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Seventh International Seminar Welcome Seventh International Seminar by GEECO Enercon Pvt. Limited, Tiruchirapalli, India M Somasundaram Technical Consultant for Boilers Former General Manager / BHEL +919443259553; [email protected] Major Job References – Technical Consultancy on Boilers of Thermal Power Plants: RCA and damages Assessment of boiler explosion- Annupur Unit-2, 600 MW, MBPMPL Review and RCA of boiler explosion- Unit-1, 300 MW at Bandhakhar, Korba Analysis of sonic vibration in 3x67.5 MW boilers at Kalinga Nagar Unburnt carbon and NOx level reduction optimisation in Units 2x500 MW boilers at Maithon Tube failure analysis of 4x600 MW boilers at Vedanta Jharsuguda Combustion optimisation for firing varying qualities of coal in 67.5 and 120 MW boilers at Jojobera Indonesian coal firing in Unit-5, 500 MW and Unit-8, 250 MW, Tata Power Company, Trombay Reheater Metal Temperature and Tube failure analysis of 2x500 MW boilers at Maithon Tube failure presentations, discussions and analysis in the Workshop for O&M Personnel of various Utilities & CPPs held at Korba Presentations, discussions and training of O&M personnel of Adani Power Limited on Boiler and Auxiliaries, Coal, Performance/Combustion Optimisation, Tube failures, Boiler emergencies, Emission control, Inspection, etc. Tube failure analysis of 4x135 MW boilers at BALCO Korba Boiler Performance analysis and recommendations for combustion optimisation of NTPC Farakka #2, 200 MW boiler Boiler Tube Leak analysis of 3x660MW boilers at Talwandi Sabo Power Limited Mill system performance analysis at 5x660MW Mundra Thermal Power Project Combustion behaviour of boilers with different coals and upgradation to enhance efficiency of 2x90 T/hr boilers at DCM Shriram Kota Optimization of Performance, O&M issues of Boiler and Airheater Boiler • In a thermal power plant boiler has the role of converting the Chemical energy available in Coal/fuel to Heat energy in steam. • The heat energy in steam is converted to Electricity by a Turbo-generator Heat Balance for Steam Process Energy Input Steam @ pressure Feed Water Useful Energy Energy Input STEAM PROCESS Air &Fuel Output Energy Loss - Energy Loss - Energy Loss - Flue Gas Blow Down Piping Friction, Water Equipment, etc. Energy Output = Energy Input - Losses Optimization Of Boiler Two Main Factors •Thermal Efficiency- The conversion of chemical heat in fuel to production of steam. oHigher thermal efficiency will reduce fuel cost. •Auxiliary Power Consumption - by Fans, mills etc. oReduction in auxiliary power will lead to increase in net power available (NET POWER= power generated - house auxiliary power consumption). Boiler Efficiency – Indirect Method • Efficiency= 100 - Losses in % Summary of losses in Boiler Controllable Dry gas Loss % 5.542 Combustible Loss % 1.453 Carbon Monoxide Loss % 0.065 Mill Reject Loss % 0.049 % 7.109 Un-Controllable Moisture Loss % 6.523 Radiation Loss % 0.270 Air Moisture Loss % 0.200 Sensible Heat Loss % 0.415 % 7.408 Total Losses % 14.517 Efficiency (100-Losses) % 85.483 Controllable losses effected by APH sizing & performance • Dry gas loss - APH outlet flue gas temperature and leakage • Unburnt carbon loss - Air temperature leaving APH DRY GAS LOSS This is the heat carried away by Flue gas at boiler outlet The Loss is directly proportional to • Flue Gas Temperature and • Flue Gas quantity High Flue Gas Temperature Every 20 deg C increase in exit gas temp. reduces the boiler efficiency by. Improper 1% combustion air regime setting . Unclean heat transfer surfaces . Damaged / worn-out / corroded air heater elements . Air heater leakage more . Excessive entry of cold seal air, cooling air, etc. DRY GAS LOSS - Flue Gas Temperature Reduction methods . Operate the boiler at correct excess air. (Usually 20 % for coal) . Cleanliness of boiler surfaces . Good combustion of fuel. Reduction of tempering air to mill. Reduction in air ingress . Addition of heat transfer surface in economizer / redesign of second pass . Cleaning of air heater surfaces and proper heating elements . Addition of heating elements in airheater – if space is available / future provision is made DRY GAS LOSS - Flue Gas Quantity Reduction Methods •Operate with proper Excess Air •Avoid ingress of Air •Attend to Air Heater Leakages regularly Carbon Loss Reduction • Good burner maintenance • Check coal property and tune combustion • Ensuring consistent mill fineness. Replace Worn-out mill parts – classifier vane, rolls/bull ring segments, classifier cone • Proper secondary air adjustment • Reducing primary air to the minimum most possible • Cut-out oil support at higher loads where coal flame is stable. • Keep boiler heat transfer surface clean • Air temperature leaving APH Auxiliary Power Consumption The Major Auxiliaries consuming Power in Boilers are .Forced Draft Fans .Primary Air Fans .Induced Draft Fans .Pulverizing Mills Factors Affecting Auxiliary Power ID Fans PA Fans • AH Leak • AH Leakage • Gas Temperature • PA Header Pr. • Duct Leakages • Mill Air Flow • Excess Air • Pressure Loss • Load/ Plant Heat Rate o AH Choking • Draught Loss Mill o AH Choking • Coal Qty. FD Fans o GCV • AH Leak o Load/ Plant Heat Rate • Wind Box Pr. • Coal • Excess Air o Moisture • Load/ Plant Heat Rate o HGI • Pressure Loss • Coal Fineness o AH Choking • Mill Condition o SCAPH Choking Auxiliary Power Consumption Major reasons for increase in auxiliary power consumption are 1. High excess air Operation 2. Air ingress in boiler 3. Air heater leakage / Choking 4. Higher PA fan outlet pressure 5. Coal pulverization too fine Capacity Reduction in a Boiler Fuel input Draught system • Low CV coal • ID fan limitations • Milling capacity o Pressure drops high o Grinding capacity . AH choking o Drying capacity . Chimney back pressure o Carrying capacity high o Drive capacity o High volume . AH leakages Metal temperatures high . Duct leakages • High spray requirements . High gas temperatures • Fouling of surfaces • Worn out impellers Combustion optimization Combustion optimization In a steam generator combustion optimization means well tuning of fuel and air distribution to get the best flame temperature. Combustion optimization Objectives . Safety of personnel and equipment . To protect equipment from failures . To produce steam at the required parameters and quality . To achieve optimum efficiency and economy during operation Combustion Diagram Plane of Combustion Completion Point at which combustion should be completed Flame Pattern Unacceptable Combustion Basic requirements for optimizing . Coal feeder and millcombustion should be in good operating condition . Mill classifier should be free to operate with uniform opening of all vanes . Coal-air temperature, mill airflow and total airflow are accurately measured, and control systems should be in working condition . All the burner nozzle assemblies are in good condition and set properly to ensure equal movement in all elevations . SADC system in auto mode of operation . All the flame scanners are checked, tested and the flame scanning system should be in good working condition Secondary Air Damper Control System Auxiliary Air Damper 120 Fuel Air Damper Control 100 Control 80 to keep the flame front at a 120 to maintain wind box to furnace DP 60 desired distance 40 100 20 80 fuel air damper % damper air fuel 0 60 0 20 40 60 80 100 120 mmwc 40 fuel input, % maximum mill capacity 20 Furnace to W.Box DP, 0 Over Fire Air Damper Control 30 45 60 100 to control NOx Boiler load, % Upper Lower 100 0 50 75 100 OFA damper opening % opening damper OFA Boiler load, % Optimized Combustion 1. Combustion process should be stable as indicated by minimum furnace draft fluctuation. 2. Flame scanner pickup with adequate flame intensity should be reached. 3. Unburnt levels in bottom ash and fly ash should be minimum. 4. Flame condition looked through furnace peepholes of each elevation/ corner to ensure proper anchoring of flame front. (about 300-500 mm from nozzle tip) 5. Look at the S panel for brightness, visibility, minimum falling of clinkers, etc. 6. Superheater and reheater spray levels should be within its limit. 7. Exit gas temperature should be within its desired limit (130 – 1400C), which depends on the boiler load. 8. Emission levels of SOx and NOx should be optimum. 9. Flame temperatures measured at various elevations / burner corners to be uniformly distributed across the elevations. Air Preheaters Air Preheaters Purpose: Recover heat from the hot flue gases that leave steam generating units – (the heat from the flue gas leaving the furnace is transferred to the incoming air supply from the FD fans and PA fans) Thus • Improving the boiler efficiency • Also, Provide the drying and transporting medium for pulverised coal Other advantages of Air Preheaters • Hot air improves stability of combustion • Intensified and improved combustion • Burning poor quality fuel efficiently • High heat transfer rate in the furnace • Less unburnt • Intensified combustion permits faster load variation Types of Air preheaters Recuperative Regenerative Tubular Air Preheater, Plate Type Air Ljungstrom Air Preheater and Preheater & Steam Coil Air Preheater Rothemuhle Air Preheater (SCAPH) Heat exchangers without storage Heat exchangers with storage Two fluids flow at different temperatures One heating surface is exposed at in a space separated by a solid partition certain intervals of time, first to a hot fluid and then to a cold one Heat is transferred by Convection & Surface of APH first removes heat Conduction through the separating wall from
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