Performance Evaluation of Mills, Boiler and Fans in Thermal Power Plants.

Introduction of power plant
performance and monitoring, need,

objectives, controllable and
uncontrollable factors
Material Written, compiled and presented by:

Mr. V.K.Gupta, Maintenance Faculty, NPTI, Badarpur
1 1
Objectives: The sole objective of monitoring the
plant performance and calculating various
efficiencies can be summarised as follow:
To maximise generation, i.e. With the burning of the unit
quantity of fuel (Coal or oil) The generation of electricity must
be as close to the theoretical values. This can also be narrated
the other way : i.e. to generate one unit of electricity, fuel
consumption must be as close to the theoretical value as
possible.
This is termed as Plant Heat Rate.
Plant Heat rate can be what is desired and what we achieve.
The later is always more than the earlier one.
There can be no of factors responsible for a higher value of the
plant heat rate.
2
The coal plant getting coal from mines is inferior than
for what it is designed for.
The inferior coal means it may have lower carbon
contents, higher percentage of ash, higher moisture and
volatile matters. In other words the Gross calorific value
and net calorific value may be lower than what is desired.
Incomplete burning of coal inside the furnace.
The quantity of unburnt coal going waste into the bottom
and fly ash is high.
Mills not performing as they should.
Quantity of Excess air is either high or low than the
theoretical one.
Fan not performing as expected. In other words a proper
furnace draught is not established.
High air ingress inside the furnace. 3
Condition of boiler tube is bad. i.e High Scale
deposits inside Super heater tubes, Ash deposits on
the outside of the tubes, reducing heat transfer,
Boiler tubes leakages, Clogging of economiser fins,
Distortion in alignments in the various tube banks,
Poor weld joints.
Soot Blower not operating as expected.
Higher rate of Boiler blow down.
Improper operation.
Lack of training.
Still many more obviously will reduce the boiler
efficiency meaning less heat being transferred to the
boiler feed water and Steam.
4
What are the things which are in our control and if we care
about them certainly plant performance / availability /
capacity factor and as a result more generation and higher
efficiency can be achieved.
For a given power plant, heat rate depends on the plants

design, its operating conditions, and its level of electric
power output. In theory, 3,412 Btu of thermal energy is
equivalent to 1 kWh of electric energy. For existing coal-
fired power plants, heat rates are typically in the range of
9,000 Btu/kWh to 11,000 Btu/kWh. A plant with the U.S.
industry average heat rate of 10,300 Btu/kWh is operating
with an overall plant efficiency of about 33% (3,412/0.33 =
10,339).
5
When it comes to efficiency, the first thing that we should
consider are the losses. If we are able to minimize the
losses then ultimately the efficiency will increase. Similarly
in case of thermal power plant also many methods are
employed in order to improve the efficiency.
1.Good Quality Coal
2. Proper Coal Pulverization
2. VFD for Motors
3. Bag Filters in ESP
4. TD-BFP
5. Duplex Heaters
6
Now a days you will see that a new technology called
"SUPER CRITICAL" is being employed by many new plants.
In case of super critical power plants the efficiency of the
turbine is increased as the super critical boilers work at a
very high pressure, which ultimately increases the work
done by the turbine.
There are 3 TPS technologies available at present
1) Sub-critical technology (design efficiency 3637%)
2) Super critical technology (design efficiency 4445%)
3) Ultra Super critical technology (design efficiency more
than 45%).
So, Ultra Super critical technology power plant shall be
the best from efficiency point of view.
7
Some general methods to improve the efficiency
are
1. Operate the power plant near to design main steam
pressure & temperature.
2. Use of VFDs
3. Replace conventional 6.6 KV HT motors with energy
efficient motors.
4. Proper maintenance of LP & HP heaters, Economiser,
Super heaters & Air-preheaters.
5. Attending passing of high energy drain valves.
6. Maintaining proper vacuum in condenser.
7. Using LED lights for lighting purpose
8
8. Optimizing and attending leakages of instrument &
service air.
9. Checking of conditions of pumps
10.Optimizing the running of air conditioning system
11.Operating equipment close to design efficiency
12.Optimizing the number of coal mills running
13.Optimizing the running of conveyor belts for
transporting coal from coal handling plant to main
power house site.
14.Optimizing total air flow
15.Ensuring proper working of SADC dampers, soot
blowers & burner tilt mechanism.
16. Maintain thermal insulation in right condition
17. Plant operation, follow procedures
18. Operate the Pump and fans near to it,s BEP 9
18. Training, peer review, honest audit
19. Proper maintenance, Testing and calibration
20. On line instrumentation and their calibration
21. Efficient online repairing or maintenance facility
22. Root Cause analysis and implementation of the finding
23. Research and material failure analysis
24. Market/venders support
25. Welders qualification
26. ISI program and still many more
27. House Keeping
28. Labelling, sign boards and paintings of pipe lines
29. Implementation of safety culture
30. Workers (Operation and Maintenance qualifications) with
incentive
10
What is not in our hand:
1. Quality of coal supplied
2. Quality of water supplied
3. Quality of ambient air
11
With my limited knowledge, few things which I
can think of to improve thermal plant efficiency
are as follows-
Using good quality coal
Thermal plants have very low efficiency mainly due to burning
of coal which requires a lot of energy.
In India, we generally mix very small amount of high quality
coal which is imported from foreign countries with coal
obtained from Indian mines which is of generally low
efficiency.
By increasing the amount of high quality coal concentration,
efficiency can be improved but then it will also lead to increase
in power production cost which ultimately is to be paid by
consumers. Hence , there must be balance between efficiency
and cost.
12
By reducing the leakage of steam, flue gases etc:
The leaked out steam does not contribute to the power
generation and is wasted thus decreasing the overall efficiency.
Hence, leakage must be reduced which can be done by
continuous real time monitoring of boiler, pipes, heat exchanger
etc using advanced software and computation technologies.
Also, the seals of boiler, pipes etc must be examined regular and ,
if required, must be replaced.
Continuous monitoring of coal and air input to boiler
The amount of coal and air being fed to boiler must be
continuously monitored in real time and must be regulated as
required.
13
Higher plant availability or higher availability factor will
also lead to higher plant efficiency.
Online data or operating parameters monitoring by data
acquisition or the distributed digital control system will
also help in achieving exacting information helping to
take corrective measure timely , which is a key to
achieving higher plant efficiencies.
Overall Plant/Station efficiency = Output of the station

----------------------- x100
Input of the station
Energy sent out (KW)
= ---------------------------------------
Fuel burnt(kg) x Calorific Value of fuel (Kcal/kg)
14
The turbine and generator efficiency are also taken into calculation
while calculating the overall efficiency along with Boiler efficiency.
Boiler efficiency for(RH boiler) B = Steam supplied in kg x Total

heat in superheated steam
Total heat added to feed water in Boiler / kg

= -----------------------------------------------------------------
Fuel burnt (kgs) x Calorific value of fuel (Kcal / kg)
ShB - hf
B = ----------------------- x 100
L x C.V Where:
ShB= Enthalpy of S.H Steam ( Kcal/Kg) at Boiler
hf = Enthalpy of feed water (kcal /kg)at F
TS = Total Steam supplied in kg
L = Fuel Burnt
CV = Calorific Value of fuel 15
Turbine efficiency:
Mechanical work output (kcal)

T = ------------------------------------------------ x 100
Isentropic heat drop across turbine
Mechanical work output (kcal)

= ---------------------------------------------- x 100-
S (hB hA)
A & B are the points considered at turbine inlet and outlet

hA = Enthalpy of steam at point A
hB = Enthalpy of steam at point B
16
The heat rejected in condenser is about 45 to 55% of the total
available heat energy available at turbine inlet. Thus cycle
efficiency:
Eenrgy available for conversion into work (kcal)

C = ------------------------------------------------- x 100
Energy given as heat in boiler
17
G = Electrical energy sent out (kWhr x 860)
----------------------------------------------------- x 100
Mechanical Work
os = B x T x C x G
Thus overall station efficiency = Boiler efficiency x Turbine

efficiency x Condenser efficiency x Generator efficiency
OTA = T x C x G
OS = B x OTA
18
Heat Rate: Heat rate is defined as heat supplied to
steam to produce I KWh of electrical energy:
Heat supplied to steam in (Kcal) in boiler

HR = ----------------------------------------------------------
Electrical energy sent out in KWhr
Since one 1KW = 860 Kcal

860
OS = ---------- x 100
Plant HR
19
Typical Losses
Typical Losses
Pressure Temp. Boiler Turbine & Generator Total To bus bar
cycle
Bar 0C % loss % loss % loss % age %age
output
41.4 455 14 50.25 1.75 72 28
62 480 13 55 2 70 30
93 510 12.5 53.75 2.25 68.50 31.5
103 536 11 52.5 2.5 66 34
162 565 10 49 3 62 38
241 593 9 48.25 3.75 61 39
310 650 9 46.5 4.0 50.5 49.5
20
Typical Boiler Losses:
1. Dry Flue Gas loss
2. Wet flue gas loss (loss due to moisture in fuel and due
to moisture formed by combustion of H2 in fuel
3. Moisture in combustion Air Loss
4. Unburnt carbon loss carbon in Ash Loss
5. Unburnt gas loss -- Due to incomplete combustion of
carbon
6. Radiation and unaccounted losses
21
Dry Flue Gas Loss depends upon two factors
Excess Air
Air Preheater gas outlet temperature high
Excess Air: Excess air is the quantity of air over and above
theoretical air being fed into the furnace by FD fans for
complete combustion of pulverised coal. This hoovers
around 20%. Too little excess air fuel is not completely
burnt and too much lead to greater amount of heat carried
to stack by flue gas by N2 contained in the excess. This
heat loss amount to significant loss and this can be
measured by measuring the O2 in flue gas.
22
Air heater gas outlet temperature:
The air heater outlet gas temperature should be lowest
from the point of overall efficiency. On the other hand
this temperature should be higher than the dew point of
sulphur which otherwise will cause condensation and
then corrosion of the ducting. For Indian coal with
sulphur around 0.5% air preheater gas outlet temp be
around 1300C. Lower leads to corrosion and higher
decrease in Boiler eff. A typical 220C rise in gas outlet
temp. reduces the boiler eff. By 1%.
Causes for higher gas outlet temp.
Lack of shoot blowing
Deposits on Boiler heat transfer surface
High excess air
23
Low final feed water temperature
Higher ele. Burner in service at low loads.
Defective baffles and bypass dampers, causing gas
short circuiting some heater transfer surface.
Improper combustion
Poor milling plant performance An incorrect PA / Sa
ratio causing delayed combustion
Air re-circulation reduces the heat removed from flue
gas.
Air in leakage before the combustion chamber.
24
Low air heater gas outlet temperature: Though in the
short run, low APH gas outlet temperature improves
eff. In the long run it can result in lower boiler eff.
Because of deposition of sulphur on its elements and
corrosion. The deposited material may also cause loss
of availability and reduction in heat transfer in the air
heater.
Wet Flue Gas loss: Moisture that enters the
combustion chamber as part of the fuel causes a heat
loss, because it must be heated to its boiling point first,
then evaporation and then superheating before it
leaves the boiler along with flue gas. So lot of heat is
wasted in doing so.
25
Carbon in Ash Loss: This loss depends upon the
fineness of pulverised coal, excess air and combustion
condition. If the conditions are not monitored properly
the loss which should be around 1% may be as high as
4 to 5%.
Causes of high carbon in ash are:
Coarse grinding
Mal adjustment of flame
Unequal loading of different mills
Incorrect PA fan temperature.
Causes of Coarse grinding:
Mill in need of adjustment
Exhauster speed too high in relation relative to feed rate.
Weak fuel / air mixture i.e high PA
Separator (Classifier) speed too high 26
Radiation and Unaccounted Heat Losses: These are the heat losses as follows
1) Heat carried away in ash
2) Loss from boiler casing to the surrounding
3) Heat loss in bottom water seal
4) Loss of heat due to unburnt volatile matter
5) These loss account for around 1%.
Radiation loss depends upon effectiveness of the insulation all around the boiler casing
and feed water piping.
Problem associated with high ash contents in coal:
Effect of varying boiler load on efficiency:
Control of Boiler Blow Down:
Usually it is for a period of around 2 minutes in every shift and
increase in boiler blow down will reduce the Boiler eff.
Auxiliary Power Consumption: Running additional auxiliary only
when it is essential and that only when it is going to yield fruitful
result.
Using efficient type of control for regulation of fans and pumps
Optimization of air, fuel and water consumption
Better maintenance and house keeping.
27
Optimization of oil consumption:
PF boiler consumes oil under different operating
conditions. It makes little difference in heat consumption.
Too much dependence on oil for flame stabilization and lt
low loads should be only as necessary and not an easy
remedy. Cost of oil is far more than cost of coal so the
generation cost will also be high. Oil should be used
judiciously.
28
Performance monitoring of Pumps and Fans
The objective of observing the Performance of Fan and
Pumps is very vital. Both Fans and Pumps are similar
machines. Both have same like components. Even the
operating principle of two is also similar. We understand
the Bernoulli's theorem and also know that sum total of
energies of the fluid flowing through a confined passage
is constant. Usually there are three components of Total
pressure that is Pressure energy, kinetic energy and
potential energy. While the fluid is flowing through a pipe
line or the duct one is altered at the cost of other until
and unless energy is not added.
29
30
Pumps and Fans add energy to fluid with the help of a
motor and the rotating component that is impeller.
Which increases the kinetic energy which if then
converted to pressure at its own cost. These are known
as Centrifugal machines. There is another which is called
axial flow machines which only displaces the fluid at high
rate axially without converting to pressure energy.
We must understand the internals or the type to monitor
its behaviour and gauge the performance. We must
understand whether the energy input, after all it is
costing to us, how much of it is doing it job. So come
efficiency into picture. Every fan or a pump has a specific
point of operation where its efficiency is maximum. Do
we know that.
31
At this point the fan or the pump will deliver a known flow against a
specified head. How much energy the pump or the fan is drawing
from the motor should be know. If it is more than the specified one
that means pumps is not performing well or where I am operating the
pump is not correct.
One more point depending upon the demand or the load on the unit
the flow by the pump or the fan has to alter that is less or more than
the operating point at which the efficiency was maximum, by
throttling the discharge valve or the speed or the inlet damper or
varying the pitch of the vanes what ever we do the flow should in
the most efficient manner, one thing you must understand it is
always at the cost efficiency and so it is uneconomical. That is what
comes into picture. If I am operating the plant at less load than
rated load it is always inefficient and performance of the fan or the
pump will e considered to be poor. As said how do we do this is also
important. It is therefore very essential that before we proceed into
the job of calculating the performance and efficiency we must
understand the following. 32
In figure of pumping layout the pump
takes water from below its centre line
and deliver to some higher elevation.
Various pumping terminologies or the
terms have been mentioned. Let us
study them.
Suction Lift marked is known as Static
Suction lift. When Velocity head and
Suction friction head is added to static
Suction lift it is called Suction lift or the
total suction lift.
Suction Lift = Static Suction Lift +
Velocity Head + Frictional Head + Entry
loss etc.
hL = hSSL + hv2/2g + hf + hi
Or
hSSL = hL ( hv2/2g + hf + hi)
33
Here the water source is above the pump
centre line. This is known as Suction Head.
And Static Suction head S = Suction Head +
Velocity head + Frictional Head + other losses
it can be written like this:
S = hs + Hv2/2g + Hf + He
In both suction lift and suction head velocity of
flow is almost decided as around 4 to 5 m/s what
can be altered is the frictional head loss and entry
losses.
2L/2gd
hf is given by = 4fv
34
Hf can be reduced by
F is a constant and depends upon the type of flow and internal
condition od the suction piping. It should be as smooth as
possible.
Velocity of flow is almost fixed
Length of the suction pipe should be as short as possible
Diameter of the suction pipe should be as large as possible
Similarly he can also be reduced by reducing entry losses and no

of fittings etc. Avoid zig zag suction piping
That is why entry point is always like a funnel or skirt.
35
Similarly Static Discharge head hd = hD (hV2/2g + H f d + h exit)
So when pumps and fans performance is monitored friction head

loss and entry and exit losses are seen Since they have direct
bearing on static suction head and static discharge head. Some
times Velocity may have to be reduced by increasing the suction
pipe diameter.
Now NPSH = NPSH is a phenomenon at the suction side only. It is

known as minimum pressure required at the pump inlet which will
cause the full flow to entre the impeller eye.
36
37
38
39
40
41
42
43
44
45
46
47
Affinity laws
The affinity laws for pumps/fans are used in hydraulics
and/or HVAC to express the relationship between variables
involved in pump or fan performance (such as head,
volumetric flow rate, shaft speed) and power. They apply to
pumps and fans in common. In these rotary implements,
the affinity laws apply both to centrifugal and axial flows.
The affinity laws are useful as they allow prediction of the

head discharge characteristic of a pump or fan from a
known characteristic measured at a different speed or
impeller diameter. The only requirement is that the two
pumps or fans are dynamically similar, that is the ratios of
the fluid forced are the same.
48
Law 1. With impeller diameter (D) held constant:
Law 1a. Flow is proportional to shaft speed:
Q1 N1
------ = -------
Q2 N2
Law 1b. Pressure or Head is proportional to the square of shaft
speed:
H1 N1
------ = { ---- } 2
H2 N2
Law 1c. Power is proportional to the cube of shaft speed:
P1 N1
------ = { ---- } 3
P2 N2
49
Law 2. With shaft speed (N) held constant:
Law 2a. Flow is proportional to the impeller diameter:
D1 N1
------ = -------
D2 N2
Law 2b. Pressure or Head is proportional to the square of the
impeller diameter:
D1 N1
------ = { ---- } 2
D2 N2
Law 2c. Power is proportional to the cube of impeller diameter:
D1 N1
------ = { ---- } 3
D2 N2
50
where
Q is the volumetric flow rate (e.g. CFM, GPM or

L/s),
D is the impeller diameter (e.g. in or mm),
N is the shaft rotational speed (e.g. rpm),
H is the pressure or head developed by the
fan/pump (e.g. psi or Pascal), and
P is the shaft power
51
Three Phase
KW E I PF = 173
1000
52
COAL -COKE.
Grades of Coking Coal

Grades of Non-coking Coal
Grades of Semi-coking and Weakly Coking Coal
Grade Ash Content
Steel Grade - I Not exceeding 15%
Exceeding 15% but not
Steel Grade -II
exceeding 18%
Washery Grade -I
exceeding 21%
Washery Grade -II
exceeding 24%
Washery Grade -III
exceeding 28%
Washery Grade -IV
exceeding 35%
53
COAL GARDES.CIL
Corresponding Gross Calorific Value

Useful Heat Value (UHV) (Kcal/Kg) UHV= 8900-
Grade Ash% + Moisture % GCV (Kcal/ Kg) (at
138(A+M)
at (60% RH & 40OC) 5% moisture level)
A Exceeding 6200 Not exceeding 19.5 Exceeding 6454
Exceeding 6049 but

B Exceeding 5600 but not exceeding 6200 19.6 to 23.8
not exceeding 6454
Exceeding 5597 but

C Exceeding 4940 but not exceeding 5600 23.9 to 28.6
not exceeding. 6049
Exceeding 5089 but

D Exceeding 4200 but not exceeding 4940 28.7 to 34.0
not Exceeding 5597
Exceeding 4324 but

E Exceeding 3360 but not exceeding 4200 34.1 to 40.0
not exceeding 5089
Exceeding 3865 but

F Exceeding 2400 but not exceeding 3360 40.1 to 47.0
not exceeding. 4324
Exceeding 3113 but

G Exceeding 1300 but not exceeding 2400 47.1 to 55.0
not exceeding 3865
54
55
PERFROMANCE TESTING ..A TYPICAL SCHEDULE
56
PERFROMANCE TESTING ..A TYPICAL REPORT
57
BOILER PERFORMANCE. DIRECT METHOD
Basically Boiler efficiency can be tested by the following methods:
1) The Direct Method: Where the energy gain of the working fluid (water and steam)
is compared with the energy content of the boiler fuel.
2) The Indirect Method: Where the efficiency is the difference between the losses and
the energy input.
The Direct Method Testing
58
BOILER PERFORMANCE. DIRECT METHOD
59
BOILER PERFORMANCE. INDIRECT METHOD
60
BOILER PERFORMANCE. INDIRECT MATHOD
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
82
83
Step 4: Estimate all heat losses
Step-1: Calculate the theoretical air requirement i. Percentage heat loss due to dry flue gas
= [(11.43 x C) + [{34.5 x (H2 O2/8)} + (4.32 x S)]/100 = m x Cp x (Tf Ta ) x 100
kg/kg of oil ----------------------------
GCV of fuel
= [(11.43 x 84) + [{34.5 x (12 1/8)} + (4.32 x 3)]/100 m = mass of CO2 + mass of SO2 + mass of N2 + mass of O2
kg/kg of oil 0.84 x 44 0.03x64 20.74x77
= 13.82 kg of air/kg of oil m = ----------- + ---------- + ----------- (0.07 x 32)
12 32 100
Step-2: Calculate the % excess air supplied (EA) m = 21.35 kg / kg of oil
21.35 x 0.23 x (220 27)
Excess air supplied (EA)
= ------------------------------- x 100
= (O2 x 100)/(21-O2) 10200
= (7 x 100)/(21-7) = 9.29%
= 50%
Step 3: Calculate actual mass of air supplied/ kg of A simpler method can also be used:Percentage heat loss due to dry flu
fuel (AAS) gas
m x Cp x (Tf Ta ) x 100
AAS/kg fuel = [1 + EA/100] x Theo. Air (AAS)
= ------------------------------
= [1 + 50/100] x 13.82 GCV of fuel
= 1.5 x 13.82 m (total mass of flue gas)
= 20.74 kg of air/kg of oil = mass of actual air supplied + mass of fuel supplied
ii. Heat loss due to evaporation of water formed due to H2 in =fuel
20.19 + 1 = 21.19
9 x H2 {584+0.45 (Tf Ta )} = 21.19 x 0.23 x (220-27)
------------------------------- x 100
= --------------------------------- 10200
GCV of fuel = 9.22%
where H2 = percentage of H2 in fuel
9 x 12 {584+0.45(220-27)}
= --------------------------------
10200
= 7.10%
iii. Heat loss due to moisture present in air
AAS x humidity x 0.45 x ((Tf Ta ) x 100
= ------------------------------------------------- 84
GCV of fuel
BOILER PERFORMANCE. BLOW DOWN
Boiler Blow Down
When water is boiled and steam is generated, any dissolved solids contained in the water
remain in the boiler. If more solids are put in with the feed water, they will concentrate and
may eventually reach a level where their solubility in the water is exceeded and they
deposit from the solution. Above a certain level of concentration, these solids encourage
foaming and cause carryover of water into the steam. The deposits also lead to scale
formation inside the boiler, resulting in localized overheating and finally causing boiler tube
failure.
It is therefore necessary to control the level of concentration of the solids. This is achieved
by the process of 'blowing down', where a certain volume of water is blown off and is
automatically replaced by feed water - thus maintaining the optimum level of total
dissolved solids (TDS) in the boiler water. Blow down is necessary to protect the surfaces of
the heat exchanger in the boiler. However, blow down can be a significant source of heat
loss, if improperly carried out.
85
Conductivity as indicator of boiler water quality
Since it is tedious and time consuming to measure total dissolved solids (TDS) in
boiler water system, conductivity measurement is used for monitoring the overall
TDS present in the boiler. A rise in conductivity indicates a rise in the
"contamination" of the boiler water.
Conventional methods for blowing down the boiler depend on two kinds of blow
down: intermittent and continuous
86
Intermittent blow down
The intermittent blown down is given by manually operating a valve fitted to discharge
pipe at the lowest point of boiler shell to reduce parameters (TDS or conductivity, pH,
Silica and Phosphates concentration) within prescribed limits so that steam quality is not
likely to be affected. In intermittent blow down, a large diameter line is opened for a
short period of time, the time being based on a thumb rule such as once in a shift for 2
minutes.
Continuous blow down
There is a steady and constant dispatch of small stream of concentrated boiler water,
and replacement by steady and constant inflow of feed water. This ensures constant TDS
and steam purity at given steam load. Once blow down valve is set for a given
conditions, there is no need for regular operator intervention.
Even though large quantities of heat are wasted, opportunity exists for recovering this
heat by blowing into a flash tank and generating flash steam. This flash steam can be
used for pre-heating boiler feed water or for any other. This type of blow down is
common in high-pressure boilers.
87
Blow down calculations
The quantity of blow down required to control boiler water solids concentration is calculated by
using the following formula:
If maximum permissible limit of TDS as in a package boiler is 3000 ppm, percentage make up water
is 10% and TDS in feed water is 300 ppm, then the percentage blow down is given as:
= 300 x 10 / 3000
=1%
If boiler evaporation rate is 3000 kg/hr then required blow down rate is:
= 3000 x 1 / 100
= 30 kg/hr
Benefits of blow down control
Good boiler blow down control can significantly reduce treatment and operational costs that include:
Lower pretreatment costs
Less make-up water consumption
Reduced maintenance downtime
Increased boiler life
Lower consumption of treatment chemicals
88
BOILER PERFORMANCE. a TYPICAL TEST FOR 500 MW
Abbreviated Efficiency Tests
Boiler Losses Typical values

Dry Gas Loss 5.21
Unburnt Loss 0.63
Hydrogen Loss 4.22
Moisture in Fuel Loss 2.00
Moisture in Air Loss 0.19
Carbon Monoxide Loss 0.11
Radiation/Unaccounted Loss 1.00
Boiler Efficiency 86.63 89

BOILER PERFORMANCE. OBJECTIVES
Boiler Performance Optimization
To evolve an optimum operating regime for a boiler

To establish interrelationships between different operating
parameters
To build a database by various parametric tests
A baseline test is conducted with normal running

conditions. Thereafter, one variable is varied at a time
and its effect on boiler losses and other operating
parameters is studied to find an optimum set of
parameters.
90
BOILER PERFORMANCE.
Effect of Operating Parameters on Boiler Losses
91
BOILER PERFORMANCE.INSTRUMENTS
HVT - High Velocity Thermocouple Probe

92
BOILER PERFORMANCE.
Drum Penthouse
SH
Div. SH
Panel
. .
Nose
. Arch
.
Locations for HVT & HVS Sampling
93
BOILER PERFORMANCE.
Instruments Used
Dirty Pitot
Rotary Sampler
FG Sampling SystemProbes
Bubble Jar
Condenser
Desiccant jar
Vacuum Pump
Gas Analyzers
Datascan boxes
High Velocity Thermocouple
High Volume Sampler
94
BOILER PERFORMANCE.
FG
Expansion
Bellow
Test Ports
Economizer
HVS
APH
Sampling
Locations
APH
FG
95
BOILER PERFORMANCE.
High Volume Sampler

BOILER PERFORMANCE.
Sampling Ports in Flue Gas Ducts (Typical )
100mm
Sampling Point for Flue Gas Temperature & Composition 97

BOILER PERFORMANCE.
Flue Gas Sampling Train
FG Samples
from probes
Desiccant
Jar
Bubble Jar
Condenser
Datascan Gas
Boxes Analyser
s Vacuum Pump
98
Sampling Locations
Flue Gas Duct at APH in/outlet

Primary Air Duct at APH in/outlet
Secondary Air duct at APH in/outlet
Furnace Gooseneck
Economizer Outlet
Feeder Inlet chutes
Bottom Ash Hoppers
99
Air Ingress Points Furnace Roof , Expansion joints, Air
heaters, Ducts, ESP Hoppers, Peep Holes, Manholes,
Furnace Bottom
Air-in-
leakage
Furnace
Outlet
Zirconia
O2 Probe
Expansion Joints
AH ESP
Seal
Lkg
100
Oxygen % at various locations in boiler
10
6
O2 %
0
Furn Outlet AH Inlet AH Outlet ID outlet
210 MW 210 MW 500 MW 210 MW
101
BOILER PERFORMANCE.
Typical Boiler Problems

Imbalance in air and coal flow through the discharge pipes of an
individual mill
High primary air flows through the mills
Difference in pulverized coal fineness amongst the discharge pipes
of an individual mill
High furnace exit gas temperatures at furnace outlet
High SH or RH sprays
Imbalance in flue gas composition and temperature profile at
furnace exit
Air ingress from the furnace bottom, from the expansion joints in
the flue gas duct or from the duct between air heater and ID fans
and quantification of the same
102
BOILER PERFORMANCE.
Typical Boiler Problems contd..
Air ingress from the nose arch, penthouse and boiler second pass
and quantification thereof
Difference between on line zirconia reading and the actual oxygen
in the flue gas duct as measured by the sampling grid
Difference between actual and 'on line' temperature
measurement of air heater air / gas outlet temperatures
Fouling and Slagging
High unburnt Carbon in flyash or bottomash
High air heater leakage - reduced by ALCS operation
Boiler operation at high excess air
103
FAN PERFORMANCE
104
FAN PERFORMANCE
Effect of Blade Type on Erosion

Resistance and Efficiency
105
FAN PERFORMANCE
Fan Curves
Manufacturer will provide a fan curve for each fan
The fan curves predict the pressure-flow rate performance of
each fan.
Choose a fan that gives you the volumetric flow rate you need
for your system pressure drop.
Choose a fan that has its peak efficiency at or near your
operating point.
Sometimes will provide data in a table rather than in a graph.
106
FAN PERFORMANCE
107
FAN PERFORMANCE
Centrifugal Fan Performance Curve.
108
FAN PERFORMANCE
Fan Laws
Flow ? Speed Pressure ? (Speed)2 Power ? (Speed)3
Q1 N 1 2 3
SP1 N 1 kW 1 N 1
Q2 N 2
SP 2 N 2 kW 2 N 2
Varying the RPM by 10% Varying the RPM by 10% Varying the RPM by 10%
decreases or increases air decreases or increases the decreases or increases the
delivery by 10%. static pressure by 19%. power requirement by
27%.
Where Q flow, SP Static Pressure, kW Power and N speed (RPM)
109
FAN PERFORMANCE
Fan Laws
Law 1 relates to effect of changing size, speed, or density on volume
flow, pressure, and power level
Law 2 relates to effect of changing size, pressure, or density on volume
flow rate, speed, and power
Law 3 shows effect of changing size, volume flow, or density on speed,
pressure, and power
The laws only apply to aerodynamically similar fans at the same point of
rating on the performance curve.
110
FAN PERFORMANCE
Scheme of Air and Gas Path
111
FAN PERFORMANCE
Draught System Pressure Variation
Pressure drop calculation in air & gas path and its comparison
with design value.
Assessment of ID and FD fan power as a function of furnace
pressure.
Assessment of effective kinetic rate coefficient as a function of
furnace pressure.
Duct
FD Back ID
Duct
Duct APH Duct Furnace Duct APH ESP Chimney
Fan pass Fan
112
FAN PERFORMANCE
Pressure Variation
Furnace Pressure At Various Points in Boiler

FD Fan Inlet
1
250 FD Fan Outlet
2
200 Airheater Inlet
3
150 Airheater Outlet
4
100 Windbox Pressure
5
50 6 Furnace
Furnace Pressure
0 7 Superheater Platen Inlet

1 2 3 4 5 6 7 8 9 10 11 12 13 14
Reheater Inlet
-50 8
9 LTSH Inlet
-100
10 Economiser Inlet
-150
Airheater Inlet
11
-200
E.P. Inlet
12
-250 I.D. Fan Inlet
13
-300 I.D. Fan Outlet

14
Points in Boiler
113
FAN PERFORMANCE
Purpose of the Performance Test

The purposes of such a test are to determine, under actual operating conditions,
the volume flow rate, the power input and the total pressure rise across the fan.
These test results will provide actual value for the flow resistance of the air duct
system, which can be compared with the value specified by supplier.
Static Pressure: The absolute pressure at a point minus the reference atmospheric
pressure.
Dynamic Pressure: The rise in static pressure which occurs when air moving with
specified velocity at a point is bought to rest without loss of mechanical energy. It is also
known as velocity pressure.
Total Pressure: The sum of static pressures and dynamic pressures at a point.
Fan Shaft Power: The mechanical power supplied to the fan shaft
Motor Input Power: The electrical power supplied to the terminals of an electric motor
drive.
114
FAN PERFORMANCE
General: The flow measurement plane shall be located in any suitable straight length,
(preferably on the inlet side of the fan) where the airflow conditions are substantially
axial, symmetrical and free from turbulence. Leakage of air from or into the air duct shall
be negligible between the flow measuring plane and the fan. Bends and obstructions in
an air duct can disturb the airflow for a considerable distance downstream, and should
be avoided for the purposes of the test.
115
FAN PERFORMANCE
Test length: That part of the duct in which the flow measurement plane is located,
is termed the test length and shall be straight, of uniform cross section.
It shall have a length equal to not less than twice the equivalent diameter of the
air duct (i.e. 2De).
For rectangular duct, equivalent diameter, De is given by 2 LW/(L+W) where L, W
is the length and width of the duct.
For circular ducts De is the same as diameter of the duct.
Inlet side of the fan: Where the test length is on the inlet side of the fan, its
downstream end shall be at a distance from the fan inlet equal to atleast 0.75De.
.
Outlet side of the fan: Where the test length is on the outlet side of the fan, the
upstream end of the test length shall be at a distance from the fan outlet of at
least 3De.
116
FAN PERFORMANCE
117
FAN PERFORMANCE
118
FAN PERFORMANCE
119
FAN PERFORMANCE
Measurement of Air Velocity on Site
Velocity shall be measured by either pitot tube or a rotating vane anemometer.
When in use, the pitot tube shall be connected by means of airtight tubes to a
pressure measuring instrument. The anemometer shall be calibrated before
the test.
120
FAN PERFORMANCE
Calculation of Velocity: After taking velocity pressures readings, at various

traverse points, the velocity corresponding to each point is calculated using
the following expression.
121
FAN PERFORMANCE
122
FAN PERFORMANCE
123
FAN PERFORMANCE
124
FAN PERFORMANCE
125
FAN PERFORMANCE
126
FAN PERFORMANCE
127
AIRPRE HEATER PERFORMANCE
Operational Problem
High Gas Leaving Temperatures
High Leakage of Air to Gas path
Higher Pressure Drop Across APH
APH Soot-blowing Cleaning Problems.
Corrosion Of Cold End Heating Elements
Low APH exit Gas Temperature.

128
High APH Exit Gas Temp- Reasons
More gas flow.
High Gas inlet temperature
Less air flow. ( More Tempering Air, Chocking of SCAPH )
Chocking of heating elements.
Damaged APH Elements.
High Leakage of Air to Gas path

Seal clearance
Poor sealing material.
Length of seal separating two sides
Hot end / Cold end leakages
Entrained Leakage
129
Higher Pressure Drop Across APH
1. Choking of heating elements
2. Higher flows
3. Eroded/damaged heating elements - obstructs flow path.
4. Improper Soot Blowing steam parameters and eroded
nozzles and steam pipes.
5. Low cold end average temperature
Choking Of Heating Elements

1. Corrosion of heating elements
2. Boiler slagging
3. Improper drying of heating elements after water washing.
4. Excess air operation.
5. Leak in SCAPH and water washing & deluge line, soot
blower passing etc.
6. Frequent water washing of heating elements and improper
drying.
130
Corrosion Of Cold End Heating Elements
1. High sulphur content in fuel

2. Low cold end average temperature
3. Low load operation for long periods
4. Improper firing procedure
5. Boiler slagging
6. Excess air
7. Leak in SCAPH and water washing & deluge line, soot blower
passing etc
8. Frequent water washing of elements and improper drying.
131
Air Heater - Performance Indicators
1. Air-in-Leakage
2. Gas Side Efficiency
3. APH Effectiveness.
4. X - ratio
5. Flue gas temperature drop
6. Gas & Air side pressure drops.
(The indices are affected by changes in entering air or gas

temperatures, their flow quantities and coal moisture)
132
Air Heater Leakage (%)
Weight of air passing from air side to gas side to the Wt of Flue gas
passing.
Direct - Hot End / Cold End
(60% through radial seals + 30% through Circumferential bypass)
Air leakage occurring at hot end of the air heater affects its thermal
and hydraulic performance while cold end leakage increases fans
loading.
Entrained Leakage due to entrapped air between the heating elements

(depends on speed of rotation & volume of rotor air space)
Leakage of air to gas is due to

Differential Pressure between Air & Flue Gas
Increased seal clearances in hot condition
Seal erosion / improper seal settings
Damaged APH sector plates. 133
Air Heater Leakage (%)
Increased AH leakage leads to
Reduced AH efficiency
Increased fan power consumption
Higher gas velocities that affect ESP performance
Loss of fan margins leading to inefficient operation and at times
restricting unit loading
Air Heater Leakage - Calculation

Leakage is entirely between air inlet and gas outlet: Empirical
relationship using the change in concentration of O2 or CO2 in the
flue gas
= CO2in - CO2out * 0.9 *100
CO2out
= O2out - O2in * 0.9 * 100 = 5.7 2.8 * 90

(21- O2out) (21-5.7)
Leakage% = 17.1 %
134
CO2 measurement is preferred due to high absolute values
Gas Side Efficiency
Ratio of Gas Temp drop across the air heater,

corrected for no leakage, to temp head.
= (Temp drop / Temperature head) * 100
where Temp drop = Tgas in -Tgas out (No leakage)

Temp head = Tgas in - T air in
Gas Side Efficiency = (333.5-150.5) / (333.5-36.1)

= 61.5 %
135
Tgas out (no leakage) = Temp at which the gas would have left the air
heater if there were no leakage
= APH L * Cpa * (Tgas out - Tair in) + Tgas out

Cpg * 100
Say leakage 17.1%, Gas In Temp 333.5 C,

Gas Out Temp 133.8 C, Air In Temp 36.1 C
Tgas nl = 17.1 * (133.8 36.1) + 133.8

100
= 150.5 C
136
Gas side Efficiency
It refers to internal condition of APH
Low Gas side efficiency- APH problems like Basket wear, Ash
plugging, High Lkg
Low gas side efficiency results in high Exit gas temp and Low Air
outlet temp
137
X Ratio
Ratio of heat capacity of air passing through the air heater to the heat
capacity of flue gas passing through the air heater.
= Wair out * Cpa

Wgas in * Cpg
= Tgas in - Tgas out (no leakage)

Tair out - Tair in
Say leakage 17.1%, Gas In Temp 333.5 C,

Gas Out Temp 133.8 C , Air In Temp 36.1 C,
Air Out Temp 288 C
X ratio = (333.5 150.5) / (288 36.1) = 0.73
138
X-Ratio - factors
moisture in coal, air infiltration, air & gas mass flow rates
leakage from the setting
specific heats of air & flue gas
X-ratio does not provide a measure of thermal performance of the air

heater, but is a measure of the operating conditions.
LOW X-ratio due to

1. Excessive gas weight through the air heater or that air flow is
bypassing the air heater.
2. High air leakage through Boiler setting.
LOW X-ratio leads to a higher than design gas outlet temperature &
can be used as an indication of excessive tempering air to the mills or
excessive boiler setting infiltration.
139
Pressure drops across air heater
Air & gas side pressure drops change approximately in proportion to

the square of the gas & air weights through the air heaters.
If excess air is greater than expected, the pressure drops will be greater
than expected.
Deposits / choking of the basket elements would lead to an increase in
pressure drops
Pressure drops also vary directly with the mean absolute temperatures
of the fluids passing through the air heaters due to changes in density.
140
AH Performance Monitoring
O2 & CO2 in FG at AH Inlet

O2 & CO2 in FG at AH Outlet
Temperature of gas entering / leaving air heater
Temperature of air entering / leaving air heater
Diff. Pressure across AH on air & gas side
(Above data is tracked to monitor AH performance)
141
Factors affecting APH performance
PA Header Pressure
High pressure results in increased AH leakage,
higher ID fan loading, higher PA fan power
consumption, deteriorates PF fineness & can
increase mechanical erosion
Upstream ash evacuation
No. Of Mills In Service
Air ingress levels
Maintenance practices
Condition of heating elements, seals / seal setting,
sector plates / axial seal plates, diaphragm plates,
casing / enclosure, insulation.
142
MILL
PERFORMANCE
143
MILL PERFORMANCE
The Purpose of a Pulverizer:
.
Must be able to pulverize

consistently the design quantity of
coal suitable for combustion.
Able to dry wet coal up to the
design wetness even at full output
condition.
Able to maintain the products
within the desired grading
The Pulverizers are the HEART of a Pulverized Coal

Fueled Boiler! 144
MILL PERFORMANCE
MILL PERFORMANCE INDICATORS
MILL OUTLET TEMPERATURE

MILL OUT PUT M/T
MILL FINENESS FRACTIONS
MILL AIR FLOW
MILL PRESSURE DROP (D.P)
MILL REJECT RATE
MILL MOTOR AMPERES
WEAR PART LIFE
145
MILL PERFORMANCE
CAUSE OF MILL PERFORMANCE DETORIARATION
QUALITY OF COAL (MOISTUR, HGI ETC.)

UN BALANCED FLOW IN COAL PIPES.
SETTLEMENT OF COAL IN COAL PIPES.
POOR COAL FINENESS
LOW PA TEMPERATURE
FOREIGN MATERIAL INGRESS.
LOSS THROUGH REJECTION
WEAR PART LIFE
146
MILL PERFORMANCE-HGI
Calculate the Hardgrove grindability index using the formula:

HGI = 13 + 6.93 M
where
M = mass of the test sample passing through 75-micron sieve
after grinding. In practice M is obtained by deducting
from 50 g the mass of the ground sample retained on
75-micron sieve.
147
MILL PERFORMANCE
MILL PERFORMANCE - IDENTIFICATION METHODS
NO LOAD RUN
CLEAN AIR FLOW TEST
DIRTY PITOT TUBE TEST
MILL FINENESS SAMPLING
TRENDING OF COAL PIPE METAL
TEMPERATURE
148
MILL PERFORMANCE
OBJECTIVE OF TESTING
CLEAN AIR BALANCING BETWEEN

BURNERS
DIRTY AIR BALANCING BETWEEN BURNERS
FUEL BALANCING BETWEEN BURNERS
FINENESS TESTING OF PF BETWEEN
BURNERS
SETTLEMENT OF COAL PARTICLE IN COAL
PIPE.
149
MILL PERFORMANCE
CLEAN AIR FLOW TESTS

STEPS INVOLVED ARE DETAILED IN THE TEST
PROCEDURE
STANDARD L TYPE PITOT IS USED.
CLEAN AIR FLOW BALANCE IS COMPUTED
BETWEEN COAL PIPES
DEVIATION OF +\- 2% INDICATES A
SATISFACTORY FLOW BALANCE AND FURTHER
TRENDING IS REQUIRED.
150
MILL PERFORMANCE
Dirty pitot tube measuring the two phase mixture of

Coal & Air
151
MILL PERFORMNANCE S TYPE PITOT .
152
MILL PERFORMANCE
153
MILL PERFORMANCE
Acceptance range
Clean air flow distribution to be with in +/-

2.5%.
Dirty air flow distribution to be with in +/-
5.0%.
PF distribution to be with in +/-10%.
Guarantees to be established for end mills
with unequal length in fuel piping
154
MILL PERFORMANCE
ISOKINETIC COAL SAMPLING

The Isokinetic Sampler is used to extract
pulverized coal from (24) points of each coal
pipe (depending on piping size).at as close
to actual velocity entering the sampler
nozzle, as the coal particles were flowing
before collection. This is called Isokinetic
Sampling. The prefix iso means same, and
kinetic means energy or velocity of the
particles. Because the coal particles are
about a thousand times more dense than
air, isokinetic sampling is important to
obtain truly representative coal samples for
sieving.Figure No. 7
155
MILL PERFORMANCE
COAL FINENESS ANALYSIS

FINENESS SAMPLE ANALYSIS NEEDS TO BE
CARRIED OUT IMMEDIATELY TO AVOID
COAGULATION IN CASE OF HIGH MOISTURE
COALS
MINIMUM FOUR STANDARD MESH SCREENS
TO BE USED
TVA DEVELOPED SOFTWARE ENABLES
REVIEW OF MILLS PERFORMANCE DATA TO
FOCUS ON VARIOUS TRENDS
156
MILL PERFORMANCE
Accurate weighing and sieving of the samples through 4 sieves is also important. Why
four sieves? Because, with the desired near zero on 50 mesh sieve, at least three points
are needed on the
Rosin-Rammler Chart to plot the fineness Results. Four sieves of 50, 100, 150 and 200
mesh are recommended for fineness sampling. 157
MILL PERFORMANCE
U.S. MESH INCHES MICRONS MILLIMETERS
50 0.0117 297 0.297

60 0.0098 250 0.250
70 0.0083 210 0.210
80 0.0070 177 0.177
100 0.0059 149 0.149
120 0.0049 125 0.125
140 0.0041 105 0.105
170 0.0035 88 0.088
200 0.0029 74 0.074
230 0.0024 63 0.063
What does mesh size mean? Figuring out mesh sizes is simple. All you do is count the
number of openings in one inch of screen .The number of openings is the mesh size. So a
4-mesh screen means there are four little squares across one linear inch of screen. A 100-
mesh screen has 100 openings, and so on. As the number describing the mesh size
increases, the size of the particles decreases.
158
MILL PERFORMANCE
WHY IS MILL PERFORMANCE TESTING

IMPORTANT?
UNIT CAPABILITY GOVERENED BY MILL
PERFORMANCE
BOILER AND COMBUSTION SYSTEM
PERFORMACE AFFECTED BY QUALITY OF PF
COAL AND ITS DISTRIBUTIION
RELIABLE FEEDBACK SHOULD FOCUS ON
TIMELY MILL OVERHAUL
VERY EFECTIVE CROSS CHECK OF THE
STATION INSTRUMENTS FEEDBACK
159
MILL PERFORMANCE
USE OF METAL TEMPERATURE IN FUEL PIPE TO
MONITOR CHOCKING
FUEL PIPING METAL TEMPERATURE IS BEING MONITORED IN
FARAKA TO MONITOR FUEL PIPE CHOCKING.
RECENT STUDIES SHOWED THAT LOWER THAN MILL OUT LET
TEMPERATURE IS NOT NECESSARILY AN INDICATION OF PIPE
CHOCKING.
DIFFERENCE OF 7 TO 8 C WAS OBSERVED BETWEEN COAL AIR
TEMPERATURE METAL TEMPERATURE FOR A PIPE WHICH
WAS CLEAR.
160
MILL PERFORMANCE
Pulverizer Troubleshooting-Matrix
LACK OF CAPACITY OR HIGH MOISTURE
HIGH POWER LOW GCV
CONSUMPTION INCREASED RAW COAL
SIZE.
GRINDING TOO FINE
EXCESSIVE BED DEPTH
INSTRUMENT ERROR
161
MILL PERFORMANCE
EXCESSIVE MILL REJECTS CHANGE IN COAL

GRINDABILITY, SULFUR &
ASH.
IMPROPER COAL/AIR RATIO
THROAT GAP WEAR.
162
MILL PERFORMANCE
COARSE GRIND CHANGE IN COAL
GRINDABILITY
HIGH MOISTURE
INCREASED THROUGH PUT.
CLASSIFIER SETTING
MILL WEAR.
163
MILL PERFORMANCE
LOW COAL \AIR HIGH MOISTURE
TEMPERATURE LOW PA INLET TEMPERATURE
PASSING OF COLD AIR.
LOW A.H INLET
TEMPERATURE
NON AVAILABILITY OF SCAPH
164
MILL PERFORMANCE
CHANGE IN MILL LOW GRINABILITY

DIFFERENTIAL LOW MOSITURE
MILL INTERNALS PROBLEMS.
165
MILL PERFORMANCE
MILL FIRES HIGH VOLATILES

MOISTURE
LOW COAL\ AIR
TEMPERATURE.
BURNER LINE BALANCE
166
Optimization of
Boiler total air
167
BOILER PERFORMANCE. AIR OPTIMISATION
Concept
Efficient operation of boiler depends on
optimisation of CO2 and O2
This involved elimination of source of air
ingress.
As different losses of boiler is affected by
variation of air, the optimum value is
determined by plotting the total loss and
thereby determining CO2 and O2.
168
Air required for combustion

Theoretical air required =
4.31[8/3 C + 8(H O2/8) + S] Kg/ 100 Kg fuel
Excess air = Theoretical CO2 % / Actual CO2 % - 1
= O2 % X 100 / (21 O2 %)
Theoretical CO2 for
Natural gas 11.7 %
Fuel oil 15.3 %
Bituminous coal 18.6 %
Actual air x actual CO2 % = Th. Air x Th. CO2 %
169
Oxygen % at various locations in boiler
10
6
O2 %
0
Furn Outlet AH Inlet AH Outlet ID outlet
210 MW 210 MW 500 MW 210 MW
170
Air Ingress Points Furnace Roof , Expansion
joints, Air heaters, Ducts, ESP Hoppers, Peep
Holes, Manholes, Furnace Bottom
Air-in-
leakage
Furnace
Outlet
Zirconia
O2 Probe
Expansion Joints
AH ESP
Seal
Lkg
171
Air Ingress Calculations

Air ingress quantification is done with the same formulae as those
used for calculation of AH leakage
Air ingress = O2out - O2in * 0.9 * 100

(21- O2out)
The basis of O2 or CO2 calculation should be the same either wet or dry.
172
Air optimization process

Find Dry gas, unburnt gas, combustible in ash
and auxiliary power (fans) to find the total
loss.
Repeat the same for different test air (% of
CO2 at A/H inlet) settings.
Find the minimum total loss.
Find air setting corresponding to minimum
total loss.
173
174
175
176
MILL PERFORMANCE.FEILD TEST
Specific energy Consumption (Kwh./T of Coal)
SEC Comparision
Acceptable SEC
11.00
10.00
9.00
SEC
8.00
7.00
6.00
5.00
Mill A Mill B Mill C Mill D Mill E Mill F Mill G Mill H Mill J Mill K
Unit-3 7.91 7.63 8.82 7.93 8.05 7.44 7.34 7.52 6.90 7.05
Unit-4 6.29 7.79 6.45 7.54 7.59 7.32 6.21 7.06 7.07 7.25
Unit-5 10.53 7.43 6.48 7.90 7.81 7.78 7.33 7.28 8.15 7.20
Unit-6 10.3 8.8 7.1 6.6 7.0 6.8 7.7 7.6 9.0 10.0177
SEC(PG Test).
PG Test SEC
Unit-3 Unit-4 Unit-5 Unit-6
Mill A 7.8 7.5 7.7 7.8
Mill B 7.7 7.4 7.5 7.5
Mill C 8.0 7.6 7.5 7.6
Mill D 7.6 7.6 7.9 7.8
Mill E 7.9 7.5 7.8 7.8
Mill F 7.9 7.6 7.5 7.9
Mill G 7.7 7.7 7.8 7.6
Mill H 7.6 7.6 7.7 7.8
Mill J 7.9 7.8 7.6 7.5
Mill K 7.8 7.6 7.6 7.6
Standard Deviation 0.148 0.110 0.143 0.15
SD of Audit 0.532 0.560 1.071 1.348
178
Current (Amps)
Acceptable Amp
Current(Amps) Comparision.
140
135
130
125
SEC
120
115
110
105
100
Unit-3 130 130.4 113 131 121 122.9 120 120 132.8 120
Unit-4 113 130.4 113 129 121 124 120 120 124 123.2
Unit-5 134 115 112 129 127 123.4 119 118.4 130.1 115.7
Unit-6 134.0 138.0 117.0 117.0 113.0 118.0 130.0 124.0 131.4 125.1
179
Classifier O/L temp
Clssifier O/L Temp.
85
83
81
79
Temp Degree C
77
75
73
71
69
67
65
Unit-3 78 79 82.2 80.9 79.9 75.6 83.3 82.3 82.5 75.6
Unit-4 74.9 83 74.4 75 78.1 82 82 72 72.5 76.4
Unit-5 81.5 74 74 78.9 76.9 77.9 84 79 82.5 83
Unit-6 73.5 76 75 80 74.9 72.6 73.5 75.2 75.4 76.2
180
Coal Flow (T/hr)
Coal Flow T/hr
70
65
Coal Flow T/hr
60
55
50
45
40
Unit-3 65 65 55 64.2 65 64.5 65.4 59.6 64.9 64
Unit-4 65 60.2 64 62.6 62.59 64.5 62.8 59.6 62.4 60.3
Unit-5 50.8 63.13 64.5 63.4 64.3 63.39 62.5 63.2 62.8 63.5
181
Unit-6 50 61.7 63 65.3 63.4 64.3 62.9 64 60 45.74
Mill Loading
Mill Loading (Percent)
105.00
100.00
95.00
90.00
Percent
85.00
80.00
75.00
70.00
65.00
60.00
Unit-3 97.90 94.48 92.38 96.95 99.62 91.43 91.43 85.33 85.33 85.90
Unit-4 77.90 89.33 78.67 89.90 90.48 89.90 74.29 80.19 84.00 83.24
Unit-5 101.90 89.33 79.62 95.43 95.62 93.90 87.24 87.62 97.52 87.05
182
Unit-6 98.04 103.24 85.14 81.52 84.57 82.86 92.76 92.76 102.48 87.05
P-Air/Coal ratio
183
Mill Fineness.
Mill Finness
77
% Coal through -200
76
75
74
73
72
71
70
A B C D E F G H J K
Unit-3 70 74 73 75 75 71 74 74 74 71
Unit-4 73 71 72 74 73 74 72 71 75 72
Unit-5 74 75 73 71 72 74 74 74 72 74
Unit-6 74 76 74 74 74 72 74 74 71 71
Limits : +50 mesh 1%, -200 mesh 70 %

184
Unit-3 Coal pipe Temp (Degree C)
U3 Pulveriser Pipe Temp
69
67
65
Temp Degree C
63
61
59
57
55
MILL A MILL B MILL C MILL D MILL E MILL F MILL G MILL H MILL J MILL K
Cr-1 63.5 65.2 62.3 63.5 66 66 62 59.8 62.5 64
Cr-2 64 66.5 63 63.5 65.2 65 65 59.8 63 64
Cr-3 65 64.9 63.2 64.5 63.5 65 65 60.2 63.2 65
Cr-4 65 65 63 62.9 64.8 65.3 64 60.2 64.2 65
185
U-4 Pulveriser Pipe Temp

70
65
Temp Degree C
60
55
50
45 Cr-4 Pipe temp was less

Pipe was found choke during Dirty Pitot Test
40
Cr-1 67 65.2 59 63.5 65.8 67 66 65.5 67.8 65
Cr-2 67.5 66.5 59.2 64 64.5 67 68 66.5 69.9 66
Cr-3 68 64.9 60.1 64.2 64.3 68 68 66.4 68.4 65
Cr-4 67.4 67 60.2 64.3 66 67.2 64 67 41.6 66
186
69
67
65
Temp Degree C
63
61
59
57
55
Cr-1 65 67.2 63 60.2 62 62 63 64 63.2 64
Cr-2 66 66.2 63 65.2 62.4 64 64 64 63 64
Cr-3 66 68 65 64.2 63 66 63 60 62.5 64
Cr-4 68 67.4 66 61.7 62.2 63.4 64 64 64.2 65
187

70
65
60
Temp Degree C
55
50
45
40 Cr-4 Pipe temp was less

Pipe was found choke during Dirty Pitot Test
35
Cr-1 62 61 55 60 58 64 63 64 63.2 65
Cr-2 61 62 57 59 59.2 63 64 63 65.5 64
Cr-3 62 60 57 60 59.6 64 63 64 65 64
Cr-4 62 62 57 60 59.6 63.8 64 64 37 64
188
Mill Capacity after Correction for Fineness.
Mill Capacity for Fineness

102
100
98
% of Cpacity
96
94
92
90
88
Unit-3 100 94.8 96.1 93.5 93.5 98.7 94.8 94.8 94.8 98.7
Unit-4 96.1 98.7 97.4 94.8 96.1 94.8 97.4 98.7 93.5 97.4
Unit-5 94.8 93.5 96.1 98.7 97.4 94.8 94.8 94.8 93.5 97.4
Unit-6 94.8 92.2 94.8 94.8 94.8 97.4 94.8 94.8 98.7 98.7
189
Corrected Mill Capacity.
U-3
Moisture HGI FINENESS C1 C2 C3 CF CAP
Design 15 55 70
PG TEST 0.973 1.05 0.95 0.971 63.57
Mill A 19 52 70 0.953 0.97 1 0.924 60.55
Mill B 19 52 74 0.953 0.97 0.948 0.876 57.40
Mill C 19 52 73 0.953 0.97 0.961 0.888 58.19
Mill D 17 52 75 0.976 0.97 0.935 0.885 57.98
Mill E 17 52 75 0.976 0.97 0.935 0.885 57.98
Mill F 17 52 71 0.976 0.97 0.987 0.934 61.20
Mill G 16 52 74 0.984 0.97 0.948 0.905 59.27
Mill H 16 52 74 0.984 0.97 0.948 0.905 59.27
Mill J 16 52 74 0.984 0.97 0.948 0.905 59.27
Mill K 17 52 71 0.976 0.97 0.987 0.934 61.20
Where Correction factor
190
For moisture-C1, For HGI-C2, For fineness-C3, C=C1*C2*C3
Corrected Mill Capacity.
U-6
Moisture HGI FINENESS C1 C2 C3 CF CAP
Design 15 55 70
PG TEST 0.973 1.05 0.95 0.971 63.57
Mill A 17 52 74 0.976 0.97 0.948 0.897 58.79
Mill B 17 52 76 0.976 0.97 0.922 0.873 57.17
Mill C 15 52 74 1 0.97 0.948 0.920 60.23
Mill D 17 52 74 0.976 0.97 0.948 0.897 58.79
Mill E 17 52 74 0.976 0.97 0.948 0.897 58.79
Mill F 17 52 72 0.976 0.97 0.974 0.922 60.40
Mill G 17 52 74 0.976 0.97 0.948 0.897 58.79
Mill H 17 52 74 0.976 0.97 0.948 0.897 58.79
Mill J 17 52 71 0.976 0.97 0.987 0.934 61.20
Mill K 17 52 71 0.976 0.97 0.987 0.934 61.20
191
Velocity Profile Mill-3A
24.0 MILL 3A
22.0
20.0 Cr-1
Velocity of Pulv. Coal in Pipes
Cr-2
18.0 Cr-3
Cr-4
16.0
m/Sec.
Poly. (Cr-1)
Poly. (Cr-2)
14.0
Poly. (Cr-3)
Poly. (Cr-4)
12.0
10.0
0 4 8 12
Travel of Pitot tube.(Num of Points)

192
Velocity Profile Mill-3K
22.0 MILL 3K
Cr-1
20.0
Cr-2
18.0
Cr-3
16.0 Cr-4
m/Sec.
Poly. (Cr-1)
14.0
Poly. (Cr-2)
12.0
Poly. (Cr-3)
10.0 Poly. (Cr-4)

0 4 8 12

193
Velocity Profile Mill-4J
24.0 MILL 4J
Cr-4 was
found choke . Cr-1
22.0
cleared by
purging & Cr-2
Hammering. 20.0
Cr-3
18.0
Cr-4
16.0
m/Sec.
Poly. (Cr-1)
14.0
Poly. (Cr-2)
Cr-4 DP and Velocity Zero
12.0
& Coal Pipe Temp 41.6 Degree C Poly. (Cr-3)
against Other Pipes 69 Degree C
10.0
Poly. (Cr-4)
0 4 8 12

194
PA Fan- Power
PAF-MW
1.6
1.4
1.2
Power(MW)
1
0.8
0.6
0.4
0.2
0
Unit-3 Unit-4 Unit-5 Unit-6
PAF-A 1.263 1.155 1.223 1.37
PAF-B 1.209 1.167 1.204 1.137
PAF-A(PAB) 1.08 1.07 1.09 1.1
PAF-B(PAB) 1.09 1.09 1.1 1.08
195
Coal Predicted Sample1 sample2

For moisture-C1 97.6/100 97.3/100 97/100
For HGI-C2 106/100 105/100 105/100
For fineness-C3 93/100 95/100 95/100
C=C1*C2*C3 0.961 0.970 0.970
196
MIL OPTIMIZATION
Guaranteed Predicted Coal Coal (Avg)*

Coal coal (actual) 20 Samples
Capacity (T/hr) 65.5 -----
moisture 15 14 14-17 15.4
HGI 55 60 62-79 68.5
Fineness 200 70 75 76-87 81.4

mesh
Mill O/L temp 82 82 -
*Samples are tested at CIMFR
197
Mill Capacity Correction Curve
Mill Capacity Vs Grindability Index
HGI limit
198
Mill Capacity Vs Fineness
Fineness limit
199
MILL OPTIMIZATION
Mill Capacity Vs Moisture
200
Pragayan MILL OPTIMIZATION
Power consumption per unit coal transported
Actual for 2009-10 vs PG test St-II
MILL Coal Flow Current Coal Flow CURRENT Current/T/H Current/T/H KW/T/H KW/T/H
A 55 110 64 124 2.00 1.94 8.00 7.75

B 51 116 65 125 2.27 1.92 9.10 7.69
C 56 113 63 126 2.02 2.00 8.07 8.00
D 54 110 65 124 2.04 1.91 8.15 7.63
E 47 114 64 126 2.43 1.97 9.70 7.88
F 50 107 64 127 2.14 1.98 8.56 7.94
G 57 111 65 125 1.95 1.92 7.79 7.69
H 52 107 63 119 2.06 1.89 8.23 7.56
J 53 121 63 125 2.28 1.98 9.13 7.94
K 53 117 64 124 2.21 1.94 8.83 7.75
Power(KW) per T on of Coal
10.00
9.00
KW/hr/Ton coal
8.00
actual
7.00
desired
6.00
5.00
4.00
1 3 5 7 9 11 13 15 17 19 201
THANK YOU
202

Performance Evaluation of Mills, Boiler and Fans in Thermal Power Plants.

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Performance Evaluation of Mills, Boiler and Fans in Thermal Power Plants.

Încărcat de

Drepturi de autor:

Formate disponibile

Introduction of power plant

performance and monitoring, need,

Material Written, compiled and presented by:

For a given power plant, heat rate depends on the plants

Overall Plant/Station efficiency = Output of the station

Boiler efficiency for(RH boiler) B = Steam supplied in kg x Total

Total heat added to feed water in Boiler / kg

Mechanical work output (kcal)

Mechanical work output (kcal)

A & B are the points considered at turbine inlet and outlet

Eenrgy available for conversion into work (kcal)

Thus overall station efficiency = Boiler efficiency x Turbine

Heat supplied to steam in (Kcal) in boiler

Since one 1KW = 860 Kcal

Similarly he can also be reduced by reducing entry losses and no

That is why entry point is always like a funnel or skirt.

So when pumps and fans performance is monitored friction head

Now NPSH = NPSH is a phenomenon at the suction side only. It is

The affinity laws are useful as they allow prediction of the

Law 1c. Power is proportional to the cube of shaft speed:

Q is the volumetric flow rate (e.g. CFM, GPM or

Grades of Coking Coal

Corresponding Gross Calorific Value

A Exceeding 6200 Not exceeding 19.5 Exceeding 6454

Exceeding 6049 but

Exceeding 5597 but

Exceeding 5089 but

Exceeding 4324 but

Exceeding 3865 but

Exceeding 3113 but

The Direct Method Testing

Continuous blow down

Abbreviated Efficiency Tests

Boiler Losses Typical values

Boiler Efficiency 86.63 89

To evolve an optimum operating regime for a boiler

A baseline test is conducted with normal running

HVT - High Velocity Thermocouple Probe

High Volume Sampler

Sampling Point for Flue Gas Temperature & Composition 97

Flue Gas Sampling Train

Flue Gas Duct at APH in/outlet

Typical Boiler Problems

Typical Boiler Problems contd..

Effect of Blade Type on Erosion

Centrifugal Fan Performance Curve.

Scheme of Air and Gas Path

Furnace Pressure At Various Points in Boiler

0 7 Superheater Platen Inlet

-300 I.D. Fan Outlet

Purpose of the Performance Test

Calculation of Velocity: After taking velocity pressures readings, at various

High Leakage of Air to Gas path

Higher Pressure Drop Across APH

APH Soot-blowing Cleaning Problems.

Corrosion Of Cold End Heating Elements

Low APH exit Gas Temperature.

High Leakage of Air to Gas path

Choking Of Heating Elements

Corrosion Of Cold End Heating Elements

1. High sulphur content in fuel

Air Heater - Performance Indicators

(The indices are affected by changes in entering air or gas

C=C1C2C3 0.961 0.970 0.970