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BEE Technical Workshop PMI B M Singh , Consultant Evonik Energy India 09560867733
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)
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 PlantSub Critical design.
3% 5% 10% Stack Auxiliary Stack Clean-up Losses Equipment Power 37% Electricity Production 45% 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%
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.
Boiler Efficiency Tests/Full load, Part load Auxiliary Power Consumption/Analyse Losses.
Heat losses Design 3.65 2.00 5.50 Uncorrected Test Value
Last Test
Dry Gas Loss Unburnt C loss Wet flue gas loss CO Loss Moisture in Air Loss Radiation & Unacc. Loss Boiler Efficiency % % % % % % % 5.90 0.76 6.42
Test
5.93 0.73 6.55
0
0.35 0.2/0.8 87.5
0.01
0.09 1.00 85.83
0.01
0.16 1.00 85.62
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.
10 8
Inlet O2
8 6 4 2 0
6 4 2 0
Average values of CO in flue gas obtained in the sampling grid at AH A and B Inlet in Test 3
B 187 105 98
C 119 53 111
D 75 62 194
E 142 181 60
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 3.65 2.00 5.50 Uncorrected Test Value
Last Test
Dry Gas Loss Unburnt C loss Wet flue gas loss CO Loss Moisture in Air Loss Radiation & Unacc. Loss Boiler Efficiency % % % % % % % 5.90 0.76 6.42
Test
5.93 0.73 6.55
0
0.35 0.2/0.8 87.5
0.01
0.09 1.00 85.83
0.01
0.16 1.00 85.62
177 4.1
190 3.3
183 2.8
183 3.2
172 4.1
4.0 3.9
6.2 5.1
7.1 5.1
5.2 5.6
2.4 2.3
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.
HR multiplier
2.5
3.5
RH Att (%)
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.
Each Outage
Rebuild pulverizer grinding elements Refurbish burners to design dimensions and tilt strokes Verify damper strokes Leak check and repair sensing lines to airflow measuring devices Inspect, repair and functionally check all dampers from inside ductwork Set airheater seals, clean baskets, check and repair sector plates and all moving parts Inspect and repair all primary and secondary dampers and ductwork Thoroughly inspect and repair all ductwork and expansion joints