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= 100 % - L
heat loss
heat loss
heat loss
heat loss
heat loss
heat loss
heat loss
losses
due
due
due
due
due
due
due
to
to
to
to
to
to
to
dry gas
combustibles in refuse
moisture in the fuel
moisture of burning hydrogen
carbon monoxide
moisture in air
radiation and Unaccounted
Unaccounted losses typically include sensible heat loss with flyash and
bottomash, radiation loss through bottom ash hopper, coal mill reject
loss etc. The individual heat losses calculations are appended as
Annexure 1.
8.8.2 Objectives
The Objectives of the routine boiler efficiency test are as follows.
1.
8.8- 1
2.
Units
%
%
%
%
kcal/kg
C
C
C
C
C
C
%
%
ppm
T/hr
T/hr
C
C
C
mmHgC
%
%
%
%
8.8- 2
Furnace wall blowers and the air heater soot blowers are
operated prior to the efficiency test.
ii.
iii.
iv.
v.
vi.
vii.
Auxiliary PRDS steam flow from the unit being tested is kept
isolated.
viii.
ix.
x.
The test is abandoned in case of any oil support during the test
period.
xi.
xii.
xiii.
8.8.4.2
Test Duration
Each test would be of two-hour duration, subject to the completion of
measurement and sampling at various locations.
8.8- 3
8.8.4.3
8.8.4.3.1 Control Room Data - A separate test log for control room
data shall be created in unit DAS for data collection at an interval of five
minutes or less and averaged over the test period.
The online measurements of flue gas and air temperatures at air heater
inlet and outlet are used for efficiency computations.
Its important to ensure that the online measurements of air and flue gas
temperatures are representative of average temperatures in the duct. The
on line feedback of flue gas exit temperature after air heaters can be
affected by gas stratification and may require more number of
thermocouples than presently installed.
In some layouts, the online thermocouples for flue gas temperature
measurement are mounted too close to air heaters in a cluster and need
to be relocated for representative measurement. Similarly the location
and number of temperature sensors on airside at air heater inlet and
outlet should be reviewed to obtain a representative average.
The new locations can be decided only by doing multiple point
temperature measurements in a plane perpendicular to the flow in the
respective ducts. The number of measurement points is determined as
per ASME PTC 19.10, Flue and Exhaust Gas Analysis and would vary
with duct configuration and size.
8.8.4.3.2 Field Measurements / Sampling - The following field
measurements / sampling are done simultaneously during the test
period.
1)
2)
3)
4)
5)
8.8.4.3.3
FG
Expansion
Bellow
Test Ports
Economizer
APH
APH
Sampling
Locations
FG
Fig-8.8.1
If a single point sampling is to be done, the representativeness of the
point and its repeatability should be ensured by a grid survey. A portable
O2 / CO2 / CO gas analyzer is used to draw a sample from the flue gas
ducts. Orsat apparatus can be used if a portable analyzer is not
available.
In 500 MW units, the flue gas sampling and temperature measurement
8.8- 5
should be done in the common flue gas duct of Primary and Secondary
air heater outlet on each side.
8.8.4.3.4 Ambient air-conditions using psychrometer
Dry Bulb and Wet Bulb temperature measurement is done using a
calibrated psychrometer near FD fan inlet at the start of the test and at
the end of the test and an average is computed for the test period.
8.8.4.3.5 As fired Coal Sampling
Coal sampling is done manually from feeder inlet chutes of all running
feeders during the test and a representative sample prepared from the
gross sample collected by quartering and coning.
A minimum of two samples from each feeder should be collected during
the test.
A separate coal sample is collected for determination of total moisture
and kept in a sealed container. For conversion of Proximate and Ultimate
analysis of coal on Air dried basis to As fired basis multiply each
component by X, which shall remain as it is.
X
8.8- 6
8.8.4.3.7
Results
8.8- 7
--------M- %
--------A- %
--------VM - %
--------FC - %
-------------------------------TOTAL - 100 %
FC
= -------------------------A
M
[ 1 - 1.1* --- - ---- ]
100
100
7.35
= VmDf(T) * [----------- - 0.013 ]
VmDf(T) + 10
8.8- 8
Summary
Efficiency
1
2
3
4
5
6
7
As Run
86.47
Corrected
87.26
13.53
4.62
0.55
2.28
4.72
0.02
0.14
1.20
12.74
4.71
0.55
2.26
3.90
0.02
0.11
1.20
Total Losses
Dry Gas Loss
Loss due to Unburnt Carbon
Loss due to moisture in fuel
Loss due to Hydrogen in Fuel
Loss due to Carbon monoxide
Loss due to moisture in air
Radiation & unaccounted Loss
Inputs
Unit Load
FW Flow at Eco Inlet
Wet Bulb Temp
Dry bulb Temp
Barometric Pressure
Total Coal Flow
Unburnt C in Bottom Ash
Unburnt C in Flysash
Radiation & Unaccounted Loss
% of Flyash to Total Ash
% of Bottom ash to Total Ash
Units
MW
T/hr
C
C
mmHgC
T/hr
%
%
%
%
%
Symbol
L
Ffw
Wb
Db
BP
Fin
Cba
Cfa
Lrad
Pfa
Pba
Value
210
615
24
30
760
140
1.2
0.4
1.2
80
20
%
%
%
%
%
%
%
kcal/kg
Ca
S
H
M
N
O
A
Gcv
36.4
0.6
2.8
12.2
1
7
40
3320
%
%
ppm
O2in
CO2in
COin
3.5
15.8
39
Avg.
Avg.
Avg.
Avg.
Avg.
Flue
Flue
Flue
Flue
Flue
Gas
Gas
Gas
Gas
Gas
O2 - APH Out
CO2 - APH Out
CO - APH Out
Temp - APH In
Temp - APH Out
%
%
ppm
C
C
O2out
CO2out
COout
Tgi
Tgo
5.0
14.3
50
350
135
C
C
C
C
Tpai
Tpao
Tsai
Tsao
40
325
34
325
T/hr
T/hr
C
Fsa
Fpa
Tref
450
250
30
Unit
Symbol
Value
Ldg
4.617
Carbon in fuel
Sulfur in fuel
Carbon in ash / kg of fuel
Specific heat of gas
Avg. Flue Gas Temp - APH Out
Unburnt C in ash
= Pfa/100*Cfa + Pba/100*Cba
C in ash / kg of coal
= A/100*Cash/(100-Cash)
%
%
kg/kg coal
kg/kg/C
C
%
Ca
S
U
Cp
Tgo
Cash
36.4
0.6
0.002253
30.6
135
0.56
kg
0.00225
T/hr
%
Fta
Rsa
700
0.64
Rpa
0.36
Trai
36.1
Tao
325
CO2out
14.3
8.8-10
Gross CV
Weight of dry gas = (Ca+S/2.67100*U)/(12*CO2out)
Sensible Heat dry gas
= Wd*30.6(Tgo-Trai)
2 Loss due to Unburnt Carbon
= U*CVc*100/Gcv
Carbon in Ash / kg of coal
CV of Carbon
Gross CV
3 Loss due to moisture in fuel
= Sw*M/(Gcv*4.186)
Moisture in Fuel
Avg. Flue Gas Temp - APH Out
Weighted Temp Air - APH In
Gross CV
Sensible heat of water vapour
Sw = 1.88*(Tgo -25)+2442+4.2*(25Trai)
4 Loss due to Hydrogen in Fuel
=9*H*Sw/ (Gcv*4.186)
Hydrogen in fuel
5 Loss due to Carbon monoxide
= COoutp*7*Cvco*(Ca-100*U) /3 /
(CO2out+Cooutp) / Gcv
Avg. Flue Gas CO2 - APH Out
Avg. Flue Gas CO - APH Out
Carbon in fuel
CV of Carbon Monoxide
Gross CV
Carbon in Ash / kg of coal
8.8-11
kcal/kg
kg/kg coal
Gcv
Wd
3315.19
0.2121
kJ/kg
Sh
641.66
%
kg/kg coal
kcal/kg
kcal/kg
Luc
U
CVc
Gcv
0.55
0.00225
8077.8
3320
%
%
C
C
kcal/kg
kJ/kg
Lmf
M
Tgo
Tai
Gcv
Sw
2.284
12.2
135
36.1
3320.0
2602
%
%
Lhf
H
4.72
2.8
Lco
0.021
%
CO2out
14.3
%
Cooutp
0.005
%
Ca
36.4
kcal/kg
CVco
2415
kcal/kg
Gcv
3320
kg/kg coal
U
0.002253
%
%
%
%
%
kg/kg coal
kcal/kg
kg/kg
Lma
Ca
H
S
O
U
Gcv
Mwv
0.139
36.4
2.8
0.6
7
0.002253
3320
0.0165
C
C
%
%
Trai
Tgo
O2out
N2out
36.14
135
5
80.7
kg/kg coal
Sa
4.83
Ea
1.30
Ma
0.1036
Unit
Symbol
Value
%
%
%
%
Md
Ad
VMd
FCd
13
40
24
23
%
%
%
%
%
%
%
Cd
Sd
Hd
Md
Nd
Od
Ad
37
0.3
2.3
12
0.8
7.6
40
Corrections to Design
Design Conditions
Proximate - As Fired
Moisture
Ash
Volatile Matter
Fixed Carbon
Ultimate Analysis - As Fired
Carbon
Sulfur
Hydrogen
Moisture
Nitrogen
Oxygen
Ash
8.8-12
kcal/kg
C
Gcvd
Tadd
RH
3300
30
60
C
C
C
C
Tad
Tadd
Trai
Trad
30
30
36.14
36.14
C
C
C
Tgi
Tgo
Tgc
350
135
135.00
Ldgc
4.707
8.8-13
%
Cd
37
%
Sd
0.3
kg/kg coal
U
0.00225
kg/kg/C
Cp
30.6
C
Tgc
135.00
C
Trad
36.14
%
CO2out
14.3
kcal/kg
Gcvd
3300
kg/kg coal
Wdc
0.2150
kJ/kg
Shc
650.26
8.8-14
Lucc
0.553
%
%
%
%
A
Ad
VM
VMd
Luc
40
40
22.93
24
0.55
Lmfc
2.260
%
C
C
kcal/kg
kJ/kg
Md
Tgc
Trad
Gcvd
Swd
12
135.00
36.14
3300
2602
%
%
Lhfc
Hd
3.899
2.3
Lcoc
0.022
%
%
%
kcal/kg
kcal/kg
kg/kg coal
CO2out
Cooutp
Cd
CVco
Gcv
U
14.3
0.005
37
2415
3300
0.00225
8.8-15
Lmac
0.107
%
%
%
%
kg/kg coal
kcal/kg
kg/kg
C
C
%
%
Cd
Hd
Sd
Od
U
cvd
Mwvd
Trad
Tgc
O2out
N2out
37
2.3
0.3
7.6
0.00225
3300
0.013
36.1429
135.00
5
80.7
kg/kg coal
Sad
4.69
Ead
1.30
Mad
0.0792
Report date:
Test Date:
Test Condition
Unit Load
MW
Coal Flow
T/hr
Steam Flow
T/hr
Mills in service
Nos.
Air flow
T/hr
FW inlet temperature
AH outlet Avg. O2
AH outlet Avg. CO
ppm
Unburned C in ashes
Moisture
Ash
Volatile Matter
%
%
Fixed Carbon
GCV
kcal/kg
Heat Losses
Unit
BOILER EFFICIENCY
PG Test
Value
Uncorrected Test
Value
Corrected Test
Value
Remarks
Format No-8.8.1
8.8-17