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1. ENERGY PERFORMANCE ASSESSMENT OF BOILERS

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1. ENERGY PERFORMANCE ASSESSMENT OF BOILERS 1.1 Introduction Performance of the boiler, like efficiency and evaporation ratio reduces with time, due to poor combustion, heat transfer fouling and poor operation
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1. ENERGY PERFORMANCE ASSESSMENT OF BOILERS 1.1 Introduction Performance of the boiler, like efficiency and evaporation ratio reduces with time, due to poor combustion, heat transfer fouling and poor operation and maintenance. Deterioration of fuel quality and water quality also leads to poor performance of boiler. Efficiency testing helps us to find out how far the boiler efficiency drifts away from the best efficiency. Any observed abnormal deviations could therefore be investigated to pinpoint the problem area for necessary corrective action. Hence it is necessary to find out the current level of efficiency for performance evaluation, which is a pre requisite for energy conservation action in industry. 1.2 Purpose of the Performance Test To find out the efficiency of the boiler To find out the Evaporation ratio The purpose of the performance test is to determine actual performance and efficiency of the boiler and compare it with design values or norms. It is an indicator for tracking dayto-day and season-to-season variations in boiler efficiency and energy efficiency improvements 1.3 Performance Terms and Definitions Heat output 1. Boiler Efficiency, η = x100 Heat input Heat in steamoutput ( kcals) = x100 Heat in fuel input ( kcals) 2. Evaporation Ratio = Quantity of Quantity of steam generation fuel consumption 1.4 Scope The procedure describes routine test for both oil fired and solid fuel fired boilers using coal, agro residues etc. Only those observations and measurements need to be made which can be readily applied and is necessary to attain the purpose of the test. Bureau of Energy Efficiency 1 1.5 Reference Standards British standards, BS845: 1987 The British Standard BS845: 1987 describes the methods and conditions under which a boiler should be tested to determine its efficiency. For the testing to be done, the boiler should be operated under steady load conditions (generally full load) for a period of one hour after which readings would be taken during the next hour of steady operation to enable the efficiency to be calculated. The efficiency of a boiler is quoted as the % of useful heat available, expressed as a percentage of the total energy potentially available by burning the fuel. This is expressed on the basis of gross calorific value (GCV). This deals with the complete heat balance and it has two parts: Part One deals with standard boilers, where the indirect method is specified Part Two deals with complex plant where there are many channels of heat flow. In this case, both the direct and indirect methods are applicable, in whole or in part. ASME Standard: PTC-4-1 Power Test Code for Steam Generating Units This consists of Part One: Direct method (also called as Input -output method) Part Two: Indirect method (also called as Heat loss method) IS 8753: Indian Standard for Boiler Efficiency Testing Most standards for computation of boiler efficiency, including IS 8753 and BS845 are designed for spot measurement of boiler efficiency. Invariably, all these standards do not include blow down as a loss in the efficiency determination process. Basically Boiler efficiency can be tested by the following methods: 1) The Direct Method: Where the energy gain of the working fluid (water and steam) is compared with the energy content of the boiler fuel. 2) The Indirect Method: Where the efficiency is the difference between the losses and the energy input. 1.6 The Direct Method Testing Description This is also known as input-output method due to the fact that it needs only the useful output (steam) and the heat input (i.e. fuel) for evaluating the efficiency. This efficiency can be evaluated using the formula: Boiler Efficiency = Heat Output x100 Heat Input Bureau of Energy Efficiency 2 Water Steam Output 1. Energy Performance Assessment of Boilers Flue Gas Fuel Input 100% + Air Boiler Efficiency = Heat addition to Steam x 100 Gross Heat in Fuel Boiler Efficiency = Steam flow rate x (steam enthalpy feed water enthalpy) Fuel firing rate x Gross calorific value x Measurements Required for Direct Method Testing Heat input Both heat input and heat output must be measured. The measurement of heat input requires knowledge of the calorific value of the fuel and its flow rate in terms of mass or volume, according to the nature of the fuel. For gaseous fuel: A gas meter of the approved type can be used and the measured volume should be corrected for temperature and pressure. A sample of gas can be collected for calorific value determination, but it is usually acceptable to use the calorific value declared by the gas suppliers. For liquid fuel: Heavy fuel oil is very viscous, and this property varies sharply with temperature. The meter, which is usually installed on the combustion appliance, should be regarded as a rough indicator only and, for test purposes, a meter calibrated for the particular oil is to be used and over a realistic range of temperature should be installed. Even better is the use of an accurately calibrated day tank. For solid fuel: The accurate measurement of the flow of coal or other solid fuel is very difficult. The measurement must be based on mass, which means that bulky apparatus must be set up on the boiler-house floor. Samples must be taken and bagged throughout the test, the bags sealed and sent to a laboratory for analysis and calorific value determination. In some more recent boiler houses, the problem has been alleviated by mounting the hoppers over the boilers on calibrated load cells, but these are yet uncommon. Heat output There are several methods, which can be used for measuring heat output. With steam boilers, an installed steam meter can be used to measure flow rate, but this must be Bureau of Energy Efficiency 3 corrected for temperature and pressure. In earlier years, this approach was not favoured due to the change in accuracy of orifice or venturi meters with flow rate. It is now more viable with modern flow meters of the variable-orifice or vortex-shedding types. The alternative with small boilers is to measure feed water, and this can be done by previously calibrating the feed tank and noting down the levels of water during the beginning and end of the trial. Care should be taken not to pump water during this period. Heat addition for conversion of feed water at inlet temperature to steam, is considered for heat output. In case of boilers with intermittent blowdown, blowdown should be avoided during the trial period. In case of boilers with continuous blowdown, the heat loss due to blowdown should be calculated and added to the heat in steam Boiler Efficiency by Direct Method: Calculation and Example Test Data and Calculation Water consumption and coal consumption were measured in a coal-fired boiler at hourly intervals. Weighed quantities of coal were fed to the boiler during the trial period. Simultaneously water level difference was noted to calculate steam generation during the trial period. Blow down was avoided during the test. The measured data is given below. Type of boiler: Coal fired Boiler Heat output data Quantity of steam generated (output) Steam pressure / temperature Enthalpy of steam(dry & Saturated) at 10 kg/cm 2 (g) pressure Feed water temperature Enthalpy of feed water : 8 TPH : 10 kg/cm 2 (g)/ C : 665 kcal/kg : 85 0 C : 85 kcal/kg Heat input data Quantity of coal consumed (Input) GCV of coal : 1.6 TPH : 4000 kcal/kg Calculation Q x( H h) Boiler efficiency( η ) = x100 q xgcv Where Q = Quantity of steam generated per hour (kg/hr) q = Quantity of fuel used per hour (kg/hr) GCV = Gross calorific value of the fuel (kcal/kg) H = Enthalpy of steam (kcal/kg) h = Enthalpy of feed water (kcal/kg) Bureau of Energy Efficiency 4 8TPH x1000kg / T x(665 85) Boiler efficiency( η ) = x TPH x1000kg / T x 4000kCal / kg = 72.5% Evaporation Ratio = 8 Tonne of steam / 1.6 Tonne of coal = Merits and Demerits of Direct Method Merits Plant people can evaluate quickly the efficiency of boilers Requires few parameters for computation Needs few instruments for monitoring Demerits Does not give clues to the operator as to why efficiency of system is lower Does not calculate various losses accountable for various efficiency levels Evaporation ratio and efficiency may mislead, if the steam is highly wet due to water carryover 1.7 The Indirect Method Testing Description The efficiency can be measured easily by measuring all the losses occurring in the boilers using the principles to be described. The disadvantages of the direct method can be overcome by this method, which calculates the various heat losses associated with boiler. The efficiency can be arrived at, by subtracting the heat loss fractions from 100.An important advantage of this method is that the errors in measurement do not make significant change in efficiency. Thus if boiler efficiency is 90%, an error of 1% in direct method will result in significant change in efficiency. i.e = 89.1 to In indirect method, 1% error in measurement of losses will result in Efficiency = 100 ( ) = = 89.9 to 90.1 Bureau of Energy Efficiency 5 The various heat losses occurring in the boiler are: Steam Output 6. Surface loss 1. Dry Flue gas loss 2. H2 loss 3. Moisture in fuel 4. Moisture in air 5. CO loss Fuel Input, 100% Boiler Flue gas sample 7. Fly ash loss Air Blow down 8. Bottom ash loss Water Efficiency = 100 ( ) (by Indirect Method) The following losses are applicable to liquid, gas and solid fired boiler L1- Loss due to dry flue gas (sensible heat) L2- Loss due to hydrogen in fuel (H 2 ) L3- Loss due to moisture in fuel (H 2 O) L4- Loss due to moisture in air (H 2 O) L5- Loss due to carbon monoxide (CO) L6- Loss due to surface radiation, convection and other unaccounted*. *Losses which are insignificant and are difficult to measure. The following losses are applicable to solid fuel fired boiler in addition to above L7- Unburnt losses in fly ash (Carbon) L8- Unburnt losses in bottom ash (Carbon) Boiler Efficiency by indirect method = 100 (L1+L2+L3+L4+L5+L6+L7+L8) Measurements Required for Performance Assessment Testing The following parameters need to be measured, as applicable for the computation of boiler efficiency and performance. a) Flue gas analysis 1. Percentage of CO 2 or O 2 in flue gas 2. Percentage of CO in flue gas 3. Temperature of flue gas Bureau of Energy Efficiency 6 b) Flow meter measurements for 1. Fuel 2. Steam 3. Feed water 4. Condensate water 5. Combustion air c) Temperature measurements for 1. Flue gas 2. Steam 3. Makeup water 4. Condensate return 5. Combustion air 6. Fuel 7. Boiler feed water d) Pressure measurements for 1. Steam 2. Fuel 3. Combustion air, both primary and secondary 4. Draft e) Water condition 1. Total dissolved solids (TDS) 2. ph 3. Blow down rate and quantity The various parameters that were discussed above can be measured with the instruments that are given in Table 1.1. Table 1.1 Typical Instruments used for Boiler Performance Assessment. Instrument Type Measurements Flue gas analyzer Portable or fixed % CO 2, O 2 and CO Temperature indicator Draft gauge Thermocouple, liquid in glass Manometer, differential pressure Fuel temperature, flue gas temperature, combustion air temperature, boiler surface temperature, steam temperature Amount of draft used or available TDS meter Conductivity Boiler water TDS, feed water TDS, Bureau of Energy Efficiency 7 make-up water TDS. Flow meter As applicable Steam flow, water flow, fuel flow, air flow Test Conditions and Precautions for Indirect Method Testing A) The efficiency test does not account for: Standby losses. Efficiency test is to be carried out, when the boiler is operating under a steady load. Therefore, the combustion efficiency test does not reveal standby losses, which occur between firing intervals Blow down loss. The amount of energy wasted by blow down varies over a wide range. Soot blower steam. The amount of steam used by soot blowers is variable that depends on the type of fuel. Auxiliary equipment energy consumption. The combustion efficiency test does not account for the energy usage by auxiliary equipments, such as burners, fans, and pumps. B) Preparations and pre conditions for testing Burn the specified fuel(s) at the required rate. Do the tests while the boiler is under steady load. Avoid testing during warming up of boilers from a cold condition Obtain the charts /tables for the additional data. Determination of general method of operation Sampling and analysis of fuel and ash. Ensure the accuracy of fuel and ash analysis in the laboratory. Check the type of blow down and method of measurement Ensure proper operation of all instruments. Check for any air infiltration in the combustion zone. C) Flue gas sampling location It is suggested that the exit duct of the boiler be probed and traversed to find the location of the zone of maximum temperature. This is likely to coincide with the zone of maximum gas flow and is therefore a good sampling point for both temperature and gas analysis. D) Options of flue gas analysis Check the Oxygen Test with the Carbon Dioxide Test If continuous-reading oxygen test equipment is installed in boiler plant, use oxygen reading. Occasionally use portable test equipment that checks for both oxygen and carbon dioxide. If the carbon dioxide test does not give the same results as the oxygen test, something is wrong. One (or both) of the tests could be erroneous, perhaps because of stale chemicals or drifting instrument calibration. Another possibility is that outside air is Bureau of Energy Efficiency 8 being picked up along with the flue gas. This occurs if the combustion gas area operates under negative pressure and there are leaks in the boiler casing. Carbon Monoxide Test The carbon monoxide content of flue gas is a good indicator of incomplete combustion with all types of fuels, as long as they contain carbon. Carbon monoxide in the flue gas is minimal with ordinary amounts of excess air, but it rises abruptly as soon as fuel combustion starts to be incomplete. E) Planning for the testing The testing is to be conducted for a duration of 4 to 8 hours in a normal production day. Advanced planning is essential for the resource arrangement of manpower, fuel, water and instrument check etc and the same to be communicated to the boiler Supervisor and Production Department. Sufficient quantity of fuel stock and water storage required for the test duration should be arranged so that a test is not disrupted due to non-availability of fuel and water. Necessary sampling point and instruments are to be made available with working condition. Lab Analysis should be carried out for fuel, flue gas and water in coordination with lab personnel. The steam table, psychometric chart, calculator are to be arranged for computation of boiler efficiency. Bureau of Energy Efficiency 9 1.7.4 Boiler Efficiency by Indirect Method: Calculation Procedure and Formula In order to calculate the boiler efficiency by indirect method, all the losses that occur in the boiler must be established. These losses are conveniently related to the amount of fuel burnt. In this way it is easy to compare the performance of various boilers with different ratings. Conversion formula for proximate analysis to ultimate analysis %C = 0.97C+ 0.7(VM+0.1A) - M( M) %H 2 = 0.036C (VM -0.1xA) M 2 (1-0.02M) %N 2 = VM where C A VM M = % of fixed carbon = % of ash = % of volatile matter = % of moisture However it is suggested to get a ultimate analysis of the fuel fired periodically from a reputed laboratory. Theoretical (stoichiometric) air fuel ratio and excess air supplied are to be determined first for computing the boiler losses. The formula is given below for the same. a) Theoretical air required for combustion b) % Excess Air supplied (EA) = [( 11.6 x C) + {34.8 x( H 2 O2 /8)} + (4.35 x S)]/ 100 kg/kg of fuel. [from fuel analysis] = Where C, H 2, O 2 and S are the percentage of carbon, hydrogen, oxygen and sulphur present in the fuel. O2 % x100 [from flue gas analysis] 21 O2% Normally O 2 measurement is recommended. If O 2 measurement is not available, use CO 2 measurement 7900 x[( CO2 %) t ( CO2 %) a] [from flue gas analysis] ( CO ) % x [100 ( CO %) ] Where, (CO 2 %) t = Theoretical CO 2 (CO 2 %) a = Actual CO 2 % measured in flue gas Moles of C ( CO 2 ) t = Moles of N + Moles of C 2 a Moles of N 2 = Wt of N2 in theoritical air Wt of N2 in fuel + Mol. wt of N2 Mol. Wt of N2 Moles of C = Wt of C in fuel Molecular Wt of C c) Actual mass of = {1 + EA/100} x theoretical air air supplied/ kg of fuel (AAS) 2 2 t Bureau of Energy Efficiency 10 The various losses associated with the operation of a boiler are discussed below with required formula. 1. Heat loss due to dry flue gas This is the greatest boiler loss and can be calculated with the following formula: Where, L 1 = L 1 m C p T f T a m xc p x( T GCV of f T ) fuel a x 100 = % Heat loss due to dry flue gas = Mass of dry flue gas in kg/kg of fuel = Combustion products from fuel: CO 2 + SO 2 + Nitrogen in fuel + Nitrogen in the actual mass of air supplied + O 2 in flue gas. (H 2 O/Water vapour in the flue gas should not be considered) = Specific heat of flue gas in kcal/kg = Flue gas temperature in o C = Ambient temperature in o C Note-1: For Quick and simple calculation of boiler efficiency use the following. A: Simple method can be used for determining the dry flue gas loss as given below. m xc p x( Tf Ta ) a) Percentage heat loss due to dry flue gas = x 100 Total mass of flue gas (m)/kg of fuel = mass of actual air supplied/kg of fuel + 1 kg of fuel Note-2: Water vapour is produced from Hydrogen in fuel, moisture present in fuel and air during the combustion. The losses due to these components have not been included in the dry flue gas loss since they are separately calculated as a wet flue gas loss. 2. Heat loss due to evaporation of water formed due to H 2 in fuel (%) The combustion of hydrogen causes a heat loss because the product of combustion is water. This water is converted to steam and this carries away heat in the form of its latent heat. Where 9 x H2 x {584 + Cp (Tf - Ta )} L 2 = x 100 H 2 C p T f = kg of hydrogen present in fuel on 1 kg basis = Specific heat of superheated steam in kcal/kg o C = Flue gas temperature in o C Bureau of Energy Efficiency 11 T a = Ambient temperature in o C 584 = Latent heat corresponding to partial pressure of water vapour 3. Heat loss due to moisture present in fuel Moisture entering the boiler with the fuel leaves as a superheated vapour. This moisture loss is made up of the sensible heat to bring the moisture to boiling point, the latent heat of evaporation of the moisture, and the superheat required to bring this steam to the temperature of the exhaust gas. This loss can be calculated with the following formula where L 3 = M x {584 + Cp (Tf - Ta )} x 100 M = kg of moisture in fuel in 1 kg basis C p = Specific heat of superheated steam in kcal/kg o C T f = Flue gas temperature in o C T a = Ambient temperature in o C 584 = Latent heat corresponding to partial pressure of water vapour 4. Heat loss due to moisture present in air Vapour in the form of humidity in the incoming air, is superheated as it passes through the boiler. Since this heat passes up the stack, it must be included as a boiler loss. To relate this loss to the mass of coal burned, the moisture content of the combustion air and the amount of air supplied per unit mass of coal burned must be known. The mass of vapour that air contains can be obtained from psychrometric charts and typical values are included below: Dry-Bulb Wet Bulb Relative Humidity Kilogram water Temp o C Temp o C (%) per Kilogram dry air (Humidity Factor) where AAS x humidity factor x Cp x (Tf - Ta ) L 4 = x 100 AAS = Actual mass of air supplied per kg of fuel Humidity factor = kg of water/kg of dry air C p = Specific heat of superheated steam in kcal/kg o C T f = Flue gas temperature in o C T a = Ambient temperature in o C (dry bul
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