Asme PTC4 1

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Thefollowinglossesareapplicabletoliquid,gasandsolidfiredboiler
L1Lossduetodryfluegas(sensibleheat)
L2Lossduetohydrogeninfuel (H
2
)
L3Lossduetomoistureinfuel(H
2
O)
L4Lossduetomoistureinair(H
2
O)
L5Lossduetocarbonmonoxide(CO)
L6Lossduetosurfaceradiation,convectionandotherunaccounted*.
*Losseswhichareinsignificantandaredifficulttomeasure.
Thefollowinglossesareapplicabletosolidfuelfiredboilerinadditiontoabove
L7Unburntlossesinflyash (Carbon)
L8Unburntlossesinbottomash(Carbon)
BoilerEfficiencybyindirectmethod=100(L1+L2+L3+L4+L5+L6+L7+L8)
! 1 - > @=1 8 1 9 ? > & 1 < @5= 1 0 2 : = $ 1 = 2 : = 8 - 9 / 1 > >1 > >8 1 9 ? ( 1 > ? 59 3
Thefollowingparametersneedtobemeasured,asapplicableforthecomputationofboilereffi-
ciencyandperformance.
a) Fluegasanalysis
1. PercentageofCO
2
orO
2
influegas
2. PercentageofCOinfluegas
3. Temperatureoffluegas
b) Flowmetermeasurementsfor
1. Fuel
2. Steam
3. Feedwater
4. Condensatewater
5. Combustionair
c) Temperaturemeasurementsfor
1. Fluegas
2. Steam
3. Makeupwater
4. Condensatereturn
5. Combustionair
6. Fuel
7. Boilerfeedwater
d) Pressuremeasurementsfor
1. Steam
2. Fuel
3. Combustionair,bothprimaryandsecondary
4. Draft
1. EnergyPerformanceAssessmentofBoilers
6 BureauofEnergyEfficiency

e) Watercondition
1. Totaldissolvedsolids(TDS)
2. pH
3. Blowdownrateandquantity
The various parameters that were discussed above can be measured with the instruments
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( 1 > ? : 9 0 5? 5: 9 > - 9 0 $ = 1 / - @? 5: 9 > 2 : = 9 0 5= 1 / ? ! 1 ? 4 : 0 ( 1 > ? 59 3
( 4 1 1 2 2 5/ 51 9 / D ? 1 >? 0 : 1 > 9 : ? - / / : @9 ? 2 : =
Standby losses. Efficiencytestistobecarriedout,whentheboilerisoperatingundera

steady load. Therefore, the combustion efficiency test does not reveal standby losses,
whichoccurbetweenfiringintervals
Blowdownloss. Theamountofenergywastedbyblowdownvariesoverawiderange.
Sootblowersteam. Theamountofsteamusedbysootblowersisvariablethatdependson
thetypeoffuel.
Auxiliary equipment energy consumption. The combustion efficiency test does not
accountfortheenergyusagebyauxiliaryequipments,suchasburners,fans,andpumps.
$ =1 ; - = - ? 5: 9 > - 9 0 ; = 1 / : 9 0 5? 5: 9 > 2 : = ? 1 >? 59 3
Burnthespecifiedfuel(s)attherequiredrate.
Dothetestswhiletheboilerisundersteadyload. Avoidtestingduringwarmingupofboil-
ersfromacoldcondition
Obtainthecharts/tablesfortheadditionaldata.
Determinationofgeneralmethodofoperation
Samplingandanalysisoffuelandash.
Ensuretheaccuracyoffuelandashanalysisinthelaboratory.
Checkthetypeofblowdownandmethodofmeasurement
Ensureproperoperationofallinstruments.
Checkforanyairinfiltrationinthecombustionzone.

9 >? = @8 1 9 ? ( D; 1 ! 1 - >@= 1 8 1 9 ? >
Flue gas analyzer Portable or fixed %CO
2
,O
2
andCO
Temperatureindicator Thermocouple,liquidin Fueltemperature,fluegas
glass temperature, combustion air
temperature,boilersurface
temperature,steamtemperature
Draft gauge Manometer, differential Amount of draft used
pressure or available
TDS meter Conductivity Boiler water TDS, feed water TDS,
make-upwaterTDS.
Flow meter As applicable Steamflow, water flow, fuel flow,
airflow
The various parameters that were discussed above can be measured with the instruments
thataregiveninTable1.1.

7@1 3 - > >- 8 ; 759 3 7: / - ? 5: 9
Itissuggestedthattheexitductoftheboilerbeprobedandtraversedtofindthelocationofthe
zoneofmaximumtemperature.Thisislikelytocoincidewiththezoneofmaximumgasflow
andisthereforeagoodsamplingpointforbothtemperatureandgasanalysis.
# ; ? 5: 9 > : 2 2 7@1 3 - > - 9 - 7D>5>
ChecktheOxygenTestwiththeCarbonDioxideTest
If continuous-reading oxygen test equipment is installed in boiler plant, use oxygen reading.
Occasionallyuseportabletestequipmentthatchecksforbothoxygenandcarbondioxide.Ifthecar-
bondioxidetestdoesnotgivethesameresultsastheoxygentest,somethingiswrong.One(orboth)
ofthetestscouldbeerroneous,perhapsbecauseofstalechemicalsordriftinginstrumentcalibration.
Anotherpossibilityisthatoutsideairisbeingpickedupalongwiththefluegas. Thisoccursifthe
combustiongasareaoperatesundernegativepressureandthereareleaksintheboilercasing.
CarbonMonoxideTest
Thecarbonmonoxidecontentoffluegasisagoodindicatorofincompletecombustionwithall
typesoffuels,aslongastheycontaincarbon. Carbonmonoxideinthefluegasisminimalwith
ordinaryamountsofexcessair,butitrisesabruptlyassoonasfuelcombustionstartstobeincom-
plete.
$ 7- 9 9 59 3 2 : = ? 4 1 ? 1 > ? 59 3
Thetestingistobeconductedforadurationof4to8hoursinanormalproductionday.
Advancedplanningisessentialfortheresourcearrangementofmanpower,fuel,waterand
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Advancedplanningisessentialfortheresourcearrangementofmanpower,fuel,waterand
instrument check etc and the same to be communicated to the boiler Supervisor and
ProductionDepartment.
Sufficientquantityoffuelstockandwaterstoragerequiredforthetestdurationshouldbe
arrangedsothatatestisnotdisruptedduetonon-availabilityoffuelandwater.
Necessarysamplingpointandinstrumentsaretobemadeavailablewithworkingcondition.
LabAnalysisshouldbecarriedoutforfuel,fluegasandwaterincoordinationwithlabper-
sonnel.
Thesteamtable,psychometricchart,calculatoraretobearrangedforcomputationofboil-
erefficiency.
: 571 = 2 25/ 51 9 / D . D 9 0 5= 1 / ? ! 1 ? 4 : 0 - 7/ @7- ? 5: 9 $ = : / 1 0 @= 1 - 9 0 : = 8 @7-
Inordertocalculatetheboilerefficiencybyindirectmethod,allthelossesthatoccurinthe
boilermustbeestablished. Theselossesareconvenientlyrelatedtotheamountoffuelburnt.
Inthiswayitiseasytocomparetheperformanceofvariousboilerswithdifferentratings.
: 9 A1 = >5: 9 2 : = 8 @7- 2 : = ; = : C 58 - ? 1 - 9 - 7D>5> ? : @7? 58 - ? 1 - 9 - 7D>5>
%C = 0.97C+0.7(VM+0.1A)M(0.60.01M)
%H
2
= 0.036C+0.086(VM0.1xA)0.0035M
2
(10.02M)
%N
2
= 2.100.020VM
where C = %of fixed carbon
A = % of ash
VM = %of volatile matter
M = % of moisture

The various losses associated with the operation of a boiler are discussed below with
requiredformula.
1 - ? 7: > > 0 @1 ? : 0 = D 2 7@1 3 - >
Thisisthegreatestboilerlossandcanbecalculatedwiththefollowingformula:
However it is suggested to get a ultimate analysis of the fuel fired periodically from a
reputed laboratory.
Theoretical(stoichiometric)airfuelratioandexcessairsuppliedaretobedeterminedfirst
forcomputingtheboilerlosses.Theformulaisgivenbelowforthesame.
mxC
p
x(Tf-Ta)
L1 = x 100
GCV offuel
Where,
L
1
= %Heatlossduetodryfluegas
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L
1
= %Heatlossduetodryfluegas
m = Massofdryfluegasinkg/kgoffuel
= Combustionproductsfromfuel:CO
2
+SO
2
+Nitrogeninfuel+
Nitrogenintheactualmassofairsupplied+O
2
influegas.
(H
2
O/Watervapourinthefluegasshouldnotbeconsidered)

1 - ? 7: >> 0 @1 ? : 8 : 5> ? @= 1 ; =1 >1 9 ? 59 2 @1 7
Moistureenteringtheboilerwiththefuelleavesasasuperheatedvapour. Thismoisturelossis
madeupofthesensibleheattobringthemoisturetoboilingpoint,thelatentheatofevapora-
tionofthemoisture,andthesuperheatrequiredtobringthissteamtothetemperatureofthe
exhaustgas. Thislosscanbecalculatedwiththefollowingformula
C
p
= SpecificheatoffluegasinkCal/kgC
T
f
= FluegastemperatureinC
T
a
= AmbienttemperatureinC
" : ? 1
: = % @5/ 6 - 9 0 >58 ; 71 / - 7/ @7- ? 5: 9 : 2 . : 571 = 1 2 2 5/ 51 9 / D @>1 ? 4 1 2 : 77: B 59 3
` 58 ; 71 8 1 ? 4 : 0 / - 9 . 1 @>1 0 2 : = 0 1 ? 1 = 8 59 59 3 ? 4 1 0 = D 2 7@1 3 - > 7: >> - > 3 5A1 9 . 1 7: B
mxC
p
x(T
f
T
a
) x100
a)Percentageheatlossduetodryfluegas=
GCV offuel
Totalmassoffluegas(m)/kgoffuel=massofactualairsupplied/kgoffuel+1kgoffuel
" : ? 1 WatervapourisproducedfromHydrogeninfuel,moisturepresentinfuelandairdur-
ingthecombustion.Thelossesduetothesecomponentshavenotbeenincludedinthedryflue
gaslosssincetheyareseparatelycalculatedasawetfluegasloss.
1 - ? 7: >> 0 @1 ? : 1 A- ; : = - ? 5: 9 : 2 B - ? 1 = 2 : = 8 1 0 0 @1 ? : 59 2 @1 7
The combustion of hydrogen causes a heat loss because the product of combustion is water.
Thiswaterisconvertedtosteamandthiscarriesawayheat intheformofitslatentheat.
9xH
2
x{584+C
p
(T
f
T
a
)}
L
2
= x 100
GCV offuel
Where
H
2
= kgofhydrogenpresentinfuelon1kgbasis
C
p
= SpecificheatofsuperheatedsteaminkCal/kgC
T
f
T
a
584 = Latentheatcorrespondingtopartialpressureofwatervapour
Mx{584+C
p
(T
f
T
a
)}
L
3
= X 100
GCV offuel

where
M = kgmoistureinfuel on1kgbasis
C
p
T
f
T
a
584 = Latentheatcorrespondingtopartialpressureofwatervapour
1 - ? 7: >> 0 @1 ? : 8 : 5>? @= 1 ; =1 >1 9 ? 59 - 5=
Vapourintheformofhumidityintheincomingair,issuperheatedasitpassesthroughtheboil-
er.Sincethisheatpassesupthestack,itmustbeincludedasaboilerloss.
Torelatethislosstothemassofcoalburned,themoisturecontentofthecombustionairand
theamountofairsuppliedperunitmassof coalburnedmustbeknown.
Themassofvapourthataircontainscanbeobtainedfrompsychrometricchartsandtypical
valuesareincludedbelow:
= D @7. + 1 ? @7. & 1 7- ? 5A1 @8 50 5? D 57: 3 = - 8 B - ? 1 =
; 1 = 57: 3 = - 8 0 = D
( 1 8 ; G ( 1 8 ; G - 5= @8 50 5? D - / ? : =
20 20 100 0.016
20 14 50 0.008
30 22 50 0.014
40 30 50 0.024
AASxhumidityfactorxC
p
x(T
f
T
a
)x100
L
4
=
GCV offuel
where
AAS = Actual mass of air supplied per kg of fuel
Humidityfactor = kgofwater/kgofdryair
C
p
T
f
T
a
= AmbienttemperatureinC(drybulb)
1 - ? 7: >> 0 @1 ? : 59 / : 8 ; 71 ? 1 / : 8 . @>? 5: 9
Productsformedbyincompletecombustioncouldbemixedwithoxygenandburnedagainwith
afurtherreleaseofenergy. SuchproductsincludeCO,H
2
,andvarioushydrocarbonsandare
generallyfoundinthefluegasoftheboilers. Carbonmonoxideistheonlygaswhoseconcen-
trationcanbedeterminedconvenientlyinaboilerplanttest.
ASME.PTC4.1 .Boiler efficiency test
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Standby losses. Efficiencytestistobecarriedout,whentheboilerisoperatingundera

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