Professional Documents
Culture Documents
National Seminar on Prospects and Challenges of Electrical Power Industry in India - NSPCEPII 347
Abstract— Furnace and convective pass slagging and fouling have a negative effect on boiler performance
and emissions. The purpose of soot blowers is to keep the heat transfer surface clean so as to contribute towards
optimal performance of the boiler. Excessive soot blowing can cause increased maintenance in fossil-fired boilers.
Soot blowers perform on-line cleaning of localized areas consuming substantial amounts of costly high pressure
Main Steam; this cost motivates the study of soot blowers and development of improved soot blowing strategies.
Boiler operators typically follow one continuous soot blowing sequence. Most rely on manufacturer’s
recommendations, while some try to improve soot blower activation strategy by employing a trial-and-error
approach. Considering the importance of soot blowing on plant operations and availability, soot blower
operations need more attention. The Jindal Power Limited – different Dept. teamed up and has taken the
initiative to perform a study on soot blower optimization by implementing pattern wise blowing. For this,
different combination of tiers wise SB was done and the requirement and effectiveness of each tier was observed
by studying different parameters and developed a practical, knowledge-based approach to soot blowing
optimization and has implemented it in Unit # 3 & Unit # 1 of 4 x 250 MW, OPJSTPP. This approach can deal with
the reduction of soot blower activation frequency, and steam temperature control. This paper describes the
approach; implementation on a 250 MW tangentially fired boiler, operating experience, and benefits to the
plants.
Keywords— Soot Blower, Slagging
I. INTRODUCTION
A LL coals contain mineral matter in coal ash. Furnace slagging occurs as molten or sticky fly ash particles
come in contact with the furnace walls or other radiant surfaces and form deposits due to the quenching
effect of the tube wall. Slag deposits reduce heat transfer to the furnace walls, and increase the amount of heat
available to the convection pass. This results in a higher furnace exit gas temperature (FEGT) and, for subcritical
boilers, in a higher steam temperature, de-superheating spray flows and NOx emissions. Deposition of ash on
tubes or heat transfer surfaces in the convective pass reduces heat transfer in that part of the boiler. The
convective pass fouling results in less heat is transfer to the working fluid, a decrease in steam temperature and
de-superheating spray flows, and in an increase in flue gas temperature at the boiler exit.
The challenge in sootblowing optimization is to determine which sections of the boiler to clean and on what
schedule, considering the factors such as tube life, sootblower steam or steam consumption and maintenance
cost. For best boiler performance, it is important to maintain an optimal balance between furnace and convective
pass heat transfer.
A. Basics of Soot Blowing
Sootblowing controls the level of ash and slag deposits on heat transfer sections. Sootblowers perform on-
line cleaning of localized areas using high-pressure steam or air. Wall blowers and water cannons remove slag
from furnace water walls, while retractable blowers clean the convective pass of the boiler (including the air
preheater). Furnace cleaning increases radiation heat transfer to water walls and reduces the FEGT. This
decreases the amount of heat that is available to the convective pass. Therefore, over-cleaning of furnace walls
can result in low steam temperatures (below design level) with resulting heat rate penalties and increased
moisture levels and erosion damage in last stages of the low-pressure turbine. Reduced reheat steam
temperature also results in lower turbine and unit power output.
Fig. 1
The procedure for wall blower operation can be evolved after the study and data analysis for the most
effective way of wall blowing.
The use of heat flux meter by embedding thermopiles at appropriate location in the furnace walls to
understand whether the tube in the region is clean or with deposition the operation of the wall blower
requirement can be decided.
In the case of fully automated intelligent wall blower system, the need to wall blow each blower is
understood from the effective heat flux falling on the tubes. Designers use different methods to establish this.
G. Observation
Following are the observations taken under notice with the data collected:
Table no. 2
H. Resent Scenario
Table no. 3.
J. SH & RH Trend
Fig. 2.
VI. CONCLUSION
A series of upgraded steps at the JPL have been coupled with optimization systems to gain performance benefits
in the form of fuel savings, reduced emissions, increased net power generation and improved dispatch capability
along with financial saving. The combination of a flexible and capable toolset, application expertise and the power of
continuous improvement are now Providing continuous and significant performance benefits to the station.
REFERENCE
[1] 1.Sarunac, N., Romero, C.E., Clements, B., Pomalis, R., Henrikson, J., Cylwa, W.and Luk, J., “Sootblowing
Optimization: Part 1 - Methodology, Instrumentationand Determination of Section Cleanliness,” Presented at
Combustion Canada 2003 Conference, September 21-24, 2003, Vancouver, BC, Canada.
[2] 2. Sarunac, N., Romero, C.E., Shan, J., Bian, X., Clements, B., Pomalis, R., Henrikson, J., Cylwa, W. and Luk, J.,
“Sootblowing Optimization: Part 2–Sootblower Characterization and Implementation of an Intelligent
Sootblowing Advisor,” Presented at Combustion Canada 2003 Conference, September 21-24, 2003, Vancouver,
BC, Canada.
[3] 3. Sarunac, N. and Romero, C., “Sootblowing Optimization and Intelligent
[4] Sootblowing,” Presented at 4th Intelligent Sootblowing Workshop, Houston,
[5] Texas, March 2002.
[6] 4. Sarunac, N., Romero, C. E. and Bilirgen, H., “Optimization of Sootblowing in Utility Boilers,” EPRI Heat Rate
Conference, Birmingham, Alabama, January 28- 30, 2003.
[7] 5. Sarunac, N., Romero, C.E. and Levy, E. K., “Combined Optimization for NOx Emissions, Unit Heat Rate and
Slagging Control with Coal-Fired Boilers,” 28thInternational technical Conference on Coal Utilization and Fuel
Systems, March 9-14 2003, Clearwater, Florida.
[8] 6. Pomalis, R., Clements, B. R. and Abdallah, I. “Ash Monitoring System forLambton Generation Station Unit 3,”
CETC Division Report CETC-O-ACT-03-14 (CF), Natural Resources Canada, 2003.
[9] 7. Sarunac, N. and Romero, C.E. “Sootblowing Operation: The Last OptimizationFrontier,” Presented at the 29th
International Technical Conference on Coal Utilization & Fuel Systems, Clearwater, Florida, April 18-22, 2004.
[10] 8. Sarunac, N. and Romero, C.E. “Sootblowing Operation: The Last Optimization Frontier,” Presented at the 29th
International Technical Conference on Coal Utilization & Fuel Systems, Clearwater, Florida, April 18-22, 2004.
[11] Sarunac, N., Romero, C.E., Bilirgen, H., Bokowski, J. And Cilinski, M., “Comprehensive Approach to Performance
Improvement and Emissions Reduction on a 400 MW Tangentially-Fired Boiler: Part 2 –ESP Performance
Improvement and Sootblowing Optimization,” Presented at the 30th International Technical Conference on Coal
Utilization and Fuel Systems, April 2005, Clearwater, Florida.
[12] Congdon, P., “Control Alternatives for Industrial Boilers,” InTech,December 1981.
[13] Walsh, T. J., “Controlling Boiler Efficiency,” Instruments and ControlSystems, January 1981.
[14] ANSI/ASME, “PTC 4.1, Steam Generating Units Power Test Codes,”American Society of Mechanical Engineers
(ASME), 1965.
[15] Culp, A. W., Jr., Principles of Energy Conversion, New York:McGraw-Hill, 1979, p. 102, pp. 204–207.
[16] MacDonald, J. A., “Optimizing Power Boiler Efficiency Calls forHeat Loss Cuts, System Insulation, and
Modifications,” Energy-Tech,April 2004.
[17] Shinskey, F. G., Energy Conservation through Control, AcademicPress, 1978.
[18] Babcock and Wilcox, Steam: Its Generation and Use, 40th ed., NewYork: Babcock and Wilcox, 1992.
[19] NFPA, NFPA-85 — Boiler Combustion Safety, National Fire ProtectionAssociation, 2004.
[20] Garton, D., “Water Cannon for Water Wall Cleaning Applications,”EPRI Intelligent Soot Blowing Conference,
December 6–7, 1999.
[21] McMahon, J. F., president, Cleveland Controls, verbal communications.
[22] Dickey, P. S., “A Study of Damper Characteristics,” Bailey Meter Co.,Reprint No. A8.
[23] Jorgensen, R., “Fans,” in Marks Standard Handbook for MechanicalEngineers, 8th Ed., McGraw-Hill, New York,
1978, p. 14.53.
[24] Dukelow, S. G., The Control of Boilers, 2nd ed., Research TrianglePark, NC: Instrumentation, Systems, and
Automation Society, 1991.
[25] Hurlbert, A. W., “Air Flow Characterization Improves Boiler Effi-ciency,” InTech, March 1978.
[26] DeLorenzi, O., Combustion Engineering, Inc., 1967.
[27] ANSI/ISA-77.42.01, “Fossil Fuel Power Plant Feedwater ControlSystem: Drum Type,” Instrumentation, Systems,
and AutomationSociety, 1999.
[28] Shinskey, F. G., “Taming the Shrink–Swell Dragon,” Control, March2004.
[29] Fisher Controls International, Control Valve Sourcebook: Power andSevere Service, Marshalltown, IA: Fisher
Controls International,1990.
[30] Miller, H. L. and Stratton, L. R., “Fluid Kinetic Energy as a SelectionCriteria for Control Valves,” American Society
of Mechanical Engineers,Fluids Engineering Division, summer meeting, June 22–26,1997.
[31] Shinskey, F. G., Process Control Systems, New York: McGraw-Hill,1979.
[32] Latta, C. A., “Methods for Reducing NOx Emissions,” Plant Engineering,September 1998.
[33] McDonald, J. A., “Controlling the NOx after the Burn,” Energy-Tech,December 2002.
[34] Schwartz, J. R., “Carbon Monoxide Monitoring,” InTech, June 1983.
[35] O’Meara, J. E., “Oxygen Trim for Combustion Control,” InTech,March 1979.
[36] McFadden, R. W., “Multiparameter Trim in Combustion Control,”InTech, May 1984.
[37] American Technical Services, “Boiler Audits,” June 1982.
[38] McMahon, J. F., President, Cleveland Controls, verbal communications.
[39] Westinghouse Electric Corp., “Oxygen Trim Control,” AD-106-125,Westinghouse Electric Corp., June 1979,
January 1985.
[40] Moelback, T., “Advanced Control Superheater Steam Temperatures:An Evaluation Based on Practical
Applications,” Control EngineeringPractice, Vol. 7, 1999, pp. 1–10.
[41] Dukelow, S. G., The Control of Boilers, 2nd ed., Research TrianglePark, NC: ISA, 1991.
[42] Schieber, J. R., “The Case for Automated Boiler Blowdown,” UniversalInterlock, 1969.
[43] Cho, C. H., “Optimum Boiler Allocation,” InTech, October 1978.
[44] Wood, A. J., and Wollenberg, B. F., Power Generation, Operation,and Control, 2nd ed., New York: Wiley
Interscience, 1996.
[45] Romero, C., Sarunac, N., and Levy, E., “Soot Blowing Optimizationin Coal-Fired Boilers,” Lehigh University Energy
Research CenterEnergy Liaison Program Annual Meeting, 2001.
[46] Cheng, X., Kephart, R. W., and Williams, J. J., “Intelligent SootBlower Scheduling for Improved Boiler Operation,”
Proceedings ofISA POWID/EPRI Instrumentation and Control Conference, St.Petersburg, FL, June 1999.
[47] Booth, R. C., and Roland, W. B., “Neural Network-Based CombustionOptimization Reduces NOx Emissions while
Improving Performance,”Proceedings of 1998 ASME International Joint Power GenerationConference,
Baltimore, MD, 1998.
[48] Lefebvre, C., Lynch, M., and Roland, R., “Application of ProcessLinkReal-Time Optimization System to Cajun
Electric Power Cooperative’sBig Cajun II Generating Station,” Proceedings, 1999 InternationalPower-Gen
Conference, New Orleans, LA, 1999.
[49] Lipták, B. G., “Save Energy by Optimizing Your Boilers,” InTech,March 1981.
Yashpal Sahu,
Education qualifications:
ME- Mechanical, BIT, Mesra Ranchi
BE-Mechanical, GRKIST, Jabalpur
Certified Energy Auditor
Certfied BOE
Work Exp: 10 yrs 8 months with Jindal Power Limited,
- Project Monitoring of 250 MW
- Commissioning & Operation of 250MW
- Efficiency and CEEPI department
- Commissioning of 600 MW unit
Cell no: +91 9329445005
Email: yashpal@jindalpower.com
Md Shahabuddin
Education: B.Tech in Electrical & Electronics Engineering (EEE)
From Bengal College of Engineering & Technology , Durgapur
PGDC in Thermal Power Plant from NPTI, Guwahati
Work Exp: 1. Since Aug 2009 to Jul 2012 as a Desk Operation Engineering (Asst Manager) in Vedanta Aluminium Ltd. ,
Jharsuguda.
2. Currently working as a CEEPI TEAM (Asst Manager) in Jindal Power Ltd. , Tamnar.
Cell no: +91 7898905434
Email: md.shahabuddin@jindalpower.com
Email: amitpandey@jindalpower.com
Pooja Agrawal Education: B.Tech in Electrical Engineering (EE)From Indian School of Mines, Dhanbad
Work: Currently working as a CEEPI TEAM (Asst Manager) in Jindal Power Ltd. , Tamnar. Cell no: +91 7898902697
Email: pooja.agarwal@jindalpower.com