BOILER EFFICIENCY TEST

MANUAL INPUTS
STATION: UNIT: Manual Inputs Unit Load Steam Flow Wet Bulb Temp Dry bulb Temp Barometric Pressure Total Coal Flow Unburnt C in Bottom Ash Unburnt C in Flysash Radiation & Unaccounted Loss % of Flyash to Total Ash % of Bottom ash to Total Ash Proximate - As Fired Moisture Ash Volatile Matter Fixed Carbon Gross Calorific Value Sulfur Avg. Flue Gas O2 - APH In (optional) Avg. Flue Gas CO2 - APH In (optional) Avg. Flue Gas CO - APH In (optional) Avg. Flue Gas O2 - APH Out Avg. Flue Gas CO2 - APH Out Avg. Flue Gas CO - APH Out Avg. Flue Gas Temp - APH In Avg. Flue Gas Temp - APH Out Primary Air to APH Temp In Primary Air from APH Temp Out Secondary Air to APH Temp In Secondary Air from APH Temp Out Total Secondary Air Flow Total Primary Air Flow Design Ambient / Ref Air Temp AH Inlet O2 L/R (UCB) AH Inlet O2 L/R (Local) PAPH-A/B Gas O/L Temp SAPH-A/B Gas O/L Temp Mills in service FW inlet temperature Units MW T/hr C C mmHgC T/hr % % % % % REPORT DATE: TEST DATE: Symbol L Ffw Wb Db BP Fin Cba Cfa Lrad Pfa Pba Value 519.46 1582 24 30 760 300 1.65 0.7 1.2 80 20

% % % % kcal/kg % % % ppm % % ppm C C C C C C T/hr T/hr C % % C C C

M A VM FC Gcv S O2in CO2in COin O2out CO2out COout Tgi Tgo Tpai Tpao Tsai Tsao Fsa Fpa Tref

12.27 33.06 22.9 31.7 3927 0.38 3.5 15.8 39 5 14.3 50 363.9 158 33 329 30.07 333 1202 565 30 3 3.2 164 152.5 ABCD 255.8

Computations

Losses - Test Conditions Ultimate Analysis - As Fired FREE CARBON ON DRY ASH FREE BASIS VOLATILE MATTER ON DRY ASH FREE BASIS FIXED CARBON ON DRY ASH FREE BASIS HYDROGEN ON DRY ASH FREE BASIS NITROGEN ON DRY ASH FREE BASIS Carbon Sulfur Hydrogen Moisture Nitrogen Oxygen Ash Gross Calorific Value

Unit

Symbol FcDc VmDf Cdf Hdf Ndf k

Value 61.76 38.24 83.58 5.33 1.64 0.55 45.68 0.4 2.91 12.3 0.90 4.80 33 3927

% % % % % % % kcal/kg

Ca S H M N O A Gcv

1 Dry Gas Loss = Sh*100/(Gcv*4.186) Carbon in fuel Sulfur in fuel Carbon in ash / kg of fuel Specific heat of gas Avg. Flue Gas Temp - APH Out Unburnt C in ash = Pfa/100*Cfa + Pba/100*Cba Cin ash / kg of coal = A/100*Cash/(100-Cash) Total air flow = SA + PA flow Ratio SA flow to Total Air flow=Fsa/Fta Ratio PA flow to Total Air flow=Fpa/Fta Weighted Temp Air In = Tsai*Rsa + Tpai*Rpa Weighted Temp Air Out = Tsao*Rsa + Tpao*Rpa Avg. Flue Gas CO2 - APH Out Gross CV Weight of dry gas = (Ca+S/2.67100*U)/(12*CO2out) Sensible Heat dry gas = Wd*30.6(Tgo-Trai) 2 Loss due to Unburnt Carbon = U*CVc*100/Gcv Carbon in Ash / kg of coal CV of Carbon Gross CV 3 Loss due to moisture in fuel = Sw*M/(Gcv*4.186) Moisture in Fuel Avg. Flue Gas Temp - APH Out Weighted Temp Air - APH In Gross CV Sensible heat of water vapour Sw = 1.88*(Tgo25)+2442+4.2*(25-Trai)

% % % kg/kg coal kg/kg/C C % kg T/hr % % C C % kcal/kg kg/kg coal kJ/kg

Ldg Ca S U Cp Tgo Cash U Fta Rsa Rpa Trai Tao CO2out Gcv Wd Sh

6.274 45.6823855 0.38 0.00283419 30.6 158 0.85 0.00283 1767 0.68 0.32 31.0 331.720996 14.3 3927 0.2654 1031.31

% kg/kg coal kcal/kg kcal/kg

Luc U CVc Gcv

0.58 0.00283 8077.8 3927

% % C C kcal/kg kJ/kg

Lmf M Tgo Tai Gcv Sw

1.991 12.27 158 31.0 3927.0 2666.81114

4 Loss due to Hydrogen in Fuel =9*H*Sw/(Gcv*4.186) Hydrogen in fuel 5 Loss due to Carbon monoxide = COoutp*7*Cvco*(Ca-100*U) /3 / (CO2out+Cooutp) / Gcv Avg. Flue Gas CO2 - APH Out Avg. Flue Gas CO - APH Out Carbon in fuel CV of Carbon Monoxide Gross CV Carbon in Ash / kg of coal 6 Loss due to moisture in air = Ma*1.88*(Tgo-Trai)*100/(Gcv*4.186) Carbon in fuel Hydrogen in fuel Sulfur in fuel Oxygen in fuel Carbon in ash / kg of fuel Gross CV Moisture in Air Ref.air temp Avg. Flue Gas Temp - APH Out Avg. Flue Gas O2 - APH Out Avg. Flue Gas N2 - APH Out = 100 - (O2outCO2out-Cooutp) Stoichiometric air = (2.66*(CU*100)+7.937*H+0.996*S-O)/23.2 Excess Air = 1+[(O2out-Cooutp/2)]/[0.2682*N(O2out-Cooutp)] Total Moisture in air = Sa*Ea*Mwv

% %

Lhf H

4.25 2.91301463

% % % % kcal/kg kcal/kg kg/kg coal

Lco CO2out Cooutp Ca CVco Gcv U

0.023 14.3 0.005 45.6823855 2415 3927 0.00283419

% % % % % kg/kg coal kcal/kg kg/kg C C % % kg/kg coal

Lma Ca H S O U Gcv Mwv Trai Tgo O2out N2out Sa Ea Ma

0.189 45.6823855 2.91301463 0.38 4.79759439 0.00283419 3927 0.01663626 31.01 158 5 80.7 6.01 1.30 0.1300

Heat Losses (%) Dry Gas Loss Loss due to Unburnt Carbon Loss due to moisture in fuel Loss due to Hydrogen in Fuel Loss due to Carbon monoxide Loss due to moisture in air Radiation & unaccounted Loss BOILER EFFICIENCY % % % % % % % %

PG Test Value 4.8 0.5 2 3.2 0.02 0.11 1.2 88.17

Last Test Value 5 0.5 2.5 3 0.02 0.11 1.2 87.67

Design Conditions Proximate - As Fired Moisture Ash Volatile Matter Fixed Carbon Design Eqv. AH Air inlet temp Ultimate Analysis - As Fired Carbon Sulfur Hydrogen Moisture Nitrogen Oxygen Ash Gross Calorific Value Ambient Temperature Relative Humidity

Unit % % % % C

Symbol Md Ad VMd FCd Trad

Value 13 40 24 23 38

% % % % % % % kcal/kg C %

Cd Sd Hd Md Nd Od Ad Gcvd Tadd RH

37 0.3 2.3 12 0.8 7.6 40 3300 30 60

Gas Temp Leaving AH - Corr to design ambient Ambient Temp - test Ambient Temp - design Ref. Air Temp - test Ref. Air Temp - design = Design Eqv. AH Air inlet temp Gas Temp entering AH - test Gas Temp leaving AH - test Gas Temp leaving AH (Corr) =(Trad*(Tgi-Tgo)+Tgi*(Tgo-Trai)) / (Tgi-Trai)

C C C C C C C

Tad Tadd Trai Trad Tgi Tgo Tgc

30 30 31.01 38.00 363.9 158 162.33

Losses - Corrected to Design 1 Dry Gas Loss =Shc*100/Gcvd/4.186

Ldgc

5.911 37 0.3 0.002834 30.6 162.33 38.00 14.3 3300 0.2146 816.49

Carbon in fuel % Cd Sulfur in fuel % Sd Carbon in ash / kg of fuel kg/kg coal U Specific heat of gas kg/kg/C Cp Avg. Flue Gas Temp - APH Out C Tgc Ref Air Temp - design C Trad Avg. Flue Gas CO2 - APH Out % CO2out Gross CV kcal/kg Gcvd Weight of dry gas = (Cd+Sd/2.67-100*U)/(12*CO2out) kg/kg coal Wdc Sensible Heat dry gas = Wdc*30.6(Tgc-Trad) kJ/kg Shc 2 Loss due to Unburnt Carbon - Corrected = Luc* [(Ad * Gcv) / (A * Gcvd)] +V V = 0 (where volatile matter of fuel > 17 %) If the volatile matter < 17 % then V = .013 * [(Ad * Gcv) / (A * Gcvd)] * Kc Kc = Exp [0.225 * Cd/Hd] Exp [0.225 Ca/Ht] Volatile Matter - test Volatile Matter - design Ash -test Ash -design Test Unburnt Carbon Loss 3 Loss due to moisture in fuel (Corrected) = Sw*Md/(Gcvd*4.186) Moisture in Fuel - design Avg. Flue Gas Temp - APH Out (corr) Ref Air temp - design Gross CV - design Sensible heat of water vapour Sw = 1.88*(Tgc25)+2442+4.2*(25-Trad) 4 Loss due to Hydrogen in Fuel =9*Hd*Swd/(Gcvd*4.186) Hydrogen in fuel - design % % % %

Lucc

0.839393

V Kc VM VMd A Ad Luc

0.060812 3.248931 22.94 24 33.06 40 0.58

% % C C kcal/kg kJ/kg

Lmfc Md Tgc Trad Gcvd Swd

2.298 12 162.33 38.00 3300 2645.572

% %

Lhfc Hd

3.964 2.3

5 Loss due to Carbon monoxide = Cooutp*7*Cvco*(Cd-100*U) /3 / (CO2out+Cooutp) / Gcvd% Avg. Flue Gas CO2 - APH Out Avg. Flue Gas CO - APH Out Carbon in fuel - design CV of Carbon Monoxide Gross CV - design Carbon in Ash / kg of coal 6 Loss due to moisture in air = Mad*1.88*(Tgc-Trad)*100/(Gcvd*4.186)

Lcoc

0.022 14.3 0.005 37 2415 3300 0.00283

% CO2out % Cooutp % Cd kcal/kg CVco kcal/kg Gcv kg/kg coal U

Lmac Cd Hd Sd Od U cvd Mwvd Trad Tgc O2out N2out Sad Ead Mad

0.134 37 2.3 0.3 7.6 0.002834 3300 0.013 38 162.33 5 80.7 4.68 1.30 0.0791

Carbon in fuel - design % Hydrogen in fuel - design % Sulfur in fuel - design % Oxygen in fuel - design % Carbon in ash / kg of fuel kg/kg coal Gross CV - design kcal/kg Moisture in Air (from Psychrometric Chart) kg/kg Ref.air temp - design C Avg. Flue Gas Temp - APH Out (Corr) C Avg. Flue Gas O2 - APH Out % Avg. Flue Gas N2 - APH Out = 100 - (O2out-CO2outCooutp) % Stoichiometric air = (2.66*(CdU*100)+7.937*Hd+0.996*Sd-Od)/23.2 kg/kg coal Excess Air = 1+[(O2out-Cooutp/2)]/[0.2682*N2out(O2out-Cooutp)] Total Moisture in air = Sad*Ead*Mwvd %

BOILER EFFICIENCY TEST - REPORT

STATION: UNIT: TEST CONDITION 1 Unit Load 2 Steam Flow 3 Air flow Flue Gas analysis AH Inlet O2 L/R (UCB) AH Inlet O2 L/R (Local) AH outlet Avg. O2 AH outlet Avg. CO2 MW T/hr T/hr 519.46 1582 1767 4 Coal Flow 5 Mills in service 6 FW inlet temperature Avg. Air Temperatures Design air inlet temp Dry Bulb Temperature Wet Bulb Temperature PAPH Air inlet Temp T/hr Nos. C 300 ABCD 255.8 REPORT DATE: TEST DATE:

1 2 3 4

% % % % ppm C C

3 3.2 5 14.3 50 164 152.5

8 9 10 11

C C C C C C C

30 30 24 33 30.07 329 333

5 AH outlet Avg. CO 6 PAPH-A/B Gas O/L Temp 7 SAPH-A/B Gas O/L Temp Coal - Proximate Analysis 1 2 3 4 5 S.N Moisture Ash Volatile Matter Fixed Carbon GCV Heat Losses (%)

12 SAPH Air inlet Temp 13 PAPH Air outlet Temp 14 SAPH Air Outlet Temp Unburned C in ashes

1 2 3 4 5 6 7

% 12.27 6 Unburnt C in bottom ash % % 33.06 7 Unburnt C in fly ash % % 22.94 % 31.72 kcal/kg 3927 Design Expected Current Test Uncorrected Test Corrected Test Value Value Dry Gas Loss (%) 4.8 6.27 5.91 Loss due to Unburnt Carbon (%) 0.5 0.58 0.84 Loss due to moisture in fuel (%) 2 1.99 2.30 Loss due to Hydrogen in Fuel (%) 3.2 4.25 3.96 Loss due to Carbon monoxide (%) 0.02 0.02 0.02 Loss due to moisture in air (%) 0.11 0.19 0.13 Radiation & unaccounted Loss (%) 1.2 1.20 1.20 88.17 85.49 85.63

1.65 0.65

Last Test Value 5 0.5 2.5 3 0.02 0.11 1.2 87.67

8 BOILER EFFICIENCY TEST SETUP

REMARKS