Professional Documents
Culture Documents
ASSESSMENT OF BOILERS
Heat output
Heat Input
Heat in steam output (kCals)
Heat in Fuel Input (kCals)
Evaporation Ratio
Standards
British standards, BS845: 1987
This describes the methods and conditions under which a boiler
should be tested.Boiler should be operated under steady load
conditions (generally full load) for a period of one hour before taking
reading
ASME Standard: PTC-4-1 Power Test Code for Steam Generating
Units
PartOne:Directmethod(alsocalledasInput-outputmethod)
PartTwo:Indirectmethod(alsocalledasHeatlossmethod)
Boiler Efficiency
6. Surface loss
Boiler
Air
8. Bottom ash loss
Blow down
InstrumentsusedforBoilerPerformance
Assessment.
Instrument
Type
Measurements
Fluegas
analyzer
Portableorfixed
%CO2,O2andCO
Temperature
indicator
Thermocouple,
liquidinglass
Fueltemperature,fluegas
temperature,combustion
airtemperature,boiler
surfacetemperature,
steamtemperature
Draftgauge
Manometer,
differential
pressure
Amountofdraftusedor
available
TDSmeter
Conductivity
BoilerwaterTDS,feed
waterTDS,make-upwater
TDS.
Flowmeter
Asapplicable
Steamflow,waterflow,
fuelflow,airflow
BoilerIDcodeandMake
YearofMake
Boilercapacityrating
TypeofBoiler
Typeoffuelused
Maximumfuelflowrate
EfficiencybyGCV
Steamgenerationpressure&superheattemperature
Heattransferareainm2
10
Isthereanywasteheatrecoverydeviceinstalled
11
Typeofdraft
12
Chimneyheightinmetre
Fuel Fired
GCV of fuel
Specific gravity of fuel (Liquid)
Bulk density of fuel (Solid)
Proximate Analysis
Date of Test:
Fixedcarbon
Volatilematter
Ash
Moisture
Ultimate Analysis
Carbon
Date of Test:
Hydrogen
Sulphur
Nitrogen
Ash
Moisture
Oxygen
WaterAnalysisDateofTest:
FeedwaterTDS
ppm
BlowdownTDS
ppm
PHoffeedwater
PHofblowdown
FluegasAnalysisDateofTest:
CO2
O2
CO
Fluegastemperature
4.Formatsheetforboilerefficiencytesting
Date:
S
.
N
T
i
m
1
.
Ambientair
Dry
bulb
Temp,
o
C
Wet
Bulb
Temp,
o
C
2
.
3
.
4
.
Fuel
T
e
m
p
Flo
w
rat
e,
m3 /
hr
5
.
6
.
7
.
8
.
Fluegas
analysis
Surface
Tempof
boiler,oC
T
e
m
p
O C C
O
2
O
% 2
T
e
m
p
kg
/c
m2
g
Flow
rate,
m3/hr
Steam
T
e
m
p
Boiler Supervisor
Flow
Rate,
kg/hr
Feedwater
Energy Manager
Pr
ess
ur
Energy Auditor
Thedatacollectedare
foraboilerusingcoal
asthefuel.
Findouttheboiler
efficiencybyindirect
method.
= 5599.17 kg/hr
= 21937.5 kg/hr
Steam pressure
= 43 kg/cm2(g)
Steam temperature
= 377 oC
= 96 oC
= 14
= 0.55
= 190 oC
Ambient temperature
= 31 oC
= 70 oC
= 3.5 m/s
= 90 m2
= 800 kCal/kg
= 452.5 kCal/kg
= 90:10
= 8.63
Moisture in coal
= 31.6
Carbon content
= 41.65
Hydrogen content
= 2.0413
Nitrogen content
= 1.6
Oxygen content
= 14.48
GCV of Coal
= 3501 kCal/kg
Moles of C
=
Moles of N2 + Moles of C
Where,
4.84 x 77/100
0.016
Moles of N2
Where moles of C
= 0.4165/12 = 0.0347
28
0.0347
( CO2 )t
=
0.1332 + 0.0347
= 20.67
= 0.1332
28
= 14.0%
7.13 x 77
+ 0.016 +
12
= 7.562 kg / kg of coal
(7.13-4.84) x 23
+
100
100
m x cp x (Tf Ta )
x 100
GCV of fuel
7.562 x 0.23 x (190 31)
=
x 100
3501
L1 = 7.89 %
9 x H2 x {584 + Cp (Tf Ta )}
x 100
GCV of fuel
9 x .02041 x {584 + 0.45(190-31)}
=
x 100
3501
L 2 = 3.44 %
M x {584 + Cp ( Tf Ta )}
X 100
GCV of fuel
0.316 x {584 + 0.45 ( 190 31) }
=
x 100
3501
L3 = 5.91 %
=
3501
L4 = 0.29 %
%CO x %C
5. % Heat loss due to partial
conversion of C to CO (L5)
5744
x
% CO + (% CO2)a
0.55 x 0.4165
GCV of fuel
5744
x
=
0.55 + 14
L 5 = 2.58 %
x 100
3501
100
633.3 w/m2
633.3 x 0.86
544.64 kCal / m2
544.64 x 90
= 49017.6 kCal
= 49017.6 x 100
3501 x 5591.17
= 0.25 %
=
=
=
=
=
=
=
=
=
8.63
90:10
452.5 kCal/kg
0.1 x 0.0863
0.00863 kg
0.00863 x 452.5
3.905 kCal / kg of coal
3.905 x 100 / 3501
0.11 %
800 kCal/kg
0.9 x 0.0863
0.077 kg
0.077 x 800
62.136 kCal/kg of coal
62.136 x 100 / 3501
1.77 %
FactorsAffectingBoiler
Performance
Periodical cleaning of boilers
Periodical soot blowing
Proper water treatment programme and blow down
control
Draft control
Excess air control
Percentage loading of boiler
Steam generation pressure and temperature
Boiler insulation
Quality of fuel