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Effective Operation & Maintenance
Practices - Boilers
Na RAGHU
TPS
TECHNOPLUS SERVICES
PLOT NO.18, SURESH NAGAR MAIN ROAD, VALASARAVAKKAM, CHENNAI 600087,
TELEFAX: +91 44 24868464 Website: www.technoplusservices.com
Boiler Capacity
Calculate the actual output of 5TPH ,17.5kg/cm^2, F@A at 100 boiler, where feed water temperature is 30
deg C
5000 * 540 / (Enthalpy of steam at 17.5 feed water temp.)
= 5000 * 540 / (667.5-30) =4235 kg/hr
From this you can observe
observe, if the boiler pressure / feed water temperature changes the output also
changes. Try to give feed water temperature close to 100 deg C to get maximum output.
Do not get confused with efficiency of a boiler.
Efficiency = Output heat / Input Heat and nothing to do with boiler output
Na.Raghu
www.technoplusservices.com
Na.Raghu
www.technoplusservices.com
Blow down should be given based on feed water TDS and Total Alkalinity for Low Pressure boilers
TDS in Boiler water should not exceed 3500ppm and TA should not exceed 700ppm
If feed water is having 450ppm TDS and TA of 300ppm, Calculate % blow down
Based on TA
= 300 / (700-300)=75%
Whichever is higher, blow down should be maintained on the higher value. From this we find 75% of boiler
output should be drained every hour to maintain steam quality and avoid corrosion in boiler.
Na.Raghu
www.technoplusservices.com
Condensate
C
d
t management:
t E
Ensure condensate
d
t is
i recovered
d and
d pumped
d
back to the feed water tank. Higher the feed water temperature better the
efficiency.
Avoid group trap
trap. Provide autoamtic air vent in pipe line and process
process.
Quality of condensate water should be checked.
Install plate heat exchanger or shell and tube heat exchanger to recover the
heat if contamination is noticed or from p
process heat.
Steam pipe should be sized properly.
Boilers available in the market are 10.54 / 17.5 bar. (standard boilers)
If yyour operating
p
gp
pressure is 4 bar or less than 4 bar,, consider installing
g
turbine and generate power instead of using PRV.
For existing boilers, consider saturated steam turbine, if super heating is not
viable.
For new boilers, consider a medium pressure boiler with super heater.
COGEN power cost would be approximately Rs2/- per unit.
If the steam load is fluctuating, careful analysis should be done. Installing a
steam accumulator will help.
help
Na.Raghu
www.technoplusservices.com