to explosion and damage. Therefore some actions should be taken such as maintain water level and give good actions if low water level is detected. The actions are turn on the alarm and turn off the operation of steam boiler.
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Code and Calculation Required in Performance Assessment

Performance of power plant generally and steam boiler specifically should be assessed to evaluate them, so they can perform perfectly and give highest efficiency. Performance of all of equipments should be monitored and maintained to give reliable, economical and safety operation. Beside that, performance assessment of steam boiler is used to detect when boiler running with poor efficiency and extend the life of steam boiler.

Code and calculation of performance assessment are taken based on American Society of Mechanical Engineer (ASME) Power Test Code for each equipment. The performance assessments include:

  • Efficiency of Steam Boiler Based on ASME 4.1
  • Performance Calculation of Feedwater Heater
  • Performance Calculation of Steam Turbine Based on ASME PTC 6
  • The calculations include efficiency, heat rate and steam flow of steam turbine.
  • Calculation of Turbine Cycle Based on ASME 6.1
  • Performance Calculation of Condenser Based on ASME PTC 12.1-1983
  • The calculations include transmittance of thermal, pressure, fouling resistance, cleanliness factor, and cooling process of condenser.
  • Performance Calculation of Overall Plant
  • The calculations include heat rate, thermal efficiency and output power either gross or net of overall plant.
  • Performance Calculation of Cooling Tower
  • The calculations include range, approach, and cold water temperature of cooling tower.
  • Performance Calculation of Gas Turbine Based on ASME PTC 22
  • The calculations include heat rate, fuel consumption, output power and thermal efficiency of gas turbine.
  • Performance Calculation of Heat Recovery Steam Generator Based on ASME PTC 4.4-1981
  • The calculation include efficiency, fuel consumption, pinch point and overall effectiveness of HRSG
READ MORE - Code and Calculation Required in Performance Assessment