13-02-2017

Assessing Performance & Reliability Diagnosis is the identification of the nature

and cause of a certain phenomenon

Most commonly it is associated with “the art

or act of identifying a disease from its signs
and symptoms by the Doctor”

By Diagnosis of Boiler Parameters

Let us imagine one such act of identification
first
Ansuman Sen Sharma

India Boiler dot Com

I get a fever

It’s still there even after four- Takes out a tongue depressor
five days and asks me to open my
mouth wide and say Aah....
I go to my doctor

The first question he asks me – He checks the throat and

‘since when?’ nose cavity for congestion

Then he asks me how high it

goes (the temperature)?
He writes a prescription (giving me a broad spectrum
Then he asks me is there any other problem? antibiotic perhaps), asks me to use vapour
inhalation....and

I am also having cough and cold and tell him so Asks me to get certain tests done and come back
again with the test reports
He takes out a stethoscope and checks my chest and
listens for congestion

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 13-02-2017

Along with other tests, he asked for Complete blood

count (CBC) with differential I observe a FG temperature
rise at the Platen Super
Heater inlet
What he suspects perhaps is a Respiratory Tract
Infection and wants to confirm by the test before
The first thing I check is –
prescribing the right drug
‘since when?’

Now lets imagine a condition in the boiler system

Then I check what else have changed during this
period?

I Check attemperation spray, Platen outlet steam

temperature

I am suspecting either Water Wall soot formation, or a

delayed combustion condition

I operate wall blower

A Doctor with good diagnostic skills must have a

very good knowledge of Human Physiology.

A boiler O&M engineer therefore should first know

the Boiler system thoroughly in order to develop the
diagnostic skills.

Every component in the system has a defined

objective to fulfil.

In order to meet the objective, the component/

system has to work on a defined engineering
principle.

In ideal conditions, the performance and reliability

would be reflected in some of the parameters we
measure.

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 13-02-2017

Diagnostic Technique in Boiler System

Separate Steam Generating System into its various The engineer should know his system good enough
sub-system and take a close look at each to understand the limitations
components

For each component the engineer should ask the

following questions.
If you have the capability to
1. What is its objective? associate this deviation with the field
2. Which basic engineering principle it follows? condition, you can diagnose the
problem with reasonable accuracy
3. What are the ideal conditions? and take necessary corrective
actions.
4. What are the field limitations in their system?

The issues we would discuss:

Inadequate Steam Flow

Exit Temperature high
High LOI in Fly Ash
High Attemperation spray
SH/ RH temperature low Let’s start by taking a close look at
Water Wall Tube leakage
the system
Super heater Tube leakage
Economizer Tube leakage
Drum Silica high
High bed temperature in AFBC/ CFBC boilers
Drum pH Low
Drum pH High
Low phosphate in drum
Excessive blow-down due to high chloride

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 13-02-2017

Power Boiler Flow Diagram Various Sub-Systems:

HP IP / LP

GEN

Feed Water System:

Circulating Water & Steam System :

Fuel System :

Combustion Air System :

comer
Down

Deaerator

Flue Gas System :

HP Heater

LP Heater

Condenser

Boiler Feed Pump

Steam System :

Ash Handling System :

PA / FD Fan Cond. Extraction Pump

FROM FUEL HANDLING

SYSTEM
ID Fan

ESP

Objective:
Boiler Feed Water System:

Ensuring sufficient supply of Feed Water to

PT LT TE maintain the drum level
Economizer

TE
SH-1 SH-2
Heating of Feed Water close to drum
TE temperature:
TE Deaerator
LP Heater
Down comer
Riser

Riser

Removal of dissolved oxygen to the desired

HP Heater

PT FT
PT

level
TE
TE

Boiler Feed Pump

Cond. Extraction Pump

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 13-02-2017

Objective:
Deaerator Performance diagnosis:

Removal of Dissolved Oxygen:

…… up to 0.007 ppm

Regenerative Heating of Feed Water:

Provide required NPSHa for Feed Pump:

Diagnostic check points:

Solubility of Oxygen depends on :
Temperature
…… 0 solubility at saturation temperature
Steam Flow through vent is in a continuous
plume
Vent valve is not throttled

Partial pressure of Oxygen on water surface

Hydrazine dozing quantity is not changing for
the same load
PT LT TE

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 13-02-2017

What might happen if NPSHa < NPSHR?

Cavitation :

Released Impact Energy:

½ ρ v2 , v ≈ 1310 m/s

Cast steel feed water-pump impeller severely damaged by

cavitation

NPSHa : Pda

Circulating Water & Steam Circuit:

NPSHa = Pda + H – Hf - Pvap

NPSHa > NPSHR

- Hf
H

24

6
 13-02-2017

Natural Circulation:
Temperature of steam and Water in
the whole Evaporator system is Ts Furnace Temperature in the
range of 1100o to 1200oC

Carbon Steel; SA 210 Gr. A1/ C

Water
Mixture of steam
and Water Creep starts in Carbon Steel at 370oC and it doesn’t
have strength against creep

25

Nucleate Boiling : Departure from Nucleate Boiling (DNB):

Film Boiling

27

7
 13-02-2017

Why the bubbles are getting dislodged

and going up?

Is it because of buoyancy since steam

density is less than water density?

Density difference is a factor of pressure;

as the pressure goes up, density difference
goes down
Over Heating Failure

Nucleate Boiling : Steam bubbles are coming out in

Nucleate Boiling
At Atmospheric pressure the difference is
nearly 1600 times

Whereas at 120 kg/ cm2 absolute drum

pressure, it is only 9.6 times

At critical pressure both densities are same

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 13-02-2017

Departure from
Steam bubbles formed and
Nucleate Boiling : sticking at the bottom

But the density difference is nearly

1600 times!

Therefore it is not the buoyancy!!

It is the flow in the water due to natural

circulation, which is influencing the Nucleate
boiling

Natural Circulation Natural Circulation

ΔP = H g (ρd – ρr)

H Therefore circulation would be maximum at

Down comer

ρr ρd
MCR
Riser

ΔP = H ρd g - H ρr g = H g (ρd – ρr)

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 13-02-2017

Natural Circulation
Drum Level

Down comer

ρr ρd
Riser

120oC
500

120oC
300

ΔP = H g (ρd – ρr)

Overheating of evaporator tube and Factors inducing DNB and tube

raptures are caused by: overheating
Fast Ramp up during cold start
Poor Circulation
Low drum level

High Heat Flux – more than Critical Heat Obstruction due to foreign object fouling
Flux the tube
Formation of scale inside the tube

Flame shifting towards one side wall

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 13-02-2017

The steam generator performance depends

on two aspects

Factors influencing Performance of

Boiler Combustion
Conversion of Heat Energy from Chemical
energy of fuel (Fuel and Air System)

Transfer of Heat energy into water &

Steam (Flue Gas system)

The types of ‘Fossil’ fuels we will discuss:

Fuel Characteristics Coal

Oil
Combustion Mechanism
Gas
Combustion Systems
For coal; the types of combustion systems we
Combustion assessment will discuss:

Combustion Performance Optimization Pulverized Coal Fired

AFBC
CFBC

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 13-02-2017

Fuel
Fuel:
The primary source of heat in boiler system is Solid → Coal, Lignite, Bagasse, Petcoke
considered to be ‘Fossil’ fuels.
Liquid → Furnace Oil, LDO, Naptha
Two major ingredients of these fuels are Gaseous → NG, RFG, BFG, COG
Carbon and Hydrogen.
Fuel Analysis:
Carbon, Hydrogen and Sulphur are the three Proximate
Ultimate analysis:
analysis:  Moisture
Carbon – C kg
ingredients in fuel which gives away heat  Hydrogen – H kg
 Volatile
Sulfur – Matter
S kg
during an exothermic reaction with Oxygen. Nitrogen – N kg
 Ash
 Oxygen – O kg
 Fixed
H2O – Carbon
M kg
 Ash – A kg
Total: 1 kg

VM Coal Ash
Volatile Matter is a complex mixture of
organic materials, which volatilizes quickly
Ash is the incombustible mineral matter (MM)
on heating at appx. 300°C and burns in
left behind when coal is burnt. In the
suspension in a furnace.
laboratory, it is the residue left on complete
combustion at 700–750°C in a muffle furnace
The higher the VM, the greater the performed in a carefully controlled and
combustion speed specified manner
Increases Flame length

Increases chance of spontaneous

combustion
Increases Mill o/l temperature in PF

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 13-02-2017

Range of Chemical Constituents of Ash

Ash
Oxide Range (%) by wt Acidic (A)/ Basic (B)
SiO2 10–70 A Problems:
Al2O3 8–38 A
Fe2O3 2–50 B Erosion
CaO 0.5–30 B
MgO 0.3–8 B
Slagging & Fouling
Na2O 0.1–8 B
K2O 0.1–3 B
TiO2 0.4–3.5 A Corrosion
SO3 0.1–30 A

Typical proximate analysis result of Indian Coal Typical ultimate analysis of Indian Coal:

Carbon 41.11%
Moisture 5.98%
Hydrogen 2.76%
Ash 38.63%
Sulphur 0.41%
Volatile Matter 20.70%
Nitrogen 1.22%
Fixed Carbon 34.69%
Oxygen 9.89%
Total 100%
Moisture 5.98%

Mineral Matter (1.1 x Ash) 38.63

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 13-02-2017

Typical proximate analysis result of Indonesian Coal Typical ultimate analysis result of Indonesian Coal

Moisture 24%
Nitrogen 1.09%
Inherent Moisture 13%
Carbon 69.40%
Ash 5%
Hydrogen 5.69%
Volatile Matter 41%
Sulphar 0.17%
Fixed Carbon 39%
Oxygen 23.65%
Sulphur 0.17%

GCV (Kcal/Kg) 5400

Typical NG Analysis

Unit GAIL Natural

Fuel Gas Component
Methane % mole 93.4306
Proximate to Ultimate Analysis:
(CH4) %C = 0.97C+ 0.7(VM+0.1A) - M(0.6 - 0.01M)
Ethane % mole 3.7209 %H2 = 0.036C + 0.086 (VM - 0.1xA) - 0.0035M2 (1-
(C2H6)
Propane % mole 1.4839 0.02M)
(C3H8) %N2 = 2.10 - 0.020 VM
N Butane % mole 0.1144
(C4H10)
I Butane % mole 0.1195 Where
(C4H10)
C = % of fixed carbon
N Pentane % mole 0.0145
(C5H12) A = % of ash
I Pentane % mole 0.0123 VM = % of volatile matter
(C5H12)
M = % of moisture

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 13-02-2017

Problems with Liquid Fuel

Viscosity
Solid contamination
Water contamination
High Sulfur

Important factors to be considered for Combustion Mechanism

Liquid fuel:
Heating
Atomizing
Cleaning
Draining
Exit Temperature and Cold End temperature

Oxidation of 1 kg of Carbon:
Combustion is a chemical reaction of:

C + O2 = CO2 + 8084 kcal/ kg 2430 kcal 5654 kcal

2H2 + O2 = 2H2O + 34500 kcal/ kg 2C + O2 = 2CO + O2 = 2CO2

S + O2 = SO2 + 2224 kcal/ kg

Incomplete Combustion Complete Combustion

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 13-02-2017

Combustion mechanism:

Fuel + Air Flue Gas + Heat

C N2 N2
H2
Assessing Air Requirement
O2 CO2
S SO2
N2 CO
O2 H2O
H2O O2
Ash

Some molecular weight we should know: Molar reaction to mass reaction:

Component Molecular Wt. Molar mass C + O2 = CO2

C 12 12 kg/ kmol 1 kmol
121kg
kg ++
+32
2.67
1 kmol
kg kg ==
=44
1
3.67
kmol
kg kg
H2 2 2 kg/ kmol
N2 28 28 kg/ kmol
O2 32 32 kg/ kmol 2H2 + O2 = 2H2O
S 32 32 kg/ kmol 124kg
kg ++ 8
kmol kg
+321kg = 9
kmol= kg
=362kg
kmol
CO2 44 44 kg/ kmol
CO 28 28 kg/ kmol
SO2 64 64 kg/ kmol
H 2O 18 18 kg/ kmol S + O2 = SO2
11
kg
32kmol
kg
+ 1++
kg32
1 kmol
=kg2 kg
== 64
1 kmol
kg

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 13-02-2017

Ultimate analysis:
 Carbon – C kg 2.67 x C kg/ kg of fuel
 Hydrogen – H kg 8 x H kg / kg of fuel
 Sulfur – S kg S kg/ kg of fuel
Nitrogen – N kg
Oxygen – O kg O kg of O2 not required
H2O – M kg
Ash – A kg 3 T of Combustion
Total O2 required per kg of fuel = [2.67C + 8H - O + S] kg

For comb calculation air is consider as a mixture of O2 and

N2.Their proportions being,
On mass basis: O2 -23%, N2 - 77%
On volume basis: O2 -21%, N2 - 79%
Minimum Theoretical Air required for complete
combustion
= [2.67C + 8H - O + S] x 100/23

Reaction Time of coal particle in PF Boiler:

From HPT
To HPT

To IPT

Time
FSH

HRH

PSH CRH

Temperature volatiles LTSH

Turbulence Char
coal particle ECO
d=30-70m

APH

tdevolatile=1-5ms tvolatiles=50-100ms tchar=1-2sec

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 13-02-2017

Flue Gas Temperature Profile in PF Boiler:

Delayed To HPT
From HPT

Ignition Temperatures of different combustible Combustion ~ 800 - 850oC To IPT

Secondary
Combustion

~ 650 - 700oC
Sulphur 250oC FSH

Fixed Carbon 400oC

HRH

PSH CRH
~ 900 - 950oC
C2H2 (Acetylene) 480oC
LTSH ~ 450 - 480oC
C2H6 (Ethane) 540oC
C2H4 (Ethylene) 550oC
~ 1100 - 1200oC ~ 350 - 380oC
Hydrogen 610oC
ECO

CH4 (Methane) 650oC

APH
CO 655oC

~ 130 - 140oC

% Excess air supplied (on O2 basis)

= (O2 x 100) / (21 - O2)

Total air supplied as:

 Primary Air
Coal Combustion Systems
 Secondary Air

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 13-02-2017

Pulverized Coal Fired Furnace:

Pulverized Coal

Bubbling Fluidized Bed

Circulating Fluidized Bed

Fuel System Fuel Circuit:

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 13-02-2017

The usual safe mill outlet temperatures for various

fuels:
PF Furnace:

Coal size distribution For PF Boiler.

Corner
Fire Ball:
Fired:

70% < 200 mesh (75 micron)

Size Distribution : 100 – 150 ~ 30%

75 - 100 ~ 10%

Retention in 50 mesh should be less than 1%

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 13-02-2017

Fluidized Bed Combustion :

Fluidized Bed Combustion :

At relatively higher fluidizing velocities (4 to 7 m/s) - CFB

At low fluidizing velocities (1 to 3 m/s) - BFB

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 13-02-2017

Fuel Size for BFB / CFB Boiler

Bed Temp. / Furnace Temperature

Size : 0 to 8 mm,
800°C for fuels with low-melting compounds less then 1mm not allowed more then 10%
in ash such as lignite
Distribution : 1 to 5mm – 70%
850°C for fuels needing sulfur removal 5 to 8mm – 20%
0 to 1mm – 10%
900°C for difficult to burn low-volatile fuels
with more FC and ashy bituminous coals

For Pet Coke; top Size : 4.5 mm to 6 mm

Sulfur removal in FBC:

Calcination: CaC03 → CaO + C02 + 425.5 kcal/ kg
Sulfaction: CaO + S02 + ½ 02 + 3740.5 kcal/ kg
→ CaS04

Combustion Optimization

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 13-02-2017

Negative aspects of high excess air

Increase in loss of sensible heat carried away by

flue gas
Increase in auxiliary power (FD & ID fan)
Limitation on boiler load due to exhaustion of ID
fan capacity
Increase in NOx and SO3 formation
Increase in erosion due to increase in flue gas
velocity

Loss
Shift in heat transfer from furnace to convection
pass resulting in heating up of down stream
components

Air

Draught System

Combustion Optimization ΔP across the furnace = 450 mmwc

Combustion condition (3T) optimization

+ 450 - 450
Combustion Air optimization

Eva SH1 SH2 Eco APH

+ 100 - 350

92

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 13-02-2017

Optimization Steps
For PF Boilers Identify and stop Furnace Ingress
Parameters/ data needed Calculate min. theo. Air from ultimate analysis

Ultimate Analysis of coal Measure FD and PA flow as per actual

O2, CO and CO2 at exit gas Measure fuel flow and calculate air to fuel ratio

Calculate actual excess air

LOI in Fly ash and Bottom ash
Check O2 and calculate theoretical excess air
Platen SH inlet and boiler exit temperature
Try to reduce PA flow by little margin
Furnace-wind box DP
Check Mill reject and Fuel pipe chocking
PA & FD mass flow
Check Furnace Temperature and Boiler Pressure
Mill reject
Increase SA through WB by the same margin to
Fuel flow increase furnace DP

Adjust classifier setting / spring load to control fines For AFBC/ CFBC Boilers
to optimize LOI in FA and BA Parameters/ data needed
Use burner tilt to bring FG temp. to FSH inlet near
O2, CO and CO2 at exit gas
design value and reduce spray
LOI in Fly ash and Bed ash
Continue reducing PA and increasing SA to reach
optimum Furnace SH inlet and boiler exit temperature

Combustion is optimized when the difference between Bed Temperature

Actual excess air and theoretical excess air is minimum PA & FD flow
Calculate CO loss, Dry gas loss
Fuel flow
Reduce total air by delta to draw loss curve

Select optimum air zone

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 13-02-2017

Flue Gas System

FS
H
SH 2

Transfer of Heat energy into

water & Steam (Flue Gas system)
SH 1

ECO

APH

Mode of heat transfer in furnace Drum

~ 800 - 850oC 400oC

ECO 1
480oC
Evaporator
ECO 2
FS
H ~ 650 -
SH 2
700oC
SH-1
300oC
~ 900 - 950oC
SH 1
SH-2
~ 450 - 480oC APH

SH-3 145oC

~ 1100 - ECO ~ 350 - 380oC Screen

1200oC

850oC

APH

~ 130 - 140oC

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 13-02-2017

Heat Transfer mode:

Luminous & Non-luminous Gas Radiation
Drum SCW
Gas convection
700oC
Particle Convection for FBC
~ 800 - 850oC
791oC FSH

~ 650 - 700oC
~ 900 - 950oC

LTSH
870oC 690oC
~ 450 - 480oC
~ 1100 - 1200oC
421oC

ECO ~ 350 - 380oC

850oC

252oC

APH

138oC ~ 130 - 140oC

Heat transfer through Radiation process is

much higher as compared to Convection Sensible heat

Radiation Heat Transfer P = eσA(Th4 – Tc4) Heat in Water & Steam

Latent heat
Radiation Heat Transfer depends on :
 Available Surface Area of the tubes
 Presence of more tri-atomic gases like CO2 and H2O
Sensible heat: H = m C Δt
 Fly ash
 Gas temperature
Latent heat: From Steam Table
Convection Heat Transfer q = hc A dT
Convection Heat Transfer depends on :
 Available Surface Area of the tubes
 Available heat load (gas temperature)
 Mass velocity of flue gas

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 13-02-2017

Enthalpy vs Temperature Diagram

When Pressure is more

Atmospheric
BC >> EF >> HI >> KL M

J
Temperature

Pabs = 220.9 bar

G
Tsat 373.14oC
K
L
D

H
I

E
F

100oC B
C

Enthalpy

Enthalpy vs Temperature for a Power Boiler

Tsup 540oC

Tsat 350oC

Eco out 310oC

HPH out 260oC

DA out 173oC
LPH out 140oC

CEP out 46oC

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 13-02-2017

Diagnosis of Performance from

Boiler Parameters
Diagnosis of cause of Inadequate Steam
Flow

The boiler is not able to generate steam even

if we try to increase loading manually

At full load ID is getting saturated and

furnace becomes positive

Super heater and Re-heater metal

temperature and attemperation spray is
increasing

Mill output gets saturated

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 13-02-2017

Water & Steam Temperature Profile

Package Boiler Case Study

12 TPH; 8 ksc; FO fired, package boiler fitted

Eco out
HPH out
with external Economizer
DA out

Since installation, it could not generate rate

LPH out

CEP out
capacity steam
SH/ RH temperature is increasing

Check Eco out temperature first

In operation for 5 years

Exit temperature 2000C against design exit

temperature 170oC

Package Boiler Case Study Package Boiler Case Study

Eco out 105oC

Cond. Return 98oC

Water & Steam Temperature Profile

Only 7oC rise in FW temperature in the Eco!!

And this was in operation for last 5 years !!!!

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 13-02-2017

Water & Steam Temperature Profile ~ 800 - 850oC

~ 650 - 700oC
~ 900 - 950oC

Eco out
HPH out ~ 450 - 480oC
~ 1100 - 1200oC

DA out
LPH out
~ 350 - 380oC
CEP out

At full load ID is getting saturated

check CV of fuel (decreasing)

check Mill saturation
~ 130 - 140oC
check Platen SH inlet temperature (decreasing)
check super heater attemperation (decreasing)
check Eco outlet water temperature (minor increasing)
This could be due to poor CV of fuel, or high excess air, or
check exit temperature (increasing) combination of both

We can think of fuel blending, but air optimization should be

priority

STACK 160 C IPECO HPECO

HRSG exit temperature
ΔT 47.5 SH1 ACTUAL NA
211.6
I P EVA ΔT 57 SH2 : TOTAL IN SH 104.5
260.3 ACTUAL 102 WITH
HP ECO ATTEMP.WATER >3.94 TPH
HRSG behind frame 6 GT ISO rating 39MW 317 AGAINST DESIGN 1.1
HP steam pressure 74 bar at 55/56TPH, HP EVA ΔT 171 EVA. ACTUAL 126
508/510oC DESIGN HP 488.3 ΔT 57 HPECO ACTUAL 55
FLOW 71.2 TPH HP SH2
12-12.5 TPH 12 BAR, 198oC IP STEAM ΔT 48.4 IPEVA ACTUAL 5
ATTEMPERATO 545.5 ΔT 50 IPECO/HPECO ACTUAL 92
Design stack temperature 160oC R WATER HP SH1
STACK T 160 ACTUAL 172
1.1TPH
Actual steam parameters much low CONCLUSIONS
especially HP steam flow rate and pressure • HIGH HEAT PICKUP IN SH
IP Eco steaming 593 C
• VERY HIGH ATTEMPERATION
• LESS HP STEAM GENERATION
Stack temperature 172oC
• IPECO IS LIKELY TO STEAM
• LESS HEAT FOR HPECO
CAUSING LOWER STEAM
PRESSURE AND GENERATION

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 13-02-2017

BOILER RUNS VERTICAL

FROM HERE
THE FLOW IS MORE
TOWARDS RIGHT

Diagnosis of High Boiler Exit Temperature

BOILER INLET
DUCT

FLOW FROM GT
DIFFUSER

Pulverized Coal Fired 210 MW Boiler:

Let us assume it is a case of high exit
temperature in a 210 MW Pulverized Coal
fired boiler
Let us also assume the exit temperature has
increased at the base load during the last
couple of months

There is no significant change in fuel

characteristics during this period

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 13-02-2017

Typ. Flue Gas Temp. Profile in 210 MW PF Boiler:

~ 800 - 850oC
First take a close look at the Gas side
temperature profile of your system across
each heat exchanging element FSH
~ 650 - 700oC
Also refer the water and steam temperature ~ 900 - 950oC
SH 2 CRH HRH

across each heat exchanger

SH 1

~ 450 - 480oC
One should have a clear idea about the mode ~ 1100 - 1200oC
of heat transfer from the flue gas to the tube
at various boiler section ECO ~ 350 - 380oC

Check Attemperator spray quantity

Check exit O2
APH

~ 130 - 140oC

~ 800 - 850oC ~ 800 - 850oC

~ 650 - 700oC ~ 650 - 700oC

~ 900 - 950oC ~ 900 - 950oC

~ 450 - 480oC ~ 450 - 480oC

√
~ 1100 - 1200oC ~ 1100 - 1200oC

~ 350 - 380oC
√ ~ 350 - 380oC

~ 130 - 140oC ~ 130 - 140oC

Check Eco outlet temperature (APH inlet) If Eco outlet temperature has increased; then check Eco inlet temp.

Check:
If Eco outlet temperature is unchanged; then the problem lies in If temperature has not changed, then the problem could be across
Check:
 heat transfer
Passing across APH
of CAD  Economizer heat
Economizer transfer
fouling
 Fouling of APH

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 13-02-2017

~ 800 - 850oC ~ 800 - 850oC

~ 650 - 700oC
√ √ ~ 650 - 700oC
√
~ 900 - 950oC ~ 900 - 950oC

~ 450 - 480oC
√ ~ 450 - 480oC
~ 1100 - 1200oC ~ 1100 - 1200oC

~ 350 - 380oC ~ 350 - 380oC

~ 130 - 140oC ~ 130 - 140oC

If Eco inlet temperature has increased; then check LTSH inlet temp. If LTSH inlet temperature has also increased; then the problem is in
the radiant SH/ RH.
Check:
If temperature has not changed, then the problem could be across Check:
If PSH inlet temperature is unchanged, it could be the time to
 LTSH
LTSHheat transfer
fouling  operate LRSBs inspray
Attemperation that region.
decrease
 PSH inlet temperature

~ 800 - 850oC

√ ~ 650 - 700oC
~ 900 - 950oC

~ 450 - 480oC
~ 1100 - 1200oC

~ 350 - 380oC

Diagnosis of cause of High LOI in Fly Ash

~ 130 - 140oC

If LTSH inlet temperature has also increased; then the problem is in

the radiant SH/ RH.
If PSH
PSH inlet
inlettemperature
temperaturehas
is decreased,
unchanged, then
it could
it could
bebethe
because
time to
of
operate dilution;
furnace LRSBs in optimize
that region.
air/ fuel ratio

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 13-02-2017

~ 800 - 850oC

Retention Time

Time
~ 650 - 700oC
~ 900 - 950oC

Reaction Time
~ 450 - 480oC
~ 1100 - 1200oC

~ 350 - 380oC
Factors that we need to check and adjust would be:

Characteristics of fuel
Fuel fines
The viability of cutting upper level burners
~ 130 - 140oC
Gas Velocity
Type of furnace and
The carbon particle must have reached this location without getting
How the air has been given
the chance of interacting with O2

The Problem is primarily caused by the 3rd T; which is Time

Super heater picks up sensible heat,

which follows the relation:

∆T = H
m x Cp
Diagnosis of cause of High Attemperation
spray First we need to check which one is
picking more heat

Check steam temperature before

attemperation

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 13-02-2017

~ 800 - 850oC ~ 800 - 850oC

~ 650 - 700oC ~ 650 - 700oC

~ 900 - 950oC ~ 900 - 950oC

~ 450 - 480oC ~ 450 - 480oC

~ 1100 - 1200oC ~ 1100 - 1200oC

~ 350 - 380oC ~ 350 - 380oC

~ 130 - 140oC ~ 130 - 140oC

Platen Inlet Gas Temperature high Platen Inlet Gas Temperature Low

Operate Wall Blower Check Fuel CV

If the spray is increasing again within 3-4 hours, then the problem Optimize Air
can not be due to water wall soot formation
The problem could be delayed combustion

Check for spray control valve passing

Check platen SH inlet gas temperature. If it is in
range, then problem could be likely due to soot
formation. Time to operate the LRSB.
In case of 1st stage attemperation; if the
Diagnosis of cause of Low SH / RH temperature drops within two to three hours of
temperature LRSB operation, check the saturated steam
conductivity
If the SH inlet gas temperature is low then it is a
likely case of furnace dilution.
Optimize Air
Deploy top level burner and make Burner tilt
positive. But try with less percentage of fines for
that mill.

35
 13-02-2017

We will have a brainstorming session on

possible diagnostic indication of other
Boiler issues during the concluding
session of this programme

Let us now take a look into the analytical

THANK YOU
approach for diagnosis of Boiler Tube
Failure

From HPT
To IPT

To HPT

FSH

HRH

PSH CRH

LTSH

ECO

APH

36