Trouble Shooting of Boilers

Trouble shooting in Boiler operation & reduction of auxiliary power consumption
Presented by S. Sivakumar AGM- O&M Contracts Cethar Vessels Ltd, Trichy
CETHAR VESSELS LIMITED Leading manufacture of AFBC , CFBC , WHRB for sponge iron kiln Gas, cement kiln gas ,DG exhaust gas & supply of power plant on EPC basis for more than two decades . Tied up with Riley Power Inc, USA for PC fired boilers of sub critical & super critical pressure. Collaboration with Riley / Siemens Benson Technology for super critical PC boilers.
Collaboration with Siemens for Super Critical CFBC boilers.

Tied up with OJSC power machineries , Russia for turbine design and Manufacturing.
Executing O & M contracts of captive power plants of any Capacity through Cethar energy ltd.
Cethar Vessels Ltd, Trichy
Major projects under execution:
2x 135 MWe IPP with CFBC Boiler 2 x 350 MWe PF Fired Boiler 2 x 350 MWe PF Fired Boiler
- M/s.Aryan Coal Benification - M/s.Ind Barath energy Ltd. - M/s.Meenakshi energy Ltd.
2 x 150 MWe IPP with CFBC Boiler

2 x 150 MWe IPP with PF Fired Boiler
- M/s.Shree cement
- M/s.Vandana vidhuyut
3 x 70 MWe CFBC Boiler
- M/s.Jayprakash associates
65 Boilers are under execution for IPP, CPP & Co-gen
10 IPP & Captive power plants are under execution
Credentials
CVL had designed, manufactured, erected and commissioned more than 1000 FBC boilers. Based on our versatile experience during operation and maintenance, we have listed few problems faced and the causes, solution given for the information to this elite league
Low steam generation

Identifications Low steam pressure, low steam flow in the control room Causes Fuel quality Low air box pressure will lead to high bed temperature and limitation in fuel feeding Heavy air leakage in the system and limitation in combustion air to furnace.
5
Low steam generation

Identifications Low steam pressure, low steam flow in the control room Causes Heavy flue gas leakage in the system and limitation in ID fan Fouling in evaporation surface. Deposition in the evaporator tubes due to water chemistry
Low steam temperature

Identifications Low steam temperature indication in control room at boiler outlet and turbine inlet Causes Passing of desuper heater control valve
Low volatile fuel

Low bed temperature operation
Inadequate excess air operation

Fouling in super heater
7
High steam temperature

Identification Steam temperature at boiler outlet and turbine inlet is more Causes Low feed water temperature to boiler
High volatile fuel burning

High excess of air Low air box pressure Inadequate de-super heating
Furnace pressure fluctuation / positive furnace pressure

Identifications Furnace pressure indication variation in control room
Causes
Instrument calibration and impulse tube attachment intact
ID fan damper malfunctioning

Fuel input variation to furnace Pressure part leakage
Furnace pressure fluctuation / positive furnace pressure

Identifications Causes
Furnace pressure indication variation in control room
Fouling in the gas path

Accumulation of ash in gas path and ash chute
Leakage in flue gas duct and limitation of ID fan

Erosion of ID fan impeller
10
Sagging of Super heaters

Identification
Causes
Visual inspection during shut down
Flame impingement on super heater during start up. Frequent lifting of Drum safety valve Over heating of super heater coils due to boiler operation with clinker
11
Sagging of Super heaters

Identification
Causes
Visual inspection during shut down
Compartment transfer without adequate steam flow Boiler operation with more fuel fines
12
Boiler operation with clinker formation

Identification
Cause
Uneven combustor bed temperature
Damage in bed thermocouples.
Load raising restriction

Significant variation in air box pressure
Damage of air nozzle.

Fuel nozzle damage Improper air fuel mixture
13
Low Air box pressure

Identification
Cause
Low air box pressure with normal bed pressure and optimum FD airflow at MCR
FD ducting bellow leakage, heavy air leakage in FD duct, failure of air nozzle and leakage in air heater.
Inspection and rectification on the above to be taken up
14
Coal Jamming in PA line / Mixing nozzle

Identification
Cause
Bed Temperature Drop High negative furnace pressure PA line back pressure
High moisture, low PA header pressure at PA line shall lead to jamming. Inspection from coal feeder to PA line and mixing nozzle, adequate PA header air pressure to be taken care
15
Frequent tripping of FUEL feeder

Identification Trip alarm in DCS. Bed temperature drop. Causes Presence of any foreign materials and cleaning. High moisture choking and de-
High negative furnace pressure
Feeder drive mechanical arrangement failure and rectification
16
Frequent tripping of FUEL feeder

Identification Feeder speed showing zero Causes Testing condition of motor Testing the speed control drive healthiness
Feeder motor over load trip.
17
Oil firing start up failure

Causes
Identification
No bed temperature rise even after 2 hrs of light up
Inspection for nozzle choke &inadequate oil pressure(6Ksc) Ensure optimum pressure. air box
Ensure proper bed material size(2.36 to 0.86). Ensure appropriate charcoal size and moisture free charcoal. Inspection of bed condition
18
High exit flue gas temperature

Identification High flue gas temperature at the outlet of APH Causes High excess air Fouling in evaporator, super heater and air pre heater
19
High unburnt carbon in ash

Identification High % LOI in ash as per lab report Causes Operating the boiler with clinker Inadequate air supply Fuel quality High amount of fines in fuel
Heavy load fluctuation and instable furnace condition

20
High unburnt carbon in ash

Identification High % of LOI in ash Causes Low air box pressure High PA pressure
Improper distribution of fuel in furnace
21
High Plant Heat Rate

Identification
Action to be taken
Steam leakage in boiler and steam piping Low turbine inlet steam pressure and temperature Condenser low vacuum High exhaust steam temperature & pressure
Steam leakage to be arrested Operating the turbine at design temperature and pressure Condenser air ingress to be rectified HP heater under performance Turbine inspection for depositions
22
High Plant Heat Rate

Identification Low boiler efficiency Low Feed water temperature High turbine wheel chamber
Action to be taken
Combustion system heating surface area to be checked. Rectify air ingress, flue gas leakage are to be attended. Insulation condition to be checked and rectified. Turbine blade failure causes exhaust steam temperature
23
Auxiliary power consumption reduction

After plant commissioning and stabilization the design margin in the equipment shall be optimized by implementing modification in the system, providing VFD for the following equipments
24
Cooling water pumps

CEP Boiler Feed pumps(case study given) Fans(case study given) ACC fans
25

Optimization of coal handling plant operation Optimization of AHP operating and Compressors Optimization of make up water consumption and WTP operation
26
Case study I :
Reported issue:
Excess coal consumption
27
Plant design details:

Plant capacity : 1 X 8 MWe co-gen plant
Boiler capacity
Type of firing
: 40 TPH
: AFBC
Steam pressure
: 68 ata
Steam temperature : 495 C
28
Design Fuel Analysis Moisture : 13.98% GCV : 6100 kcal/kg
29
Plant visit was made,boiler operating data,fuel input were collected and analyzed
30
Boiler data:
Boiler operating capacity Steam pressure Steam temperature Feed water temperature Flue gas temperature leaving APH : 37.5 TPH : 68.007 ata : 495 C : 122C : 132C
O2 in flue gas is : 4%
31
Fired fuel analysis and efficiency

GCV Moisture : 3950 Kcal/kg : 31.50%
Efficiency achieved : 81.7% Reasons for lower Efficiency:
Excess fired fuel moisture comparing to design fuel moisture

Lower GCV of fuel comparing to design Loss in efficiency due to the above is 3.501%
32
Conclusion:
Corrected efficiency is 85.2% Fuel moisture to be controlled for achieving the guaranteed thermal Efficiency of the boiler
Expected Fuel saving by controlling moisture is 7.6 TPD
33
Case study II :
Reported issue:
Excess steam temperature drop
34
Plant design details: Plant capacity Boiler capacity Type of firing Steam pressure Steam temperature at boiler O/L : 1 X 8 MWe : 40 TPH : AFBC : 68 ata : 495 C
35
Steam temperature at T/G I/L Fuel GCV as fired
: 470C : 3950 Kcal/kg
Boiler efficiency
: 82 %
36
Observation:
Design Steam temperature drop : 5C
Excess Steam temperature drop

Excess energy loss by steam Considering 335 days operation the excess fuel consumption.
: 20C
: 1.5 TPD : 502 MT/year
37
Conclusion:
Steam line insulation to be rectified. Steam traps in steam line to be set right.
38
Case study III :

Reported Issue:
Low thermal Boiler efficiency
39
Design data: Plant capacity Boiler capacity Type of firing Steam pressure Steam temperature : 1 X 8 MWe : 40000 kg/hr : AFBC : 68 ata : 495 C
40
Feed water temperature
: 126 C
Flue gas temperature leaving APH : 140C

Air temperature at APH I/L : 40C
41
PG TEST DATA: Power generation : 1 X 8 MWe
Boiler capacity kg/hr

Steam pressure
Feed water temperature
: 37,500
: 68 ata
: 122 C
Flue gas temperature leaving APH : 132C Air temperature at APH I/L
: 38C
42
Achieved boiler efficiency with Imported coal
: 82 %
% O2 in flue gas
: 4.5%
43
Parameters after 12 months of PG test:
Power generation
Boiler capacity Steam pressure
Steam temperature Feed water temperature
: 8 MWe
: 38,000 kg/hr : 67 ata
: 495 C : 122 C
Flue gas temperature after APH : 159 C % O2 in flue gas : 4.5%
44
Results: Due to increase of flue gas temperature the following losses have been increased.
1) Dry flue gas loss.

2) Loss due to moisture in flue gas. 3) Loss due to hydrogen in flue gas. 4) Air moisture loss.
45
The overall thermal efficiency reduction is 2%.
Equivalent coal consumption
: 4878 kg/day.
Considering 335 day operation : 1635 MT/335day Coal consumption Reason:
Fouling in the cold air side of APH due to high moisture content imported coal .
Rectification: Periodic inspection and cleaning APH by water Jet.
46
CASE STUDY-IV
POWER REDUCTION OF BOILER FEEDWATER PUMP
47
Boiler Details
Boiler capacity Steam pressure :
140 Tph
86 kg/cm (g)
Drum pressure
Steam temperature Fuel Type of firing
:
: : :
98 kg/cm (g)
510c Baggasse Traveling grate
48
Boiler Feed Pump Details

Feed pump capacity Head Speed No.of pumps Pump driven by Drum level control by : : 92.1 Cum/hr 1231 mwc : 2980 rpm : 3 (2w + 1s) : Motor with VFD : FCV
49
Existing operating data

Feed water flow Feed water temperature : : 144 M3 140C
Control valve opening

Pump operating speed Feed water suction pressure Feed water delivery pressure Power consumption
:
: : : :
35%
2900 rpm 3.5 kg/cm 138 kg/cm 790 Kw (2 pumps working)
50
Initially boiler feed pump was operated at constant
speeds of around 2900 rpm and drum level control was

operated by varying the feed control valve with three element level control .
51
MODIFIED DATA :
Feed water flow : 144 m3/hr Feed water temperature : 140C Control valve opening : 100% Pump speed : (2675 2700 ) rpm Power : 660 kw (2 pumps working) Power saving : 790 660 = 130 Kw
Drum level control was implemented by VFD operation of the feed pump .The feed control valve was kept 100 % open and system pressure drop has been reduced from boiler feed pump to economizer . Based on the drum level VFD speed was varied in automatic control.
52
CASE STUDY-V FD fan motor power consumption reduction
53
FD Fan Power Saving with VFD
Boiler Capacity : 40 TPH Steam pressure : 68 ata Steam Temperature : 485 +-5 Deg CEL Type of boiler : AFBC FD fan motor : 250kW Speed : 1440 rpm Fuel : Imported coal
Cethar Vessels Ltd, Trichy 54
Initially FD fan was operated without VFD and the details of operating data are given Steam generation : 37.5 TPH Power generation : 8 Mwe
FD fan damper opening : 38%

Fan speed : 1440 rpm
Power consumption : 195kW

O2 in flue gas : 4%
Data after implementation of VFD for FD fan Steam generation : 37.5 TPH Power generation : 8 MWe FD fan damper opening : 100% Fan speed : 1250 rpm Power consumption : 160kW O2 in flue gas : 4%
Pressure drop in the damper has been eliminated by damper full open and the power saving was achieved through speed control
Power saving : 35kW / hr

840 kW/Day 281400kW for 335 days
57
Fuel saving (Plant heat rate of 4050Kcal/kWh and fired GCV of fuel is 3950 Kcal) ---861 kg/day --- 26 MT / month --- 312 MT / year
---12.5 lakhs per annum
58
Any questions please? Thanks CVL


Trouble Shooting of Boilers

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Trouble Shooting of Boilers

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Trouble shooting in Boiler operation & reduction of auxiliary power consumption

Presented by S. Sivakumar AGM- O&M Contracts Cethar Vessels Ltd, Trichy

Collaboration with Siemens for Super Critical CFBC boilers.

Cethar Vessels Ltd, Trichy

Major projects under execution:

2 x 150 MWe IPP with CFBC Boiler

3 x 70 MWe CFBC Boiler

65 Boilers are under execution for IPP, CPP & Co-gen

10 IPP & Captive power plants are under execution

Cethar Vessels Ltd, Trichy

Cethar Vessels Ltd, Trichy

Low steam generation

Cethar Vessels Ltd, Trichy

Low steam generation

Cethar Vessels Ltd, Trichy

Low steam temperature

Low volatile fuel

Inadequate excess air operation

Cethar Vessels Ltd, Trichy

High steam temperature

High volatile fuel burning

Cethar Vessels Ltd, Trichy

Furnace pressure fluctuation / positive furnace pressure

ID fan damper malfunctioning

Cethar Vessels Ltd, Trichy

Furnace pressure fluctuation / positive furnace pressure

Furnace pressure indication variation in control room

Fouling in the gas path

Leakage in flue gas duct and limitation of ID fan

Cethar Vessels Ltd, Trichy

Sagging of Super heaters

Visual inspection during shut down

Cethar Vessels Ltd, Trichy

Sagging of Super heaters

Visual inspection during shut down

Cethar Vessels Ltd, Trichy

Boiler operation with clinker formation

Uneven combustor bed temperature

Damage in bed thermocouples.

Load raising restriction

Damage of air nozzle.

Cethar Vessels Ltd, Trichy

Low Air box pressure

Cethar Vessels Ltd, Trichy

Coal Jamming in PA line / Mixing nozzle

Cethar Vessels Ltd, Trichy

Frequent tripping of FUEL feeder

High negative furnace pressure

Feeder drive mechanical arrangement failure and rectification

Cethar Vessels Ltd, Trichy

Frequent tripping of FUEL feeder

Feeder motor over load trip.

Cethar Vessels Ltd, Trichy

Oil firing start up failure

No bed temperature rise even after 2 hrs of light up

Cethar Vessels Ltd, Trichy

High exit flue gas temperature

Cethar Vessels Ltd, Trichy

High unburnt carbon in ash

Heavy load fluctuation and instable furnace condition

Cethar Vessels Ltd, Trichy

High unburnt carbon in ash

Improper distribution of fuel in furnace