Date 6/7/2012

VISIT REVIEW
Unit Boiler at Kasarwadi Plant(J.N. Marshall) Capacity 1 ton but working capacity is 700 800 Kg. Controller DCS(server-workstation)arrangement i.e smart boiler controller. Modes of control both remote & local Control strategy of loops feedback system. Boiler start up process 1. 2. 3. 4. 5. Fill water inside the boiler up to 90 %. Oil heater ON. When temperature of oil will reach 110 C. Boiler ignition state Run the boiler for 15-20 min. on low fire mode & then switch to high fire state.

Excess water in the steam at the initial stages of boiler operation is drained off. Boiler shut down process 1. 2. 3. 4. 5. 6. Switch off the oil flow Stop the furnace firing by shutting down the air flow Oil heater off Fill water inside the boiler up to 90% Due to that steam pressure reduces Close the steam outlet valve

Fuel used - Furnace oil Working duration 16 hours Air flow 1. Damper 60% open for high firing 2. Damper open 10 % for low firing Fuel 1. Oil pressure 20kg/cm^2 2. Fuel flow 57.3 kg/hr(for high air flow) Fuel flow 30 kg/hr(for low air flow)

Water Flow Pump pressure is 1.5 times the working pressure. Steam Actual steam pressure 35 kg/cm^2 Working steam pressure 22 kg/cm^2 Level control Single element drum level control is used.Two MORBE controllers are used one for feed pump & another one for flow water. Burner ignition Two electrodes are placed near to each other & it is followed by sinusoidal coil which generates sparks for 15 sec which ignites the burner. Points of losses in boiler 1. 2. 3. 4. Stack loss Steam loss Unburned fuel loss Blow down loss

For reducing losses 1. To reduce unburned losses excess air is fed into the furnace(O monitoring). 2. For reducing unburned losses economizer is must which preheats the water so that fuel required for steam generation is low causing low losses.(Economizer is absent in J.M Marshall boiler) 3. The boiler is a three pass boiler means the exhaust gases are circulated thrice through the boiler to minimize heat losses through the exhaust gases. For calculation of efficiency, consider the following points 1. 2. 3. 4. 5. Steam /hr Fuel required for generation of that steam Water enthalpy Steam enthalpy Gross calorific value

6/7/2012 Tim e Stea m (kg) Fue l(kg ) Blo w dow n(kg ) 0

11:55:24 Average boiler efficienc y(%) 82.65

Boiler operation hourly report Aver age S:F Ratio 3.86 Avera ge stack O(% ) 6.39 Avera ge stack temp.( C) 175.37 Avg. steam temp(C ) 118.95 Avg. steam press( kg/c m) 1.03 Avg Avg stack enthalpy loss loss(%) (%) 6.73 7.62 Avg radiatio n loss(%) 2.00

6.00 AM 10.0 0 AM

27

411. 0

43. 0

78.94

9.56

6.53

246.53

215.0

20.55

9.91

8.0

1.99

6/7/2012

12:08:12