XXVII.

EFFICIENCY TESTING
OF BOILERS
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Contents
1. INTRODUCTION
2. DIRECT METHOD AND INDIRECT METHOD EVALUATION OF
EFFICIENCIES
3. TEST PROCEDURE
4. EFFICIENCY CALCULATION -BS-2885(1974) /IS : 8753 : 1977
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XXVII. EFFICIENCY TESTING OF BOILERS
1. INTRODUCTION
As a part of contract obligation a guarantee clause for the performance of the equipment is
included in each and every contract. The text of a particular contract reads as follows:
Performance tests shall be conducted by the company on the proposed boiler. The purchaser
at his own expense, shall make all preparations, furnish all operating and testing personnel
and incur all expenses with such tests. The date for such performance tests shall be mutually
agreed upon by the purchaser and the company.
Performance tests and performance calculations shall be made in accordance with BS 2885
standards. The measure of performance shall be the results of such tests. Performance
calculations shall be based on the latest edition of the IS[ Steam tables.
Subject to the performance conditions specified in preceding paragraphs 1 thro 11, the company
makes the following guarantees.
The company guarantees the steam generator to be continuously operated at the rated output
capacity, when firing the specified coal. The company makes the following performance
guarantees at the rates MCR capacity of 180 T/Hr. and with a feed water temperature of
200
o
C.
Overall efficiency = 85%
Superheated Steam Pressure at Main Steam Stop Valve of each Boiler = 96 Kg/sq.cm.
Superheated Steam Temperature at Main Steam Stop Valve =510 + 10
0
c
The above guarantees are based on the higher calorific values of design coal specified with
ambient air temperature of 40
0
C and relative humidity of 60% and with normal surface
conditions in furnace.
Having seen a typical contract condition, it is but natural you may get some doubts.
Is it all the four guaranteed?
Yes : The first one guaranteed is efficiency, the second is pressure, the third one steam
temperature and the fourth is the low.. But indirectly the evaluation of efficiency takes
care of all other parameters.
What is BS 2885 Standard is the next question before you?
Each country has its own standard. For example India has IS, the British BS, the Americans
ASME-PTC, and the Germans DIN Standard. All standards are basically the same. Depending
on the origin of the manufacture the standards also are referred.
Could it be true that all standards are the same ?
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Yes, really. There are minor differences in the method of evaluation of efficiency between
these standards; but the end result normally does not change by more than 0.05% between
these standards.
Then why BS Standards is referred in this contract.
The reasons are:
i) The influence of B.S. on various countries.
ii) it is the only standard which speaks about both direct method and in i rect method of
evaluating the efficiencies. All other sandards normally mention only indirect method.
iii) Recently Indian Standard Institution has come out with IS : 8753-1977 with the
similar guidelines as that of BS : 2885-1974
2. DIRECT METHOD AND INDIRECT METHOD
EVALUATION OF EFFICIENCIES
In the direct method, the output (Steam) and input (Coal) are measured and the ratio output/
input in terms of heat values is called efficiency. In, the indirect method, the input is assumed
to be 100% and the various losses encountered are calculated and substracted from 100. The
various losses considered for this type of treatment are :
i) Exhaust Gas loss
ii) Air Moisture loss
iii) Radiation loss
iv) Fuel Moisture loss
v) Unburnt Carbon loss
vi) Unaccounted loss
vii) Loss due to hydrogen in fuel.
Which method is more reliable ?
Technically speaking both are same. Direct method physically satisfies the customer as he is
able to see the output and input. Direct method, gives an edge for the manufacturer as the
unaccounted loss and radiation loss considered at the design stage give him some advantage.
Will a manufacturer conduct the guarantee tests as per direct method? Yes ; But the purchaser
has to provide him facilities to measure positively the fuel burnt and the water evaporated.
In general for small oil/gas fired boilers, an attempt can be made to measure the efficiency by
direct method. But for large boilers, it is advisable to go for losses methods as the combursome
method of weighing tons of fuel and water can be avoided. BHEL normally does the guarantee
test by losses method.
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In general guarantee is given for maximum continuous rating load of the boiler. Hence the
test will be conducted at boilers MCR Ratings. It may so happen in a utility boiler the MCR
Rating cannot be achieved due to the reason that the turbine may not be able to consume all
steam. In such cases the boiler will be loaded according to turbine limitations and the boiler
manufacturers cannot be compelled to go for MCR load.
3. TEST PROCEDURE
3.1 Instruments
All important instruments are calibrated by customer engineers in the presence of suppliers
representatives. The important instruments are:
i) Flow meters like steam flow meter, feed water flow meter, auxiliary steam flow
meter.
ii) Temperature indicators like, . main steam temperature at superheater outlet, feed
water temperature, auxiliary steam temperature.
iii) Pressures like, steam pressures at super-heater outlet, feed water inlet pressure,
auxiliary steam pressure
iv) Flue gas outlet temperature after air heater.
v) Orsat analysis at air heater outlet.
For the meters, the DP transmitter square root extractor, and indicator/integrator should be
individually and collectively calibrated.
Ali indicators for temperature must be calibrated.
All pressure gauges must be tested by dead weight pressure gauge tester.
Flue gas outlet temperature must be measured at number of points.
Fresh KOH ; solution and Pyrogallic acid must be filled in orsat apparatus.
All these instrument calibration must be attested by the customer and BHEL before the start
of the test.
3.2 Sampling
Fuel sampling is an important factor in the guarantee test. Raw coal is collected at periodical
interval from the feeders. The sampling point is predetermined and the samples thus collected
will not lose any inherent moisture. The normal interval at which the samples are collected
can be 15 minutes.
In the case of an oil fired boiler a conti. nuous dripping arrangement for the oil will be made
so that a portion of the fuel going to the burner will get collected.
In gas fired boilers, it is not possible to store the gas in a container and then analyse it in a
laboratory. Hence normally it is analysed as the gas is fired in boiler.
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3.3 Points to be Agreed
The customers representative and the suppliers representative must agree on certain points.
i) The extent of the duties and responsibilities of the designated competent person.
ii) The specific objects of the tests.
iii) That the specified working conditions can reasonably be met and that the appropriate
fuels can be burned at the necessary rates.
iv) Correction curves or tables for deviation of test conditions from stipulated operating
conditions.
v) The number and duration of test.
vi) That the specified fuel-to be used in the tests is available in adequate quantity to
meet the requirement.
vii) In the event of plurality of fuel being burned, the ratio of the different fuels to be
used.
viii) The method of evaluating efficiency.
ix) The method of expressing the thermal efficiency (i.e.) direct method or losses method.
x) The general method of operation and responsibility for operating the plant during
the test.
xi) If various manufacturers are involved, their, respective responsibilities for the
performance of the component plant items and of the plant as a whole.
xii) The laboratory to make the necessary analysis of fuel and refuse.
xiii) The provision of reserve fuel samples and refuse samples.
xiv) Any departure from the method of measurement prescribed.
xv) The steam tables to be used.
xvi) The state of the plant, (i.e.) cleanliness of contact surfaces, wear and tightness and
the operation of cleaning equipment.
xvii) The operation of blow down and if to be used, the method of measurement.
xviii) The operation of integral ash quenching equipment.
xix) The method of measurement of fuel.
xx) The method of sampling fuel.
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xxi) The method of fuel grindability determination.
xxii) The method of determining the mass of refuse.
xxiii) The method of assessment of heat tossers from water filled ash hopper and from
solid residues of combustion.
xxiv) The method of sampling refuse.
xxv) The method of flue gas analysis.
xxvi) The method of measuring feed water.
xxvii) The instruments to be used for temperature measurement.
xxviii) When testing according to losses method, the value to be adopted when necessary
for radiation and convection losses.
xxix) The method of steam purity measurements and correction and o f boiler water
conditioning.
xxx) The location of instruments.
xxxi) Tile measurement intervals.
xxxii) The condition under which a test should be terminated as unsatisfactory.
3.4 Duration of the Test
The duration of the test is normally only 4 hours in the case of pulverised fuel fired boilers, oil
fired boilers and gas fired boilers. But however the boiler will run in the test load condition
atleast for one hour prior to the test and for one hour after the test. During these periods, the
parameters will be maintained at test load condition. But however it is expected that the
boiler should run for a period of 9 hours prior, to the control period under steady state conditions.
3.5 Frequency of reading
The aim of this is to have as many readings as possible, so that a better average will be
obtained. As per this standard, atleast 25 readings are necessary for better average. BHEL as
a policy takes all readings at every five minutes duration except flow meter readings. Due to
varying nature of our industrial load and utility load, flow meter reading are taken at every
three minutes.
The above readings are attested by the persons who recorded it, the customers representative
and the suppliers representative. A copy of these readings will be given to the supplier and as
well as the customer too.
All samples collected will be made into three equal parts, each weighing not less than one kg.
in weight. One part will be given to the customer, the other will be given to the supplier and
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the third one will be sealed and kept at the customers premises.
The customer and supplier will independently analyse the sample and agree upon the values
to be used. In case they are not able to come to an agreement, the neutral sample will be
analysed in an agreed laboratory and the results will be binding both of them However, the
results of such samples analysed should be intimated to the supplier within one month from
the date of test in order to enable the supplier to prepare the report.
3.6 Important Precautions
During the period of guarantee test, it is very much necessary that the heat transfer surfaces
are fairly clean. Hence at the start of the guarantee test, the supplier has the right to clean the
heating surfaces like economiser, water wall, superheaters and airheaters. The customer will
provide the necessary facilities including the man power etc.
The supplier will also use the soot blowers to clean the water wall surfaces just before the
start of the test. He may also use the blow downs to bring the salts under control. But, however,
he is prohibited to use these during the test period.
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