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The steady regime of boiler operation the steam parameters vary insignificantly at any load. The lowest limit is from 3040% of rated load. Smaller boilers not used for power stations have much lower control range. Bringing a boiler on load the key parameter to be maintained is temperature. In this case it is not maintained constant but is changed according to a predetermined pattern.
The steady regime of boiler operation the steam parameters vary insignificantly at any load. The lowest limit is from 3040% of rated load. Smaller boilers not used for power stations have much lower control range. Bringing a boiler on load the key parameter to be maintained is temperature. In this case it is not maintained constant but is changed according to a predetermined pattern.
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The steady regime of boiler operation the steam parameters vary insignificantly at any load. The lowest limit is from 3040% of rated load. Smaller boilers not used for power stations have much lower control range. Bringing a boiler on load the key parameter to be maintained is temperature. In this case it is not maintained constant but is changed according to a predetermined pattern.
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Attribution Non-Commercial (BY-NC)
Format Tersedia
Unduh sebagai PDF, TXT atau baca online dari Scribd
The steady regime of boiler operation The allowable boiler range The unsteady regime of boiler operation The Load Control Range
The automatic control system of a boiler
responds quickly to the load without the interference of the operating personnel. The lowest limit is from 40-50% of rated load. Smaller boilers not used for power stations have much lower control range The steady regime of boiler operation
The steam parameters vary insignificantly
at any load. The lowest limit is from 30- 40% of rated load The Allowable Load Ranges
The allowable load ranges include loads
from limit of control range to the lowest load at which the boiler can function steadily The Unsteady Regime of Boiler Operation Load variation and fluctuation of steam parameters occur due to internal or external disturbances Internal disturbances are variations in: Flow rate
Temperature
Fuel consumption rate
Combustion air flow rate
The Unsteady Regime of Boiler Operation External disturbances are variations in: Steam pressure
Load of the turbo-alternator
The degree of opening of start-up and shut down
device Steam Generators Testing
Cold testing Hydrostatic Testing Welding testing Hot testing Flow measurement Temperature measurement Dryness fraction of steam leaving the drum Flow Measurement
Steam, water, air and gas flow should be
measured using orifice, nozzle or venturi tubes so as to check any flow meters connects in the boiler lines. These measuring instruments should be manufactured according to certain standards, say ASME Performance Test Codes. Temperature measurements These are carried out by using different types of thermocouples.
Dryness fraction of steam leaving the
drum: this can be measured by a separating and a throttling calorimeter. Bringing a Boiler on Load In bringing a boiler on load the key parameter to be maintained is temperature. In this case it is not maintained constant but is changed according to a predetermined pattern. This a pattern is a compromise between the desire to bring the boiler on-load as quikly as possible and the risk of boiler damage by thermal stresses arising from uneven. Bringing a Boiler on Load
There are four stages:
1. Warming up before circulation is established 2. Warming up after circulation is established 3. Stage when significant quantities of steam are being taken 4. Bringing the boiler on load 1.Warming up before circulation is established
During this phase the limit on the system
is the temperature of boiler tubes. Until circulation is established there is a risk of local overheating in regions of pockets of trapped steam and of serious uneven heating between adjacent tubes. Limited input of energy into the system is needed and light oil burners are used. The provision of boiler circulation pumps removes this stage from procedure. 2.Warming up after circulation is established During this phase the main concern is stresses on the boiler drum arising from uneven heating along its length or through the thickness of its metal. These limitations are met by restricting the permissible rate of rise of drum pressure and hence of drum temperatures. Progressively more energy is taken from the system by steam flow to drains and slightly tighter input is needed. Careful control of the energy input is most important at this stage and this is achieved by varying the number of oil burners if applicable 3.Stage when significant quantities of steam are being taken This stage is present when boilers used for industrial processes are also used to generate power, and then turbine conditions must match with the steam output conditions. The limit now passes to the maximum permissible value in the superheater tube metal temperatures. The steam and fuel flows are increasing since appreciable energy is being taken from the system, but the steam flows are not yet adequate to ensure superheater cooling. Considerable drainage on the superheater may still be necessary 4.Bringing the boiler on load Here the limit is still the superheater temperature. During this section there must be smooth change from the light oil used in the initial stages of boiler operation to the heavy fuel oil used under spontaneous operation. The sequential ignition of these burners provides the fine control of the energy needed. As each burner is put into service, care must be taken to see that it ignites properly, and that it burns with bright smokeless flame and does not subsequently go out The following are the minimum standards for the operation as listed in ASME Section VI, VII On a daily basis, boiler operation ¨ Test performed and the results, ¨ Unusual boiler conditions, ¨ Changes in equipment status and the reason ¨ Steam pressure ¨ Stack temperature ¨ Flame condition, ¨ Confirmation that no smell of gas or evidence of fuel leaks exists ¨ Confirmation that no steam or water leaks from the boiler ¨ Operator’s name, initials, and dates of log entry. On a daily basis, boiler operation
Confirmation that pressure and temperatures
are within the guidelines set by the manufacturer of the boiler.
In no case shall the pressures/temperatures be
greater than the manufacturer’s maximum allowable working pressure/temperatures. The maximum allowable pressure and or temperature are denoted on the nomenclature plate affixed to the boiler (data plate). On a daily basis, boiler operation
Observation of condition of the flame to
determine if it is even, and not off color.
Gas burner flame should be blue with varying
amounts of yellow on the flame ends depending upon the firing rate.
The flame should be even around the burner.
Oil burner flame should be bright yellow
without dark trails off the end of the flame. On a weekly interval, the boiler operation
Observing the boiler during its shutdown
and start-up cycle while listening for the fuel solenoids to activate and listening for any unusual noises (such as the fuel valve solenoid chattering, buzzing loudly, etc.)
Testing low water cut-off and boiler low-
water alarm for low-pressure boilers while in operation. The test must show the boiler will shut off if a low water condition exists. On a weekly interval, the boiler operation Visual checks of ignition and flame detection system, looking for any abnormal conditions, such as frayed wires, loose or broken conduit, loose wiring, etc.
Checking the firing rate controls and linkage for
freedom of movement and linkage connections.
Cleaning fuel oil filters and strainers. Unless your
boiler is equipped with dual filters, this must be done with the boiler shutdown.
Always shutdown the fuel oil pump(s) and valve
off to the fuel oil filters prior to cleaning or replacement. Following approved lock out, tag out procedures. On a monthly interval, the boiler operation
Visually checking the boiler during
shutdown and start-up. Make sure the burner fan runs through its pre and post-purge ventilation cycles. Watch and listen to the fuel solenoid valves to insure they are closing as prescribed by the manufacturer’s recommendations. On a monthly interval, the boiler operation Checking all floor drains in the boiler room for proper operation. First look down the drain to see if water is visible, which will indicate the automatic drain charging system is working properly . Put about one gallon of water down each drain to insure that the drain is free from clog. If water can not be seen in the drain indicate such on the boiler room log and notify the maintenance person to have the situation corrected. On a monthly interval, the boiler operation Inspecting the combustion air louvers and or ventilation screens both inside the boiler room and outside. They must be free from dust and debris, clean if necessary. Visually checking the boiler stack, looking for areas of overheating, blackened area where flue gasses are escaping, areas of rust, free operation of barometric damper (if equipped), and joints coming apart or holes in flue ducting. On a quarterly basis, boiler operation
Testing the flame safeguard control
system. This test shall verify proper operation of control devices and cause a safety shut down and lockout. The boiler should not restart without resetting the flame safe guard control. On a quarterly basis, boiler operation Testing low gas pressure limit control system. Slowly close the gas valve upstream from the low-pressure gas limit control. This should cause the burner to shut off and lock out. For oil fired burners, conduct the same test. without damaging the fuel oil pumps or the system. Checking alternate fuel supply system by switching to the backup fuel source. Fireside parameter Monitoring and Control
The preservation of boiler operation and
performance includes meeting underlined design assumptions and process control. The boiler design involves the energy balance between the fireside and the steam side parameters. Fireside parameter Monitoring and Control
In a typical fossil power plant, there is more
steam side instrumentation installed with the original control system than there is flue gas side instrumentation. However, the fireside provides the heat energy input to the boiler system and it is extremely important to control the fireside operating parameters to ensure the boiler performance. Fireside parameter Monitoring and Control Typically, the boiler lacks fireside control.
The fuel and air are mixed, combustion
takes place in the burner system and the next monitoring point in the flue gas path is the boiler exit temperature. Basically, there is nothing in between. There is a simple logic to converting from a two point control, burner and boiler exit temperature, to a three point control; i.e., burner, furnace exit gas temperature (FEGT), then boiler exit temperature. This extra control point, FEGT, can have a major impact on boiler performance and reliability. Fireside parameter Monitoring and Control
Basically, the furnace exit point
separates the radiation zone from the convection pass. FEGT is one of the most important interface parameters in boiler design and operation. Fireside parameter Monitoring and Control Typical boiler gas side design involves the following Input/plan areas (Btu/sq. ft-hr) Gas temperature entering first pendant surface over the arch Gas temperature leaving the furnace Location and quantity of furnace wall blowers Burner input and burner clearance Total heat available to burner zone (Btu/sq.ft...-hr) Operational parameters affecting FEGT
Excess air level
Furnace heat absorption rate (modified by soot blowing) Burner selections, Burner tilt Low NOx operations Fuel quality Air in-leakage FEGT A furnace startup probe is sometimes used to protect the superheater and reheater tubes prior to the establishment of steam flow. Unfortunately, the current startup probes can not be used for the complete flue gas temperature range. FEGT
For many years the industry has
been actively involved in developing more accurate instrumentation, analysis methods, and performance improvement techniques for the fire side parameters control. FEGT A furnace startup probe is sometimes used to protect the superheater and reheater tubes prior to the establishment of steam flow. Unfortunately, the current startup probes can not be used for the complete flue gas temperature range. For many years the industry has been actively involved in developing more accurate instrumentation, analysis methods, and performance improvement techniques for the fire side parameters control. FEGT There are many techniques that can be used to obtain the FEGT on-line, i.e, direct measurement or from calculations.
Direct measurement techniques
can be intrusive and non- intrusive. Operators can use this information to balance combustion. FEGT
FEGT control is a critical parameter
which can be used to preserve the boiler operation and performance including, emission, reliability, and safety. FEGT If FEGT deviates from the design value the following Undesired condition can occur: Increased slagging/ fouling of water walls, superheater, and economizer, and air heaters Increased corrosion rates of superheater and reheater tubes Potential of convective pass tube overheating (creep damage), requiring more attemperation Altered design conditions which are more difficult to correct by the operator Increased flue gas temperature in the boiler exit which increases heat loss and lowers efficiency FEGT FEGT provides an operational safeguard and indictor for the boiler operation. The following influential Factors will be discussed: Slagging and fouling control Soot blowing Superheat steam temperature control Low NOx firing Slagging and fouling control One of the important characteristics of the fuel from a boiler design view point is the slagging and fouling control. The formation of slag deposits is caused by the deposition of molten ash on surfaces receiving heat by radiation such as the furnace and radiant sections of the supereheater. Entrained in the gas stream, molten ash particles strike the wall or tube surface becoming chilled then solidify. Slagging and fouling control If slag is allowed to accumulate on the lower furnace walls, furnace exit gas temperature will rise and the slagging area is forced higher into the furnace. The effect on the furnace performance can be drastic. Proper boiler operation requires keeping the ash particles away from the walls and in suspension in the gas stream until the ash is sufficiently cool to be admitted to the convection pass. Parameters that result in increased deposition Slagging Fuel quality Combustion problems and poor flame stability Low excess O2 or O2 imbalance Inadequate soot-blowing High FEGT Fouling Parameters that result in increased deposition include
Maintain the hot furnace can reduce the
furnace slagging problem.
Limiting FEGT to a minimum 55°C below
the ash softening temperature can substantially improve the convective pass fouling problem, because the dry ash leaving the furnace will not stick to the steam tubes. Parameters that result in increased deposition include
If the fouling and blockage in the
convective pass is reduced, the superheat soot blowing and fan power can be reduced which improves the heat rate.
It also prevent soot blower erosion.
Parameters that result in increased deposition include If the fuel being burned is changed, the ash fusion temperature for new fuel can be obtained from the laboratory test
A new FEGT limit can be established
by the operator and to adjust other operational parameters to minimize the potential of slagging/ fouling. The combustion system should be tuned to achieve the following Uniform flue gas temperature and flow distribution Uniform distribution of excess O2 Minimize fly ash unburned carbon content Minimize air heater leakage and casing air-in-leakage Balance secondary air and fuel distribution Proper primary air/fuel proportion Soot blowing Ash slag and soot deposits on the tubes act as insulators that prevent heat transfer. It can also restrict the flow of flue gas. Therefore, keeping the gas side of boiler tubes clean is essential to preserve the boiler operation. Soot blowing has proved to be the most practical method of removing the deposits. Soot blowing Observation of the boiler for slagging and fouling patterns and for soot blower effectiveness should be made on a regular basis. A prime concern in soot blower operation is to minimize the boiler tube erosion. Soot blowers must be maintained in good operating condition. Soot blowing Effective soot blowing should consider: Blowing frequency Blowing time Blowing sequence Blowing pressure Nozzle position Soot blowing FEGT can be used as the primary indicator to establish the scheme for automatic soot blowing or to alert the operator to start the manual soot-blowing operation. If FEGT exceeds the original design value, this indicates that the furnace is dirty and the operator should initiate the furnace soot blowing and the soot blowing should be stopped when FEGT has been reduced below the original design value. Soot blowing The over-blowing in the furnace is wasting the energy and can also create soot blower erosion problem in the water wall tube. Superheat steam temperature control For the tangentially fired furnace, the burner tilts are typically used as one of the methods to control the final steam temperature. The use of tilting up option to achieve desired steam temperatures should be applied at low and intermediate loads only. Burner tilts position should be horizontal or angled slightly downward at high loads. Superheat steam temperature control The reason for tilts down or horizontally is to increase residence time for complete combustion.
The burner tilts up condition may increase
FEGT, which can increase the potential of slagging and fouling problems as discussed previously.
If the final steam temperature can not be
reached, other options such as increase excess air should be considered in conjunction with the burner tilting to maintain FEGT within the allowable limit. Low NOx firing Wall fired low NOx burners normally result in longer flames and higher unburned carbon content.
The potential of secondary combustion
could become more intense and increase fouling and slagging of the convection pass and air heaters.
The under-stoichiometric combustion,
typically used in the low NOx firing, will result in starvation of oxygen in the furnace areas. Low NOx firing This can creates areas of reducing atmosphere, which can accelerate fireside wastage of water wall tubes.
Delayed combustion or secondary
combustion sometimes produce high FEGT. These high temperatures can cause overheating of superheater and reheater tubes.
It is essential for the operator to
maintain the original design FEGT to minimize other side effects. Otherwise tradeoffs are required and comprise the multiple system objectives. Using the Infra-View®Infrared Thermometers The furnace exit gas temperature (FEGT) in a boiler is a critical parameter which requires monitoring during boiler start-up and on-line operation. Start-up FEGTs must be controlled so as not to exceed allowable superheater tube metal temperatures. Many boilers use air-cooled probes, which must be retracted when temperatures reach 538°C. Using the Infra-View®Infrared Thermometers Maintaining the FEGT within the design limit during the normal operation can ensure boiler operability, thermal performance and boiler reliability. The problem in the past is the lack of on- line instrumentation to measure the high flue gas temperature. Using the Infra-View®Infrared Thermometers
Water-cooled HVT probes have been used
for many years to measure gas temperature above 538°C Because of the probe length and weight limitations, HVT is used primarily for testing purposes and not for continuous operation. Typical Infra-View® Boiler Thermometer Installation Infra-View®Infrared Thermometers Infra-View®Infrared Thermometers are remote sensing infrared detectors that are permanently flange mounted on any port, door or penetration into the boiler or furnace. It is a lightweight device and can also be used as a portable system for testing purposes. Infra-View®Infrared Thermometers
The Infra-View®patented design is
supplied with a rugged protective- cooling jacket that is factory assembled and pre-piped with an air cooler, purging and filtering system designed to work in most severe service environments. Infra-View®Infrared Thermometers Customer supplied compressed air and two wire shielded signal cable is all that is necessary for operation when integrated in a 4-20mA signal loop supplied from a DCS, digital or analog recording device.
The Infra-View®infrared "non-
contact" sensors monitors flue gas temperatures in the boiler or furnace ranging from 120° C to 1,650° C. Infra-View®Infrared Thermometers The proprietary infrared spectral response of the Infra-View thermometer is pre-set specifically to detect infrared emissions from hot CO2 gas. This is accomplished by filtering out all other wavelengths of infrared energy. Modern infrared thermometry has advanced significantly with the use of "selective filtering" of the incoming infrared signal. Infra-View®Infrared Thermometers
Specifically, selected narrow band spectral
responses are necessary in order to see through atmospheric interferences in the sight path, to obtain a measurement of gas or other substance which is transparent to a broad band of infrared energy. Infra-View®Infrared Thermometers
"Infrared radiation is observed as emitted from
excited molecules of gases. Many of the energy transitions which take place in gases excited thermally or electrically result in radiation emission in the infrared region. Infra-View®Infrared Thermometers Gaseous emission differs in character from solid emission in that the former consists of discrete spectrum lines or bands, with significant discontinuities, while the latter shows a continuous distribution of energy throughout a broad band spectrum." Gases such as CO and CO2 exhibit a strong but narrow infrared spectral response that can be detected with sensitive infrared sensors utilizing the specific spectral filter. Infra-View®Infrared Thermometers
Since CO2 gas is a by-product of the
combustion of all fossil fuels, its unique spectral response was selected because of its applicability to all boilers and furnaces regardless of the fuel burned. Infra-View®Infrared Thermometers
With a concentrations of CO2 gas typically
found in fossil fuel burning utility and industrial boilers, there is a high enough level (10 - 12%) to reach a threshold of detection where the Infra-View sensor can measure the average or peak temperature directly within the field of view of the instrument. Infra-View®Infrared Thermometers
Because the Infra-View "sees" the CO2 gas
within the boiler as semi-transparent or opaque medium, within the conical field of view (30:1) the largest volume of gas molecules are oriented farthest away from the sensor. Hotter gases, because of the selective spectral filter, are favored over the cooler gases located nearer the sensor comprising a smaller volume in the field of view. Infra-View®Infrared Thermometers
As a consequence, the Infra-View will sense
heated flue gas in the boiler yielding a temperature reading that is indicative of the overall boiler environment. Secondly, the quick response time (100 msec.) when averaged over say, 10 seconds (100 readings in all) generates a representative temperature reading of the dynamic upward flow of heated gases past the sensor posting the processed data in a time vs. temperature relationship. Conclusion The preservation of boiler operation and performance requires proper fireside operating fireside control. Basically, the existing boilers are lacking of proper fireside control. The fuel and air are mixed, combustion takes place in the burner system and the next monitoring point in the flue gas path is the boiler exit temperature. It is recommended that the process be converted from two point control, burner and boiler exit temperature to three point control; i.e., burner, FEGT, then boiler exit temperature. Conclusion This extra control point, FEGT, can have a major impact on boiler performance and reliability. The Infra-view system provides wide range flue gas temperature measurement and is a low cost effect instrumentation to measure the FEGT on-line. The system has been demonstrated successfully in more than 400 sites to provide real-time information for boiler operation, performance, and reliability improvement.