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Combipac Boiler Operation Management

This document discusses topics related to boiler efficiency and operation including: - Methods for calculating boiler efficiency such as direct and indirect methods. - Factors that influence boiler efficiency such as heat losses, fuel properties, and operating parameters. - Methods for improving boiler performance including proper fuel handling, minimizing excess air, recovering waste heat, and addressing scale buildup. - Common boiler emergencies like low water level, high pressure, furnace issues and tube failures and the appropriate response actions.

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vinod kumar
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285 views15 pages

Combipac Boiler Operation Management

This document discusses topics related to boiler efficiency and operation including: - Methods for calculating boiler efficiency such as direct and indirect methods. - Factors that influence boiler efficiency such as heat losses, fuel properties, and operating parameters. - Methods for improving boiler performance including proper fuel handling, minimizing excess air, recovering waste heat, and addressing scale buildup. - Common boiler emergencies like low water level, high pressure, furnace issues and tube failures and the appropriate response actions.

Uploaded by

vinod kumar
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PPTX, PDF, TXT or read online on Scribd
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Topics

 Boiler Efficiency
 Direct Method
 Indirect Method
 Operation Parameter Management
Continue..

 Indirect Method (heat loss method)


The efficiency can be arrived at, by subtracting the heat loss fractions from 100%. (Blow Down Losses Not
Included)
The principle losses that occur in a boiler are:
 Loss of heat due to dry flue gas
 Loss of heat due to moisture in fuel and combustion air
 Loss of heat due to combustion of hydrogen
 Loss of heat due to radiation
 Loss of heat due to unburnt

Indirect Efficiency of Boiler.pdf


 Conditioning of Coal
 The fines in coal present problems in combustion on account of segregation effects. Segregation of fines from larger
coal pieces can be reduced to a great extent by conditioning coal with water. Water helps fine particles to stick to the
bigger lumps due to surface tension of the moisture, thus stopping fines from falling through grate bars or being carried
away by the furnace draft. While tempering the coal, care should be taken to ensure that moisture addition is uniform
and preferably done in a moving or falling stream of coal.
 If the percentage of fines in the coal is very high, wetting of coal can decrease the percentage of unburnt carbon and the
excess air level required to be supplied for combustion. Table shows the extent of wetting, depending on the percentage
of fines in coal.

Fines (%) Surface Moisture (%)

10 - 15 4-5
15 - 20 5-6
20 - 25 6-7
25 - 30 7-8
 Blending of Coal
 In case of coal lots having excessive fines, it is advisable to blend the predominantly lumped coal with lots containing
excessive fines.
 Blending of coal can be done by10 to 15 % on high GCV basis between two type coal& in-between two nearer ranks
coal.

Blending by Silo Blending in Beds


Boiler Draft & Combustion air Management

 Here the pressure is maintained between 0.05 to 0.10 in. of water gauge below atmospheric pressure in the case of
boilers
 The high C02 (12.5% to 14%) and no CO are the ideal conditions.
Boiler Performance Improvement
Measures
 Ensuring proper fuel storage, handling, and preparation, for achieving good combustion conditions.
 Operating with minimum amounts of combustibles in refuse (ash) and CO in flue gases.
 Operating with variable speed options for fan motors, if capacity control is needed (rather than inefficient damper control
operations) in order to achieve power savings.
 Avoiding partial load operations of combustion equipment.
 Operating with minimum excess air for fuel economy.
 Operating with lowest the possible stack temperature for fuel economy.
 Every rise of 6ºC in boiler feed water temperature through waste heat recovery would offer about 1% fuel savings.
 For every reduction in flue gas temperature by 22ºC for heat recovery, fuel savings of about 1% can be achieved.
 (Every 1mm-thick scale (deposit) on the water side could increase fuel consumption by 5%–8 %.)
 A 3mm-thick soot deposition on the heat transfer surface can cause an increase in fuel consumption of 2.5%.
 Recover as much as possible condensate. (Provided with Condensate Polishing system)
BOILER EMERGENCIES
 Various Emergencies situations during Operation with a special emphasis on the safety aspect
like boiler protection systems controls and interlocks.
 Drum level low and low-low.
 Drum level high and high-high.
 Boiler pressure high.
 Furnace pressure high and high-high.
 Furnace Temp high
 Water wall/screen tube/Evaporator tube failure.
Drum level low and low-low.
 CAUSES:
 Failure of BFP.
 Failure of drum level controllers.
 Sudden change in load
 Water tube failure
 EFFECT:
 Boiler pressure parts may damage badly.

 ACTIONS:
 Run the boiler if drum level is within safe limit otherwise allow boiler to trip when the water level
goes low-low limit to protect the boiler pressure parts.
Drum level high and high-high.
 CAUSES:
 Failure of drum level controllers.
 Sudden increase in load
 Sudden increase in firing rate
 EFFECT:
 Water carry over in steam
 Thermal performance loss to process unit

 ACTIONS:
 Run the boiler if drum level is within safe limit by FCV.
Boiler pressure high.
 CAUSES:
 Sudden load cutoff from process
 Sudden increase in firing rate/un control fuel feeding
 EFFECT:
 Boiler Drum water level disturbance
 Safety valve setting may disturb, if it happen frequently
 Boiler trip on high pressure,

 ACTIONS:
 Open vent valve to control boiler pressure.
 Control fuel, air input & drum level.
 Allow boiler to trip on high pressure.
Furnace pressure high and high-
high
 CAUSES:
 Disturbed Combustion
 ID fan tripping/failure
 Faulty operation of PA fan control.
 EFFECT:
 Weak Part of furnace may get explode,

 ACTIONS:
 Put ID /FD/PA/SA on manual mode and maintain furnace pressure
 Allow boiler to trip on Furnace high pressure.
Furnace temperature high
 CAUSES:
 High CV, Low ash coal
 Low fan flow ( FD/PA/SA)
 Sudden load change.
 Faulty Bed thermocouple
 EFFECT:
 Chances of clinker formation
 Furnace refractory failure
 Boiler Furnace tube failuer

 ACTIONS:
 Coal Feeder should trip, if furnace temperature goes beyond design limit.
 If still temperature increases, Boiler needs to trip on high furnace temperature
Water wall/Evaporator tube failure.
 CAUSES:
 Starved water wall
 Tube scaling, eroded tube & pitting on tube
 EFFECT:
 Hissing steam leakage noise from boiler
 Unstable boiler draft
 Furnace temperature drops quickly
 ID fan load increases.
 Flue gas outlet temperature decreases.

 ACTIONS:
 Take boiler shut down & maintain drum level.
Thank You

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