Boiler Performance Improvement

through Monitoring &

Optimization
BEE Technical Workshop PMI
B M Singh , Consultant –
Evonik Energy India
09560867733
 Power Plant –Fossil fuels

• Fossil fueled fired generating stations have

very precise definition of Thermal
efficiency.
• It is the ratio of heat equivalent of Fuel fired
to the heat equivalent of electricity sent to
transmission net work.
• Even the best designed P F fired stations
are currently operating at efficiency level
less than 40% (Sub Critical design).
 Power Plant –Fossil fuels
• Thermal efficiency is an important criteria
for determination of cost of electricity.
• Increased capital cost while designing new
plant can bring about higher design
efficiency.
• Increased cost to built up redundancy
helps improve availability.
• It enables a station to sustain optimum
operating efficiency from one overhaul to
next overhaul.
Power plant cycle efficiency
• Role of Steam Generator is to generate steam
which is used to convert heat energy into kinetic
energy.
• Boilers generally operate at Gross efficiency of
87.5%. Level of boiler efficiency is marginally
dependant on unit size – Once through or
Supercritical brand
• Gross boiler efficiency level depend more on
coal quality and less on type of cycle.
• Improvement in boiler efficiency with better coal
comes at a cost .
• Why not use better coal, an optimum performance
can be sustained with less expenditure on O&M
Cost. ( This could be an Important Optimization)
Power plant cycle efficiency
• Boiler Efficiency varies with output & boiler
efficiency at MCR rating would be around 0.3 less
as compared to at nominal load
• Gross boiler efficiency at any point of operation
can be improved by consuming more electricity
through Mills & fans.
• When we are using low cost – inferior coals- we
consume more auxiliary power consumption to
improve operating efficiency.
• Usage of an additional pulverizer to handle poor
coal results in increased power consumption ,
however, corresponding improvement in Gross
boiler efficiency may not be achieved in each
case.
All Performance Indicies except
Turbine Heat Rate linked with Coal
quality.
• UNIT HEAT RATE
• NET UNIT HEAT RATE
• TURBINE HEAT RATE
• BOILER EFFICIENCY
• UNIT AUXILIARY POWER
CONSUMPTION
Heat Input into a Large
Coal Fueled Power Plant-
Sub Critical design.
3%
Stack 5% 10% 37%
Clean-up Auxiliary Stack Electricity 45%
Equipment Power Losses Production Rejected Heat to
Cooling Water/ Cooling Tower
# CYCLE EFFICIENCY
• Over all Efficiency of a power
Station depends upon.
• Steam Cycle Efficiency-45%
• Boiler Efficiency based on HHV-88
to 89%
• Auxiliary Power( in Station Energy
consumption)- 5 to 7%
# Operational Efficiencies are generally
worse than design due to
• Sootblwing frequency-which is coal dictated.
• Varitation in Steam Temperature & pressures due
to load variation.
• Variation in flue gas oxygen content due to
changing load and change in coal quality.
• Less than optimum operation of Primary and
Secondary Air heaters.( Coal Quality related)
• Off design steam conditions due to normal
inaccuracies in commercial instruments.
• Losses during startup and shut down.
• Off design SH & RH sprays ( linked with coal Qua)
CONDITION MONITORING IMPORTANT
• Air in leakage to boiler gas enclosure
• Fouling of Boiler heating Surface –higher dry gas
loss.
• Higher draft loss due to air ingress and ash
deposition.
• Air heater leakage / Air ingress after APH’s
INCREASED COAL CONSUMPTION
• Deterioration of Turbine Steam Path Condition.
• Condenser pressure/ condenser cleanliness- air
ingress and extent of tube pluggage.
• Boiler operation at low oxygen when operating at
high outputs
Opertional Efficiency vs Design
efficiency in a typical plant
• Extent of difference between design &
operational Efficiency would depend on
• Plant design
• Type of Coal
• Site conditions
• Output factor
• In a new plant, difference could be 3%
where soot blowing is not excessive .
• In an old plant ,difference could be10%.
Boiler design Criteria’s
1. Boiler Exit Temperature- Boiler would be
generally designed for a particular exit
temperature( 125-135 degree Centigrade)
2. Temperature is COAL dependant
3. Excess air controls this temperature .( Whether
excess air is Coal quality dependant)
• While evaluating Thermal efficiency , Flue gas
exit at Economizer should be considered
whereas for boiler efficiency , flue gas exit at Air
heater outlet should be reviewed.
• On Line Flue gas exit at AH outlet measured more
accurately compared to Economizer outlet.
 Heat content of Coal/ No
information with Operator
• Boiler Efficiency Calculation requires
knowledge of Calorific Value of Coal and its
composition.
• Whether Efficiency Calculation should be
based on value of Gross CV or Net CV of Coal.
• Any convention can be used, Contractual
Boiler Efficiency is generally based on GCV.
• Another efficiency term used in Performance
Analysis is Expected Efficiency.
#Operating Efficiency depends on
Coal Composition & its Rank
• Coal Moisture affects efficiency mainly due to
loss of latent heat, 0.15% per 1% change in
Moisture.
• Ash content in Coal affects efficiency in two ways-
loss of heat along with ash/Loss due to carbon
• 1% change in ash content results in0.025%
change in efficiency.
• Change in flue gas temperature to avoid low
temperature corrosion- Efficiency changes by
0.5% for a 10 degree C change in temperature.
• High moisture Coals such as Lignite results in low
cycle efficiency.
#Site temperature and Humidity
• Site temperature and humidity have influence on
both boiler and turbine efficiency.
• Condenser pressure is regulated by CW
temperature and Cooling tower performance by
humidity of air.
• Loss of boiler efficiency is dependant upon
ambient temperature and moisture in air.
• Boilers typically operate in the range of -2 to 45
degree C in Northern Part of India.
• However, where ever SCAPH is taken in to service
at low temperature ,its impact on Boiler Efficiency
is dependant on coal quality. ( Status of Scaph in
your station)
 PERFORMANCE IMPROVEMENT
• High PLF & availability should translate into
Optimum operating EFFICIENCY.
• However, even at best Boiler Efficiency,
Operating heat rate can be worse by 10%
due to high steam consumption.
• Degradation in coal quality beyond station
control , however loss of operating
efficiency can be minimized by effective
maintenance of Turbine cycle.
• Increased Auxiliary power Consumption is
first sign of performance degradation.
Plant Modifications to Improve
Performance
• Once a unit has been built, up gradation of Steam
Conditions can be done only at very high cost .
• Loss of Capability due to deterioration in coal
quality has not been faced in NTPC however,
degradation of Efficiency observed
• Not achieving rated Steam Parameters in a new
plant set up may not be due to Coal
• Is It due to large difference between design coal
and worst coal specified ? ( Any Specific Problem
in your Station)
Plant Modifications to Improve heat Rate
• Increasing Mills Capacity has been envisaged .
• Increase in operating HR due to coal
degradation/ deterioration in equipment
Performance due to coal quality very common.
• Cycle efficiency of older turbine can be improved
by around 2% by incorporating new turbine
blades.
• Reduction of Condenser back pressure by
upgrading condenser, Improving performance of
cooling Tower, integrating OLTC system.
IMPORTANCE OF GUARANTEE TESTING
• PG testing is undertaken to comply with
contractual requirement at a cost to utility.
• It could serve as a Bench mark for
performance monitoring & testing.
• This provides first opportunity to learn
about Performance Analysis & importance
of Performance Monitoring
• Regular Performance Testing which I
believe is the recommendation of BEE as
well, should be conducted because on line
data not enough to assess degradation.
Boiler Efficiency Tests/Full load, Part load
Auxiliary Power Consumption/Analyse Losses.

Heat losses Design Uncorrected Test Value

Last Test Test
Dry Gas Loss % 3.65 5.90 5.93

Unburnt C loss % 2.00 0.76 0.73

Wet flue gas loss % 5.50 6.42 6.55

CO Loss % 0 0.01 0.01

Moisture in Air Loss % 0.35 0.09 0.16

Radiation & Unacc.
0.2/0.8 1.00 1.00
Loss %
Boiler Efficiency % 87.5 85.83 85.62
BOILER EFFICIENCY LOSS ANALYSIS
• EFFICIENCY LOSSES OF BOILER ARE
COAL DEPENDENT.( 10 TO 13% LOSS)
• DRY GAS LOSS & CARBON IN ASHES
ARE CONTROLLABLE LOSSES.
• CHANGE OF COAL WITH RESPECT TO
DESIGN WOULD CALL FOR WORKING
OUT NEW TARGET VALUES.
• UTILITIES CONTINUE TO COMPARE
PERFORMANCE WITH DESIGN COAL.
Power plant cycle efficiency
• Impact of coal quality on design Boiler Efficiency
is rather difficult to predict.
• Modeling tools are generally not available with a
station to understand the role of change in
operating regime on expected performance.
• Based on actual Performance, we can revise our
targets and instead of comparing performance
with design values , we can compare with
expected values.
• Combustion efficiency is quite a different term as
compared to thermal efficiency ?
GROSS POWER GENERATION
• Gross power output is controlled by MCR Capacity
of Boiler. ( 210-220 MW)
• Rated Generator output demands very high
through put from Boiler under adverse regime (.
Some times more than MCR)
• We always look at MW meter & not at FW flow
• Unit operation at optimum boiler loading would
facilitate trouble free operation..
• Clinkering, slagging and tube failures outages
could be ascribed to high boiler loading with
deterioration in coal quality .
OXYGEN SET POINT TO BE REPRESENTATIVE OF DUCT
CONDITIONS & CONDITIONS IN THE FURNACE

• Oxygen as measured On line using ‘Zirconia

Probes” should represent the process.
• Left & right difference of Oxygen value
could be a realistic statement and not
instrument error.
• No of Zirconia probes to be increased to
improve the reliability of feedback. Probes
provided at AH outlet to work out on line
leakage.
UNIT AUXILIARY POWER CONSUMPTION
• Unit Aux. Power consumption has
direct co-relation with equipment
conditions & Coal quality.
• Higher aux. power consumption
basically reflects degradation of
equipment.
• Deviation from target Aux. power
consumption could be on account of
change in operating Regime , Coal
quality and steam demand.
MAIN STEAM TEMPERATURE
• NORMATIVE STEAM TEMPERATURE - 535 C +/-
5C FOR SUBCRITICAL BOILERS.
• Is steam temperature monitored
accurately ?
• RATED TEMPERATURE NOT ACHIEVED IN MANY
BOILERS DUE TO COAL QUALITY CHANGE.
• HIGH SPRAY RATES IN A PROPERLY DESIGNED
BOILER IS A REFELECTION OF DEGRADATION OF
COAL QUALITY & POOR OPERATING REGIME..
• AVAILABILITY OF BURNER TILT CONTROL
ESSENTIAL TO ACHIEVE & MAINTAIN TEMP.
EXCESS AIR LEVEL
/IS IT COAL QUALITY DEPENDANT?
• THIS PARAMETER HAS MAXIMUM
OPTIMIZATION POTENTIAL.
• BOILER TO BE RUN AT AN OXYGEN LEVEL OF
WHICH RESULTS IN MINIMUM OF LOSSES.
• STATION OXYGEN SENSOR TO BE PLACED AT
REPRESENTATIVE LOCATION.
• IS EXCESS AIR MONITORED ACCURTAELY ?
• AIR INGRESS UPSTREAM OF THIS SECTION CAN
ADVERSELY AFFECT THIS FEEDBACK.
 Oxygen Levels at AH Inlet / Outlet- Grid testing

Oxygen in Flue Gas at AH A Inlet / Outlet Oxygen in Flue Gas at AH B Inlet / Outlet

10 12 10 10

8 10 8 8

Outlet O2 %
Inlet O2 %

Outlet O2
8

Inlet O2
6 6 6
6
4 4 4
4
2 2 2 2
0 0
0 0
A B C D E F
A B C D E F
Probe
Inlet O2 Outlet O2 Inlet O2 Probe Outlet O2
AIR HEATER LEAKAGE
• AIR HEATER LEAKAGE LEVELS AFFECT EXIT
TEMPERATURE AND AUXILIARY POWER OF FANS.
• ACCURATE MEASUREMENT OF AH LEAKAGE
IMPORTANT TO ASSESS DEGRADATION OF
PERFORMANCE LEVEL FOR CORRECTIVE ACTION
• HIGH LEAKAGE CAN EVEN ADVERSELY AFFECT UNIT
CAPABILITY.
• FIVE MILL OPERATION RESULTS IN HIGHER LEVEL OF
LEAKAGE IN 210/200 MW UNITS.
• COAL QUALITY DETERIORATION PRIME CASUE FOR
ADDITIONAL MILL OPERATION.
 Typical % Oxygen / CO in flue gas across AH Inlet ducts
(Test 3 data)

Average values of Oxygen in flue gas obtained in the sampling grid at AH A and B Inlet in Test 3

A B C D E F A B C D E F

1 3.46 3.06 1.72 0.60 0.56 1.05 1 1.98 2.10 2.87 2.52 3.12 XXX

2 2.96 3.61 3.39 0.97 1.10 1.22 2 3.18 2.38 2.66 3.25 3.00 XXX

3 3.15 2.90 3.13 1.11 1.30 1.82 3 2.66 2.55 2.67 3.02 3.08 XXX

Air heater A - Zirconia average - 1.2 % Air heater B - Zirconia average - 2.7 %

Average values of CO in flue gas obtained in the sampling grid at AH A and B Inlet in Test 3

A B C D E F A B C D E F

1 2973 2563 2882 2495 2536 1734 1 220 187 119 75 142 XXX

2 2485 2104 2498 1990 1902 976 2 124 105 53 62 181 XXX

3 2361 2289 1976 2063 1982 1064 3 101 98 111 194 60 XXX

Air heater A - CO average - 2159 ppm Air heater B - CO average - 122 ppm
AIR DISTRIBUTION IMPROVEMENT
• Role of Excess air is important to achieve efficient
combustion.
• Equally important is to achieve improvement in
air distribution to reduce NOx emissions.
• SADC help mitigate minor deficiencies in equal
distribution of combustion air.
• Typical upgrade in this area cover use of baffles,
perforated plate or compartmentalization of wind
box.
• This is the only control with operator to respond
to change in coal quality.
FLUE GAS EXIT TEMPERATURE A DESIGN
CRITERIA
• FLUE GAS TEMP. AT AH OUTLET IS INDICATIVE
OF HEAT LEAVING THE UNIT UNUTILIZED
• FLUE GAS TEMP. IS LOWERED ON ACCOUNT OF
AIR HEATER LEAKAGE.
• FG TEMP. TO BE MEASURED AT A LOCATION
SLIGHTLY AWAY FROM AIR HEATER
• NO OF TEMPERATURE SENSOR PROVIDED
SHOULD COVER THE DUCT ADEQUATELY.
• CORRECTED FLUE GAS TEMPERATURE SHOULD
BE USED FOR COMPARISION BETWEEN
DIFFERENT TEST CONDITIONS.
AIR PREHEATER IMPROVEMENTS
• On Line Monitoring of APH Performance essential
to track efficiency loss.
• 500 mw units provided with such a facility, its
utilization need to be improved.
• Regenerative air heaters are ideal for low cost
upgrade of baskets with new design and new
seals to minimize leakage of air.
• 2% Gain in Unit Efficiency is achievable where
ever new air heater replacement is warranted.
• A n effective Air Heater overhaul should restore
efficiency by around 0.25%.
UNBURNT CARBON
• UNBURNT CARBON IN ASH IS A CONTROLLABLE PARAMETER.

• ITS DETERMINATION SUFFERS FROM UNCERTAINTIES ON

ACCOUNT OF SAMPLING ERRORS.

• SAMPLES ARE COLLECTED FROM DIFFERENT HOPPERS TO KEEP

UNBURNT CARBON LOSS IN CHECK.

• IN ONE OF THE STATIONS, UNBURNT CARBON WAS BEING

MEASURED FROM LAST ESP FIELD?

• HIGH VOLUME SAMPLER IS AN EXCELLENT DEVICE FOR

COLLECTING AN ISO KINETIC SAMPLE WHICH CAN BE CHECKED
ON DAILY BASIS.
UNBURNT CARBON

• TARGET LOSS DUE TO UNBURNT CARBON

IN ASH IS GENERALLY CONSERVATIVE.
• IT IS INTERDEPENDENT ON OTHER LOSSES.
• MILL FINENESS NEEDS TO BE CLOSELY
MONITORED.
• COAL DISTRIBUTION IS KEY TO REDUCE
THIS LOSS.
• EFFECTIVE AIR DISTRIBUTION HELPS IN
REDUCING THIS LOSSS.
Boiler Efficiency Tests/Full load, Part load
Auxiliary Power Consumption/Analyse Losses.

Heat losses Design Uncorrected Test Value

Last Test Test
Dry Gas Loss % 3.65 5.90 5.93

Unburnt C loss % 2.00 0.76 0.73

Wet flue gas loss % 5.50 6.42 6.55

CO Loss % 0 0.01 0.01

Moisture in Air Loss % 0.35 0.09 0.16

Radiation & Unacc.
0.2/0.8 1.00 1.00
Loss %
Boiler Efficiency % 87.5 85.83 85.62
 UNBURNT CARBON IN ASH - A CONTROLLABLE
PARAMETER

Load 177 190 183 183 172

Average Oxygen 4.1 3.3 2.8 3.2 4.1

Unburnt Carbon 4.0 6.2 7.1 5.2 2.4

in Flyash - Left
Unburnt Carbon 3.9 5.1 5.1 5.6 2.3
in Flyash - Right
SPARAY RATES
• H. R. DEVIATION ON ACCOUNT OF
VARIATION IN SPRAY RATE SHOULD BE
INVESTIGATED.
• SPRAY RATE - DEVIATION IS DEPENDENT
ON TYPE OF COAL, EXCESS AIR LEVEL , MILL
COMBINATION & AVAILABILITY OF
BURNER TILT CONTROL.. .
• FURNACE CLEANLINESS AFFECT SPRAY
RATES WHICH IS COAL DEPENDENT. THIS
COULD BE EVEN A DESIGN PROBLEM.
 Typical HR multiplier vs RH Attemperation Curve

1.001

1
y = -0.0015500x + 1.0000000
HR multiplier

0.999 R2 = 0.9987529

0.998

0.997

0.996

0.995
0 0.5 1 1.5 2 2.5 3 3.5
RH Att (%)
ESP Performance-linkage with
Boiler Efficiency
• ESP’s handle very high flue gas volumes.
• Particulate properties and gas stream conditions
dictate ESP Performance.
• Particle Size distribution, ash resisitivity, flue gas
flow , Coal quality and process temperature
affect the ability of ash to be collected and
removed from ESP’s.
• Increase in flue gas velocities and temperature in
Electric fields can all be related to degradation of
boiler and Air heater Performance.
• A good part of this can be ascribed to Coal.
ROUTINE PERFORMANCE TESTING
• ROUTINE PERFORMANCE TESTS TO BE
CARRIED OUT WITH SPECIAL INSTRUMENTS
DUALLY CALIBRATED
• FEEDBACK FROM SUCH TESTS WOULD FORM
THE BASIS FOR TARGET FIXATION
• TEST PROCEDURES FOR THESE TESTS ARE IN
LINE WITH PG TEST PROCEDURES.
• ONLY SUCH PRECSION TESTING CAN
ESTABLISH REASONS FOR SPECIFIC CAUSE FOR
PERFORMANCE DEGRADATION.
Overview - Boiler Performance Assessment
Modules
1. Mills’ Performance Testing

2. A .H Performance Tests (Pre & Post Outage)

3. Boiler Efficiency Tests (Pre & Post Outage)

4. Boiler Furnace Performance Tests

5. Boiler Performance Optimization

6. Auxiliary Power Consumption Tests

7 Draft Margins Test.

 Boiler Performance Optimization
• To evolve an optimum operating regime for a boiler; a
set of operating parameters and equipment settings for
safe, reliable and efficient operation.

• To establish interrelationships between different

operating parameters.

• 6 to 11 test runs are conducted using accurate Off-line

instruments used as per ASME test code.

• To build a database by various parametric tests; a

repeatable database for problem solving and diagnosis.
 Optimum Combustion
Performance Preservation
Outline
Performance preservation requires the
combined efforts of operations,
maintenance, and engineering test
personnel.
 Boiler Performance Optimization a must to reduce CO2
emissions in coal fired plants

Boiler performance optimization regime was worked out and its

effectiveness demonstrated at various stations.
Station Nominal Optimum Eff.Imp HR Imp.
O2 % O 2 % % kcal/kWh
(approx.)
210 MW -WR 3.8 2.5 0.3 8
210 MW 3.8 3.8 0.3 8
67.5 MW 3.5 2.4 0.4 10
210 MW-SR 3.8 0.8 - 2.54 $
210 MW -NR 3.8 2.25 0.65 17
$ Loss in boiler efficiency on account of operation at lower level of
oxygen as compared to a rated value.
Typical Optimum Combustion Regime

Unit load 205 MW

Main steam flow 640-650 T/hr
Total air flow 880 to 890 T/hr
Control room O2% 5.5%
PA header Pressure 740 mmWC
W B Pressure 100 mmWC
Fuel air damper closed
AA dampers 10 % open
Burner tilt -20 degree.
Each Outage
• Rebuild pulverizer • Set airheater seals, clean
grinding elements baskets, check and repair
• Refurbish burners to sector plates and all
design dimensions and moving parts
tilt strokes
• Inspect and repair all
• Verify damper strokes primary and secondary
• Leak check and repair dampers and ductwork
sensing lines to airflow
measuring devices • Thoroughly inspect and
• Inspect, repair and repair all ductwork and
functionally check all expansion joints
dampers from inside
ductwork
Each Shift or Daily
• Check fuel and ash analyses
• Excess oxygen on curve, airflow on
curve
• Windbox to furnace pressure drop
is optimum
• Feeders balanced
• Damper strokes proper
• Steam temperatures at
1005/1005°F
• Spray flows normal
• Soot blower steam temperatures,
pressures, and condensate drains
• Air heater temperature checks
• Normal operator checks
• Raw coal sizing
• Burner tilt angles, and similarity of
angles (corner fired boilers)
• Air registers and air slides,
impeller settings(wall fired
boilers)
• Pulverizer coal reject quantity
• Pulverizer outlet temperatures
• Pulverizer drive motor power or
amps
• Visual appearance of coal flames
• Nose arch and superheater area
for slag appearance
• Superheater inlet for flame
carryover by visual appearance
• Lower furnace for possible slag
bridging, bright appearance
• Air heater inlet gas duct hoppers,
hot, not plugged
• Normal operational checks
Each Three Months
• Leak checks of airflow measuring elements
• Hot K calibrations of airflow measuring
elements (primary and secondary)
• Furnace excess oxygen traverse by HVT
probe to check oxygen and stratifications
• Measure oxygen rise from furnace to stack