Boiler Auxiliaries Performance

Many steam generating units are operating day after day with efficiencies at or near test condition values. Any unit can operate at these efficiencies with the proper instrumentation , reasonable auxiliaries, proper maintenance program of instrumentation and auxiliary equipment and proper operating instruments. A standard procedure should be established by logging the consumption of individual auxiliaries for different loads. The auxiliaries those need to be monitored for their performance are : Fans and pumps (CC pumps if provided) Fuel burning equipment (coal mills, burners) Wind box dampers (air,fuel,overfire) Air Preheaters Dust collecting equipment (ESP) Soot blowers

Boiler Auxiliaries Performance

There are essentially two different kinds of fans , 1) The centrifugal fan in which gas or air accelerates radially outward in a rotor from heel to tip of blades, discharging into surrounding scroll casing. And 2) The axial flow fan in which the gas or air is accelerated parallel to the fan axis, similar to the ordinary desk fan, but with a casing added to develop static pressure. The axial fans can be a single stage or multiple stage fan. Both the types of fans are used in practice though axial fans with variable blade pitch control are preferred for their part load efficiency . The fans are called Primary Air(PA), Secondary Air(SA), Induced Draft(ID) fans , Gas Recirculation (GR) fans, Seal Air fans, Scanner Air fans and Igniter fans depending on the application of their use. FGD units are provided with booster fans to boost up the pressure. Fan control : To meet varying requirements of the system, common methods of fan output control are damper control, variable-speed control and blade pitch control in case of axial flow fans.

Fan Performance
Fan Efficiency : The energy used by a fan impeller goes into bearing friction, flow work, compression, velocity head, and heating. It is generally assumed in fan work, where the pressures are usually less than 25.5 cm of water plenum or vacuum, that the fluid is incompressible. An ordinary manometer reading on the inlet and outlet of a fan gives the static pressure static pressure relative to the atmosphere. Their difference is the working static pressure of the fan. Similarly an efficient pitot tube turned into the air stream furnishes an indication of the sum of static pressure and velocity head on the attached manometer. This is called total pressure, or dynamic pressure. Static fan efficiency = Static air hp/ Shaft hp.

Fan Performance
Fan performance is best expressed in graphical form. These functional relations are the fan characteristic curves. In these curves capacity in cfm is shown horizontally as the independent variable and head (static pressure), shaft horse power and static efficiency are dependent variables plotted vertically. Fan speed is constant. Since fan operation for a given capacity must match single values of head and horsepower on the characteristic curves, a balance between fan static pressure and system resistance is required. If the system resistance for a given capacity is less than the head indicated on the fan characteristic curve, additional variable flow resistance, such control damper, must be added to the system. Varying the operating speed to yield a family of curves, will change the numerical performance values of the characteristics. However, the nature of the curves remains substantially unaltered. Performance at different speeds for the same efficiency can be related by the following : 1. Capacity is directly proportional to speed. 2. Head is directly proportional to speed squared. 3. Power output is directly proportional to speed cubed.

Fan Performance
System resistance along with the fan static pressure characteristics at various speeds, both as function of volumetric flow rate are plotted. If the fan operates at constant speed, any output less than that shown at the intersection of the system resistance and specified rpm curves must be obtained by throttling the excess fan head. This results in wastage in power that can be avoided by using a variable speed drive. Backwardly curved blade wheels are generally selected for forced draft service because the high speed is suitable for standard motor drive. The power demand is self limiting, and the static efficiency is high. These fans may be satisfactorily operated in parallel. Induced draft fans operate in gas of much higher temperature and may handle gases laden with dust. Forwardly curved blade wheels run at the lowest speed to develop a given pressure, hence are frequently chosen for induced draft service so that the centrifugal stresses in the wheels will be least. The forward curvature reduces the blade depth, but gives a large inlet opening for the gas. conditions.

Fan Performance

The rising horsepower and pressure characteristics of this type usually render it unsuitable for parallel operation , for it can overload its driver under abnormal working conditions. Axial flow designs are found in forced draft service. Fan testing : It is difficult to obtain consistent data from field tests of fans installed in flue and duct systems because straight sections are seldom long enough to eliminate flow disturbances from such things as bends, change in section and dampers. Structural arrangements at the fan entrance and discharge also materially affect field performance results. Manufactures, therefore, generally are reluctant to guarantee fan performance except on the basis of factory tests on a test block arranged for measuring under ideal conditions. However plant engineers may perform fan tests as acceptance test. The pitot static equipment is generally employed, and there should be some provision for test openings. Experience indicates that the velocities in the ducts and breechings vary across the flow, so that the area should be divided

Fan Performance
Into small elements. Rectangular sections are divided into small squares and readings taken at the centre of each. It is the square roots of velocity head readings that are arranged for the calculation of flow velocity, not the readings themselves. On tests where it is not possible to hold the rpm constant, corrections to the readings must be made before comparing results with constant speed guarantees. If N is the rated speed and Nx is the test speed, multiply test volume by N/Nx, test pressure by (N/Nx) square and test powers by (N/Nx) cube before comparing with the ratings. Fan Safety Factors : To make sure that the fans will not limit a boilers performance, margins of safety are added to the calculated or net fan requirements to arrive at satisfactory test block specification. These margins are intended to cover conditions encountered in operation that can be specifically evaluated.

Fan Performance
For example, variation in fuel ash characteristics or unusual operating conditions may foul heating surfaces. The unit then requires additional draft. A need for rapid load increase or a short emergency overload often calls for overcapacity of the fans. The customary margins to allow for such conditions are 15 to 20 % increase in the net weight flow of air or gas, 15to 20% increase in net head, and 25F increase in the air or gas temperature at the fan inlet. General performance requirements for force draft fans. Reliability : Modern boilers must operate continuously for long periods (up to 18 months) without shut down for repairs or maintenance. The fan must be well balanced, and the blades so shaped that they will not collect dirt and disturb this balance. Efficiency : High efficiency over a wide range of output is necessary because boilers operate under varying load conditions. Pressure : Fan pressure should vary uniformly with output over the capacity range. This facilitates damper control and assures minimum disturbance of air flow when minor adjustments to the fuel burning equipment change the system resistance.

Fan Performance
Capacity : When two or more fans operate in parallel, the pressure output curves should have characteristics similar to the straight blade or backward curve blade fans in order to share the load equally near the shut off point. Horsepower : Motor driven fans require self limiting horse power characteristics, so that driving motor cannot overload. This means that the horsepower should reach a peak and drop off near the full load fan output. ID fans : Induced draft fans has the same basic requirements as forced draft fan except that it handles high temperature gas which may contain erosive ash. Flat, forward curved and occasionally backward curved blades with less curvature are used. Excessive maintenance from erosion is sometimes avoided by protecting casing and blades with replaceable wear strips. Bearings, usually water cooled have radiation shields on the shaft between rotor and bearings to avoid overheating.

Typical Fan Characteristic Curves

Control options for centrifugal fans Damper control Lowest capital cost Ease of operation-automatic control List expensive fan drive Continuous, not step operation

Wastage of power

Axial fan-Fixed pitch, adjustable pitch, variable pitch Performance control characteristics Areas of constant efficiencies run parallel to the boiler resistance line-high efficiency over a wide boiler load range Control range is very large both above and below the maximum efficiency The lines of constant blade angle are actually individual fan curvesas the curves are very steep, change in resistance produces very little volume change.

As the blade angle can be adjusted from minimum to maximum flow change is nearly linear

Stall Characteristics
Axial flow fans can experience stall Stall is the aerodynamic phenomena which occurs when a fan operates beyond its performance limit Flow separation occurs Fan operation becomes unstable- normal performance curve not followed Extended operation in the stall region should be avoided

Unpredictable flow vibration can damage rotating blades

Stall Condition. The angular relationship between the air flow impinging on the blade of a fan and the blade itself is known as the angle of attack. In axial flow fan, when this angel exceeds a certain limit, the air flow over the blade separates from the surface and centrifugal force then throws the air outwards, towards the rim of blades. This action causes a build up of pressure at the blade tip, and this pressure increases until it can be relived at the clearance between the tip and the casing. Under this condition the operation of the fan becomes unstable, vibration sets in and the flow starts to oscillate. The risk of stall increases if a fan is oversized or if the system resistance increase excessively.

Stalling of Axial Fans

Stall is aerodynamic phenomenon which occurs when a fan operates beyond its performance limits and flow separation occurs around the blade.

Stall prevention

When axial fans are sized properly and the resistance curve is parabolic chances of stall is less
Possibility of stall increases when the fan is over sized compare to volume capacity, System resistances increases significantly or fans are operated improperly Noise in a Fan Single tone noise is generated when the concentrated flow encounters a stationary object after leaving the rotating blade passage. The distance between the blades and the stationary objects affects the sound The blade passing frequency and its first harmonic is most dominant. Broad band noise is produced by the fluid passing through the fan housing, contains a range of frequencies

Mill Performance
The power consumption of coal mill should be low to minimize operating cost. The main factor of performance depends on (a) the grindability of coal. (b) Surface moisture of coal. (c) the fineness of the grind needed. Grindability : It is a term used to measure the ease of pulverizing a coal in comparison with a standard coal chosen as 100(unity) grindability. Hardgrove index is most often used to measure the grindability of a coal. The method is based on the premise that the work done in pulverizing is proportional to the new surface produced. A definite amount of grinding energy is applied is applied to a prepared sample in a miniature pulverizer (Hardgrove Grindability Machine) and the new surface is determined by sieving. A coal is harder or easier to grind if its grindability index is less or greater. If the coal has grindability index of 50, it would require twice the grinding power of the standard coal to produce a specified particle size.

Mill Performance
The capacity of a pulverizer is related to the grindability index of the coal. High HGI means Less milling power. Mill designed for higher HGI reduces the fineness as well as output while using low HGI coal. Moisture : In order to pulverize and circulate coal pneumatically within a pulverizer, enough of the moisture must be removed to leave the fuel dry and dusty. Preheated air to the pulverizer is required. Drying is accomplished quickly as the coal is being circulated and ground. The use of preheated air permits control of the temperature of the fuel-air mixture to the burners for the most stable ignition. High moisture causes less drying for the same set up and plugging of coal carrying pipes apart from reducing the capacity of the mill.

Mill Performance
Fineness : the fineness of the pulverized coal needed for successful burning depends largely on the ratio of volatile matter(VM) to the fixed carbon. Since the carbon burns slower the VM, low VM coals must be ground finer to expose more surface to permit more coal in a given residence time in the furnace. The finer the grind more the power needed. Moisture makes the coal particle adhere to each other, defeating the purpose of grinding. The coal samples for checking fineness are collected by using bag collector or a cyclone and the results of sieve analysis are plotted on a Rosin and Rammler chart. The mill fineness checks are done periodically to ensure good performance of the mills

ESP Performance
Efficiency of ESP is defined as the ratio of mass of all particles retained by collector (ESP) and the mass of all particles entering collector. The Collection efficiency of ESP is related to the time of particle exposure to the electrostatic field, the strength of the field, and the resistivity of the dust particle. Larger collection-surface areas and lower gas-flow rates increase efficiency because of the increased time available for electrical activity to treat the dust particles. An increase in the dust-particle migration velocity to the collecting electrodes increases efficiency It is easier to collect large particles than smaller particles. Care must be taken to maintain the gas temperature entering the precipitator at or above the design temperature, otherwise local cold spots result in condensation, fouling and rapid corrosion.

ESP PERFORMANCE - PROBLEMS OF ESP

BROKEN WIRES ELECTRODE FAILURE GAS DISTRIBUTION ALIGNMENT PROBLEMS CORROSION BROKEN INSULATORS ELECTRICAL SUPPLY PROBLEMS RAPPING SYSTEM PROBLEMS HOPPERS CHOKING

Boiler auxiliaries performance

Fuel air damper will Maintain the length of the flame. Modulate in proportion to fuel burner pressure or speeder speed. Auxiliary air damper will maintain the furnace to wind box DP. Over fire dampers are used to control NOx Bottom auxiliary damper is used to control unburnt carbon falling in bottom ash hopper RAPH should give the designed secondary and primary air temperatures at all loads and should ensure that the outlet flue gas temperatures are maintained without exceeding the air leakages across seals. The excessive O2 is the indication of airheater leakages and differential pressure measurement across APH on air and flue gas sides indicate the fouling of airpreheaters.