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Culture Documents
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
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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GEN
Fuel System :
Deaerator
LP Heater
Condenser
ESP
Objective:
Boiler Feed Water System:
TE
SH-1 SH-2
Heating of Feed Water close to drum
TE temperature:
TE Deaerator
LP Heater
Down comer
Riser
Riser
PT FT
PT
level
TE
TE
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Objective:
Deaerator Performance diagnosis:
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Cavitation :
NPSHa : Pda
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Natural Circulation:
Temperature of steam and Water in
the whole Evaporator system is Ts Furnace Temperature in the
range of 1100o to 1200oC
Water
Mixture of steam
and Water Creep starts in Carbon Steel at 370oC and it doesn’t
have strength against creep
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Film Boiling
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Departure from
Steam bubbles formed and
Nucleate Boiling : sticking at the bottom
ΔP = H g (ρd – ρr)
ρr ρd
MCR
Riser
ΔP = H ρd g - H ρr g = H g (ρd – ρr)
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Natural Circulation
Drum Level
Down comer
ρr ρd
Riser
120oC
500
120oC
300
ΔP = H g (ρd – ρr)
High Heat Flux – more than Critical Heat Obstruction due to foreign object fouling
Flux the tube
Formation of scale inside the tube
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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
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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%
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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%
Typical NG Analysis
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Viscosity
Solid contamination
Water contamination
High Sulfur
Oxidation of 1 kg of Carbon:
Combustion is a chemical reaction of:
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Combustion mechanism:
C N2 N2
H2
Assessing Air Requirement
O2 CO2
S SO2
N2 CO
O2 H2O
H2O O2
Ash
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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
From HPT
To HPT
To IPT
Time
FSH
HRH
PSH CRH
Turbulence Char
coal particle ECO
d=30-70m
APH
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~ 650 - 700oC
Sulphur 250oC FSH
PSH CRH
~ 900 - 950oC
C2H2 (Acetylene) 480oC
LTSH ~ 450 - 480oC
C2H6 (Ethane) 540oC
C2H4 (Ethylene) 550oC
~ 1100 - 1200oC ~ 350 - 380oC
Hydrogen 610oC
ECO
~ 130 - 140oC
Primary Air
Coal Combustion Systems
Secondary Air
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Pulverized Coal
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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
Combustion Optimization
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Loss
Shift in heat transfer from furnace to convection
pass resulting in heating up of down stream
components
Air
Draught System
+ 100 - 350
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Optimization Steps
For PF Boilers Identify and stop Furnace Ingress
Parameters/ data needed Calculate min. theo. Air from ultimate analysis
O2, CO and CO2 at exit gas Measure fuel flow and calculate air to fuel ratio
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
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
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FS
H
SH 2
ECO
APH
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
850oC
APH
~ 130 - 140oC
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~ 650 - 700oC
~ 900 - 950oC
LTSH
870oC 690oC
~ 450 - 480oC
~ 1100 - 1200oC
421oC
252oC
APH
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J
Temperature
H
I
E
F
100oC B
C
Enthalpy
Tsat 350oC
DA out 173oC
LPH out 140oC
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CEP out
capacity steam
SH/ RH temperature is increasing
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~ 650 - 700oC
~ 900 - 950oC
Eco out
HPH out ~ 450 - 480oC
~ 1100 - 1200oC
DA out
LPH out
~ 350 - 380oC
CEP out
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BOILER INLET
DUCT
FLOW FROM GT
DIFFUSER
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~ 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 exit O2
APH
~ 130 - 140oC
~ 350 - 380oC
√ ~ 350 - 380oC
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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~ 650 - 700oC
√ √ ~ 650 - 700oC
√
~ 900 - 950oC ~ 900 - 950oC
~ 450 - 480oC
√ ~ 450 - 480oC
~ 1100 - 1200oC ~ 1100 - 1200oC
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
~ 130 - 140oC
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~ 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
∆T = H
m x Cp
Diagnosis of cause of High Attemperation
spray First we need to check which one is
picking more heat
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Platen Inlet Gas Temperature high Platen Inlet Gas Temperature Low
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From HPT
To IPT
To HPT
FSH
HRH
PSH CRH
LTSH
ECO
APH
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