STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC BOILER

Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Project BOILER

Document No. Ab/B/25/19/R 00

Rev. No. Date Prepared by Checked By Approved by Revision Details

00 09.08.2019 RGK RGK KS First Issue

ARYAN BOILERS PVT LTD

CORPORATE OFFICE FACTORY

Row House:11 377/1/2, M.I.D.C, BARAMATI

Aquila Society DIST: PUNE

Yogi Park, Baner, Pune STATE: MAHARASHTRA

E-mail: bd@aryanboilers.com, Web: www.aryanboilers.com.

Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 2 of 16

PLANT VISIT REPORT FOR OBSERVING THE EXIT FLUE GAS TEMPERATURE HIGH
IN THE AIR PREHEATER

10 MW CPP, SREE RAYALASEEMA HI STRENTH HYPO LIMITED, KURNOOL

TELANGANA STATE, was visited dated on 02.08.2019 and 03.08.2019 for observing the
exit flue gas temperature high in AIR PREHEATER of below noted boiler

MAKE JIANGYIN CHUANGJIE ELECTRICAL EQUIPMENT CO.LTD.,

TYPE CFBC

MCR 53 TPH

STEAM PRESSURE 67 Kg/Cm2

STEAM TEMPERATURE 490°C

USAGE OF COAL INDONESIAN COAL70% + SOUTH AFRICAN COAL 30%

OBSERVATION:

➢ Usage of yard stock coal of Indonesian & South African having more fines and after crushed
coal also found is higher.
➢ Difference of O2 level found in LHS & RHS in which is higher than the LHS.
➢ Existing replaced SAPH & PAPH blocks were found in tubes blockage and corrosive
condition.
➢ Start up vent slight passing
➢ Un burnt coal fines in fly ash found in the ESP due to secondary firing is happening.
➢ Bed temperatures are maintaining well below 900°C.
➢ Furnace temperature also maintaining and matching with existing of the same at full load
operation.
➢ Loop seal Total air flow is higher side as per existing record of before shutdown.
➢ Difference found in the Dip leg and Riser leg of Loop seal height.
➢ Air ingression found in the RHS Economiser header seal box area.
➢ Level variation in the Deaerator as per records. No steady level.
➢ Water chemistry parameter of Boiler water PH is maintaining as 9.5 instead of 9.8 to 10.2
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 3 of 16

ACTION TO BE TAKEN:

➢ 30 % Usage coal of South African coal can be replaced with Indian coal and Indonesian coal
can be used as the same 70 %.
➢ If both side instrument is correct, Air ingression to be sealed properly.
➢ Pressure difference has to be checked frequently in the new installed APH in which tubes
may be getting build up of Soot or Scales and the O2 level also.
➢ Check the conditions of Isolation valve and Control valve also.
➢ Feed coal fines to be controlled by adjusting the crusher gap without affecting another belt
conveyor overloading and modulation of air flow in the Loop seal & Tertiary air. Both Cyclone
exit path to be checked.
➢ Loop seal air flow to be controlled by giving through Root blower and check the proper
isolation of the inter connection line valves for the PA & SA.
➢ Height of Dip leg is very important. Dip leg shall be always more than the Riser leg. Also Dip
leg air velocity shall be lower than the Riser leg.
➢ All air ingression of RHS Economizer should be sealed by ceramic wool properly..
➢ Bed ash iron to be minimized by adding fresh bed material with <1% of iron and also using of
recycled bed materials iron which should be separated to minimize < 2% by magnetic
separator.
➢ Deaerator level should be steady. ARC Valve condition of all the existing feed pumps to be
checked.
➢ As per the recommendation of Thermax, who is supplying the chemicals.
➢ Compressed air bypassing to be checked in all the SOV of the ultrasonic soot blower.
➢ Un insulated area of flue gas outlet duct to the entry of Cyclone is to be corrected.
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 4 of 16

DURATION OF SHUTDOWN DONE: 12TH MAY’19 TO 1ST JUNE’19

FOLLOWINGS WERE DONE TO CONTROL THE EXIT FLUE GAS TEMPERATURE OF

AIR PREHEATER:

➢ Bed height of PA was increased from 850 mmWC to 870 mmWC. No variation.
➢ PA Fans discharge pressure was decreased 1150 mmWC to 1100 mmWC. No improvement.

ALL PARAMETERS OF THE BOILER TAKEN FROM THE BEFORE & AFTER SHUTDOWN:

BEFORE SHUTDOWN AFTER SHUTDOWN

15.03.19 @ 30.04.19 @ 08.07.19 @ 17.07.18 @
17:00 HRS 17:00 HRS 15:00 HRS 15:00 HRS
Sl.No. PARAMETERS UNITS

1 LOAD MW 10.5 10.7 10.4 10.4

2
MS STEAM FLOW TPH 56 56 55 55
3
MS PRESSURE KG/CM2 66 66 66 66
4
MS TEMPERATURE °C 485 489 489 485
5
DRUM LEVEL (L) % 50 50 50 50
6 DRUM PRESSURE (L) % 67 67 69 69
6
DRUM PRESSURE (R) % 69 69 71 71
7 FW FLOW TPH 54 51 53 53
8
FW BEFORE FCV % 76 80 77 78
9
FCV OPENING % 60 39 50 43
10
DEAERATOR LEVEL % 66 66 69 68
11 DEAERATOR PRESSURE KG/CM2 3.3 3.3 3.3 3.3
12
DEAERATOR TEMPERATURE °C 145 145 145 145
13
FW ECO. I/L TEMPERATURE °C 102 111 122 126
14
FW ECO. O/L TEMPERATURE °C 274 274 270 273
15
PSH OUTLET TEMPERATURE °C 392 344 347 331
16
DSH WATER FLOW TPH 2 1 1 1
17 DSH 1 O/L TEMPERATURE °C 492 - 488 487
18 DSH 1 SCV OPENING % 62 6 64 64
19
DSH 2 O/L TEMPERATURE °C 492 - 487 487
20
DSH 2 SCV OPENING % 0 - 0 0
21
FEEDER A SPEED/VFD RPM/AMPS 495/33 430/30 485/32 484/32
22
BELT FEEDER A SPEED RPM 589 574 602 598
23 FEEDER B SPEED/VFD RPM/AMPS 465/32 459/30 508/35 494/32
24
BELT FEEDER B SPEED RPM 589 573 603 603
25
PA HOT AIR TEMPERATURE °C 127 127 117 119
26 PA FLOW M3/HR 30159 30061 30159 30012
27
PA WIND BOX PRESSURE MMWC 1137/1117 1136/1117 1055/1038 108/991
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 5 of 16

28 PA BED HEIGHT MMWC 850 825 878 832

30
SA FLOW M3/HR 29621 29670 30024 30024
29
SA HOT AIR TEMPERATURE °C 173 171 168 172
31
SA WIND BOX PRESSURE (L/R) MMWC 682/651 677/645 615/615 575/577
32
SA BED HEIGHT MMWC 369 333 354 304
33
TERITARY AIR PRESSURE MMWC 850/850 850/850 950/1150 900/1150
34
DCS O2 LEVEL (L/R) % 2.7/3.3 2.0/2.9 3.5/4.6 2.9/4.3
35 LOOP SEAL TEMPERATURE (L/R) °C 608/615 614/619 616/613 625/623
36 DOWN LEG WB. PRESSURE (L/R) MMWC 816/818 866/856 836 814
37
DOWN LEG AIR FLOW (L/R) M3/HR 28.0/3.0 30.0/3.0 28.0/2.0 25.0/2.0
38
RISER LEG WB. PRESSURE (L/R) MMWC 862/867 884/891 839 844
39
RISER LEG FLOW (L/R) M3/HR 1.0/98 1.0/103 1.0/109 1.0/103
40 DOWN LEG HEIGHT (L/R) MMWC 111/59 78/53 96/92 98/83
41
UPPER LEFT BED 1 (REAR) °C 824 802 837 828
42
UPPER LEFT BED 2 (REAR) °C 878 853 827 874
43
UPPER LEFT BED 3 (REAR) °C 902 873 890 889
44
LOWER BED 1 (MID) °C 902 873 884 899
45
LOWER BED 2 (MID) °C 905 876 891 898
46
UPPER LEFT BED 1 (FRONT) °C - - 857 848
47 UPPER LEFT BED 2 (FRONT) °C 872 852 851 840
48 UPPER LEFT BED 3 (FRONT) °C 887 854 868 876
49
UPPER RIGHT BED 1 (FRONT) °C 839 826 837 839
50
UPPER RIGHT BED 2 (FRONT) °C 829 816 817 824
51
UPPER RIGHT BED 3 (FRONT) °C 895 868 883 893
52
LOWER RIGHT BED 1 (MID) °C 865 866 884 880
53
LOWER RIGHT BED 2 (MID) °C 885 865 878 863
54
UPPER RIGHT BED 1 (REAR) °C - - 787 801
55
UPPER RIGHT BED 2 (REAR) °C 871 846 858 875
56
UPPER RIGHT BED 3 (REAR) °C 903 875 886 897
57
AVERAGE BED TEMPERATURE °C 877 875 868 869
58
FURNACE TEMPERATURE (L) °C 820 795 816 824
59
FURNACE TEMPERATURE (R) °C 818 804 805 800
60
CYCLONE I/L FG TEMPERATURE (L) °C 536 544 531 539
61
CYCLONE I/L FG TEMPERATURE (R) °C 523 526 524 525
62
ECO. I/L TEMPERATURE °C 484 471 478 476
63
SAPH I/L FG TEMPERATURE °C 323 323 319 312
64
SAPH O/L FG TEMPERATURE °C 256 259 253 253
65
PAPH O/L FG TEMPERATURE (L/R) °C 185/163 182/165 187/181 185/180
66
ESP O/L FG TEMPERATURE °C 145 - 138 -
67 ROOT BLOWER RUNNING B B B B
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 6 of 16

68 LOOP SEAL TOTAL AIR FLOW M3/HR 1164 1156 1281 1193
69
LOOP SEAL DIS.PRESSURE MMWC 0.2 0.2 0.2 0.2
70
COMBUSTION DRAFT MID (L/R) MMWC 0/-2 0/-4 0/-2 0/-1
71
CYCLONE DRAFT (L/R) MMWC -4 -3 -1 1/-1
72
ECO. INLET DRAFT (L/R) MMWC -101 -100 -143 -182
73
HOT APH DRAFT I/L MMWC -170 -171 -176 -189
74
COLD APH DRAFT O/L MMWC -211 -205 -216 -214
75 ESP INLET DRAFT MMWC -205 -208 -225 -218
76 ESP OUTLET DRAFT MMWC -245 -242 -251 -253
77
BFP SPEED RPM 2840 2850 2580 2813
78
C/D POWER CONSUMPTION KW 320 325 224/227 320
79
BFP 3/4 STRAINER DP MMWC 700 790 514/463 790
80 PA FAN I/L DAMPER OPEN (A/B) % 100/100 100/100 100/100 100/100
81
PA FAN O/L DAMPER OPEN (A/B) % 90/90 91/92 87/87 87/92
82
PA FAN A SPEED/CURRENT RPM/AMPS 2675/198 2706/200 2621/194 2595/189
83
PA FAN B SPEED/CURRENT RPM/AMPS 2822/164 2749/202 2624/188 2731/154
84
SA FAN I/L DAMPER OPEN (A/B) % 100/100 100/100 100/100 100/100
85
SA FAN O/L DAMPER OPEN (A/B) % 75/76 76/77 76/76 74/74
86
SA FAN A SPEED/CURRENT RPM/AMPS 2284/99 2295/97 2279/106 2216/98
87 SA FAN B SPEED/CURRENT RPM/AMPS 2119/81 2364/101 2322/101 2259/97
88 ID FAN I/L DAMPER OPEN (A/B) % 77/78 79/76 79/79 76/77
89
ID FAN A SPEED/CURRENT RPM/AMPS 765/154 775/156 775/164 745/152
90
ID FAN B SPEED/CURRENT RPM/AMPS 763/152 744/145 774/153 754/148
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 7 of 16

SNAP SHOT OF BOILER OVERVIEW WITH PARAMETERS ON 02.08.19 @15:54

HOURS:

SNAP SHOT OF BOILER OVERVIEW WITH PARAMETERS ON 03.08.19 @10:08

HOURS:
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 8 of 16

O2 READINGS WERE TAKEN IN THE DIFFERENT LOCATION GIVEN BELOW:

ECONOMISER:

PARAMETERS LEFT RIGHT PARAMETERS LEFT RIGHT

O2 3.9 7.4 O2 4.0 7.4
CO 196 156 CO 208 150
CO2 14.6 11.5 CO2 14.6 11.5
EX.AIR 24 56 EX.AIR 23 56

SA OUTLET (LEFT SIDE):

PARAMETERS LEFT
O2 4.3
CO 136
CO2 14.4
EX.AIR 25
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 9 of 16

PA OUTLET (RIGHT SIDE):

PARAMETERS FIRST SECOND

O2 7.5 7.4
CO 102 110
CO2 11.6 11.5
EX.AIR 55 56

PA OUTLET (LEFT SIDE):

PARAMETERS FIRST
O2 5.0
CO 138
CO2 14.1
EX.AIR 27
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 10 of 16

PA OUTLET COMMON DUCT (LEFT SIDE) TAKEN FROM THE LOCAL TEMPERATURE GAUGE:

PARAMETERS FIRST SECOND

O2 5.5 5.4
CO 124 130
CO2 13.2 13.3
EX.AIR 36 35
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 11 of 16

DESIGN VALUES OPERATING VALUES ACTUAL VALUES

Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 12 of 16

THE ABOVE IS MENTIONED THE COMPARISON OF FLUE GAS TEMPERATURE

PROFILES

SUGGESTIONS FOR TRIALS TO BE DONE IS BELOW:

❖ Standby equipments of PA Fan, SA Fan and Root blower to be changed over as per
schedule.
❖ PA air flow shall be adjusted to provide minimum fluidization which shall be better
combustion, as per load.
❖ Also SA shall be adjusted to maximum penetration so that there shall be adequate reaction
of O2 with fuel.
❖ SA pressure high is required for better mixing of combustion.
❖ Provided Sealing air to coal feeders to be checked properly.
❖ Returned the fly ash grains up to 90 microns shall be checked regularly from the Loop
seal/Cyclone.
❖ Ensure for maintaining the temperature profiles within the specified range is very important.
❖ Addition of Fresh bed materials frequency should be increased to control the iron & shell.
Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 13 of 16

Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 14 of 16

Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 15 of 16

Client M/s. RAYALASEEMA HI STRENGTH HYPO LIMITED, KURNOOL

STUDY FOR PERFORMANCE IMPROVEMENT OF 1 X 53 TPH, CFBC

Document Title
BOILER

Document No Ab/B/25/19/R 00 Page. No 16 of 16

THE FOLLOWING DATAS ARE REQUIRED TO IMPROVE THE PERFORMANCE

FURTHER:

➢ VOLUME OF FLUE GAS OUTLET OF CYCLONE, INLET OF ALL ECONOMISER BANK,

INLET OF SAPH, INLET OF PAPH AND INLET OF ID FAN.
➢ COAL ANALYSIS REPORT OF ULTIMATE & PROXIMATE.
➢ SIEVE ANALYSIS REPORT FOR THE BED ASH & FLY ASH
➢ BULK DENSITY AND IRON ANALYSIS OF COAL, BED MATERIAL, BED ASH & FLY ASH.