Boiler Performance

BOILER EFFICIENCY
EVALUATION
Performance Evaluation of Boilers
 What are the factors for poor efficiency?

• Efficiency reduces with time, due to poor
combustion, heat transfer fouling and poor operation
and maintenance. Deterioration of fuel and water
quality also leads to poor performance of boiler.
 How Efficiency testing helps to improve

performance?
• Helps us to find out how far the boiler efficiency
drifts away from the best efficiency. Any observed
abnormal deviations could therefore be investigated
to pinpoint the problem area for necessary corrective
action
Boiler Efficiency
 Thermal efficiency of boiler is defined as the
percentage of heat input that is effectively
utilised to generate steam.
There are two methods of assessing boiler efficiency.
1) The Direct Method:
Where the energy gain of the working fluid
(water and steam) is compared with the energy
content of the boiler fuel.
2)The Indirect Method:
Where the efficiency is the difference between
the losses and the energy input.
Test Procedure
 Plan / inform the concerned dept.
 All the Instrument should be calibrated
 Ensure fuel and water availability
 Test at maximum steam load condition
 Conduct 8 hrs minimum (1/2 or 1 hr frequently)
 Water level in drum should be same at start & end
of test
 Gas Sampling point should be proper
 No blow down during test
BOILER EFFICIENCY ASSESSMENT
PRELIMINARY DATA COLLECTION :

o Ultimate analysis of fuel (H2, O2, S, C, moisture
content, ash content)
o Heat content of fuel, GCV in kcal/kg
o Fuel flow, steam or water flow
o Temp & Pressure of steam
o Temperature of water inlet / outlet t of
economizer
o % of CO2 or O2, CO and Temperature from
Flue Gas
o Surface Temp & Ambient Temp
BOILER EFFICIENCY
ASSESSMENT
o Ambient temperature in 0C & humidity of air in
kg/kg of dry air.
o Percentage combustible in ash and GCV of ash (for
solid fuels)
o Amount of blow down
o Size & dimension of boiler
Boiler Efficiency Measurement Procedures
(Direct Method )
(A) BY DIRECT METHOD ( D) :

= Steam Generation X( Enthalpy in Steam - Enthalpy in feed water ) X 100%
Fuel consumption X (Gross Calorific Value of Fuel)
= E. R. X ( Enthalpy in Steam - Enthalpy in feed water ) X 100%

(Gross Calorific Value of Fuel
Where ,
E. R. : Evaporation Ratio ie steam generation
per unit fuel input (T/T or Kgs/Kg).
 Enthalpy of steam : From steam tables at Boiler
per unit (Hs) : Steam Pr. ( Hs = hs + x Ls ) (Kcal/Kg)
 Enthalpy of Feed
water per unit (hfw) : Feed water temp. ( to c) ( Kcal/kg)
Boiler Efficiency Measurement
Procedures
 Net
 Netheat
heatOutput
Outputfrom
fromBoiler
Boiler per perunit
unit
::((HHss––hhfwfw))((Kcal/kg)
Kcal/kg)
 G.
 G.C.
C.V.
V.of
of Fuel
Fuel::Heating
Heatingvalue valueof offuel
fuel((Kcals/Kg)
Kcals/Kg)
--LDO
LDO ::10500
10500 Kcals/Kg
Kcals/Kg
--FO
FO ::10200
10200 Kcals/Kg
Kcals/Kg
--LSHS
LSHS ::10400
10400Kcals/Kg
Kcals/Kg
--Natural
NaturalGas
Gas :: 9350 9350 Kcals/
Kcals/Nm Nm33
--Coal
Coal :: From
FromUltimate
UltimateAnalysis
Analysis
Therefore, Boiler Efficiency (Direct ) ;

D = E. R. X ( Enthalpy in Steam - Enthalpy in F.W. ) X 100%
(Gross Calorific Value of Fuel
Boiler Efficiency Calculations
( by Direct Method )
Example:
Type of boiler: Coal fired Boiler
 Heat input data
 Qty of coal consumed : 1.8 TPH
 GCV of coal : 3200 KCals/kg
 Heat output data

 Qty of steam generated : 8 TPH
 Steam pressure/temperature : 10 kg/cm 2(g)/1800C
 Enthalpy of steam (sat) at 10
kg/cm2(g) pressure . 665 K.Cal/kg
 Feed water temperature : 85 0 C
 Enthalpy of feed water : 85 K.Cal/kg
( by Direct Method )
 Boiler efficiency (D): = ( Q ) x (H – h) x 100%
(q) x (GCV)
Where
 Q = Quantity of steam generated per hour (kg/hr)
 q = Quantity of fuel used per hour (kg/hr)
 E.R.= Evaporation Ratio( Q/q )
 H = Enthalpy of saturated steam (kcal/kg)
 h = Enthalpy of feed water (kcal/kg)
 GCV = Gross calorific value of the fuel (kcal/kg)
 Boiler efficiency (D) = 8 TPH x1000Kg/Tx (665–85) x 100

1.8 TPH x 1000Kg/T x 3200
= 80.0%
 Evaporation Ratio = 8 Tonne of steam/1.8 Ton of coal
= 4.4
Procedures
(B) BYIN DIRECT METHOD ( ID) : [100 – (Sum of losses)]
Steam Output
1. Dry Flue gas loss
2. H2 loss
6. Surface loss 3. Moisture in fuel
4. Moisture in air
5. CO loss
7. Fly ash loss

Fuel Input, 100%
Boiler Flue gas
Air
8. Bottom ash loss
Efficiency = 100 – (1+2+3+4+5+6+7+8)

(by In Direct Method)
Procedures ( Indirect Method )
Data requirement for measuring Boiler Efficiency

(Indirect):
o Chemical constituents of fuel :
 ( C%,S%.M%,H%,O% & VM%,A%, )
 For Solid fuels : Proximate & Ultimate Analysis
 For Liquid/Gaseous fuels : Standard figures
o Constituents in ash samples (for solid fuels) :
 Combustibles in ash during Trial : Ca %
 Gross calorific value of Ash : ACVa Kcal/Kg
o Measurement of flue gas parameters :
 ( CO2 % or O2%)
 ( SO2%, CO%)
 OperationalData
Operational Data::
 Specific
SpecificHumidity
Humidityofofair
air : :Sh
Sh(from
(fromPsychometric
PsychometricChart)
Chart)
 Ambient
Ambientairairtemperature
temperature ((oC) C) :: Ta
Ta
o
 Average
Averageflue
fluegas
gastemperature
temperature((oC) C) : :Tg
Tg
o
 Average
Averageofofoxygen
oxygen% %ininflue
fluegas
gas : :AO
AO2%
2
%
 Excess
Excess Air
Air(Ea)(%)
(Ea)(%) ::(AO
(AO2xx100)/(21-
2
100)/(21-AO
AO)2)
2
 Theoretical or Stoichometric air
 Theoretical or Stoichometric air requiredrequired
(Kg/Kgof
(Kg/Kg of fuel
fuel))
(TAS):=
(TAS) := [11.5
[11.5xxCC++34.5
34.5xx{{HH––(O/8)
(O/8)+4.32
+4.32**(S)]/100
(S)]/100
 Standard
Standardfigures
figures::
--14.1
14.1Kgs
Kgsof
ofair/kg
air/kgof
ofFurnace
FurnaceOil
Oil
--11.54
11.54Kgs
Kgsof
ofair/Kg
air/Kgofofhigh
highcarbon
carboncontent
content(84%)
(84%) Coal
Coal
 Actual
Actualmass
massofofair
airsupplied
supplied Kg/Kg
Kg/Kgof
offuel
fuel
((AAS)
AAS) == ((11++Ea/100)
Ea/100) **TAS
TAS
 HEAT LOSS AREAS :
% Sensible Heat loss in dry flue gas ( Hg) :
= m x Cfg x (Tf - Ta) x 100 [ m= mass of F.gas)
GCV of fuel
 % Heat loss due to Moisture &Hydrogen (Hmh) :
= ( M + 9H) x { 0.45 x Tf- Ta) + 586} x 100
GCV of fuel
 % Heat loss due to Moisture in air ( Hma)
= (AAS) x (Sh) x { 0.448 x (Ts - Ta) x 100
GCV of fuel
 % Heat loss due to combustibles in refuse (ash)
(Hr)
= [{A/(100 - Ca )}x ACV] x 100
GCV of fuel
 % Heat loss due to radiation & Un - accounted
loss (Hua) :
= 5 % of MCR (assume ie 1.5 to 2 %)
 Boiler Efficiency ( Indirect Method) :

ID = 100 - ( Sum of losses )
= 100 - ( Hg + HMh+ Hm+ Hr + Hua) %
( by Indirect Method )
EXAMPLE :
 Type of boiler : Oil fired
o Ultimate analysis of Oil :C- 84.0 %; H2 - 12.0 %
S - 3.0 % ; O2 - 1.0
%
o GCV of Oil : 10200 kcal/kg
o Steam Generation Pressure: 7kg/cm2(g)-sat.
o Enthalpy of steam : 660 kCal/kg
o Feed water temperature : 60oC
o Percentage of Oxygen in flue gas : 7 %
o Percentage of CO2 in flue gas : 11 %
o Flue gas temperature (Tf) : 220 0C

o Ambient temperature (Ta) : 27 0C
o Humidity of air : 0.018 kg/kg of dry air
 Solution
Step-1: Find the theoretical air requirement
=[(11.43 x C) + [{34.5 x (H2 – O2/8)} + (4.32 x )]/100 kg/kg of
oil
=[(11.43 x 84) + [{34.5 x (12 – 1/8)} + (4.32 x 3)]/100 kg/kg of oil
=13.82 kg of air/kg of oil

Step-2: Find the %Excess air supplied
Excess air supplied (EA) = (O2 x 100
(21-O2)
= (7 x 100)/(21-7)
= 50%
Step-3: Find the Actual mass of air supplied
Actual mass of air supplied /kg of fuel : [ 1 + EA/100] xTh. Air
(AAS) = [1 + 50/100] x 13.82
= 1.5 x 13.82
= 20.74 kg of air/kg of oil
Step-4: Estimation of all losses ( Hg )

I Dry flue gas loss == m x Cfg x (Tf - Ta) x 100
GCV of fuel
Total mass of flue gas (m) = mass of actual air supplied
mass of fuel supplied = 20.74 + 1 =21.74
%Dry flue gas loss = 21.74 x 0.23 x (220-27) x 100
10200
= 9.46%
2. % Heat loss due to Moisture &Hydrogen (Hmh) :

= ( M + 9H) x { 0.45 x Tf- Ta) + 586} x 100
GCV of fuel
= (0.25 + 9x12 ) x{ 0.45x( 220- 27) + 586 } x 100 = 7.14 %
10200
3. % Heat loss due to Moisture in air ( Hma)

= (AAS) x (Sh) x { 0.448 x (Ts - Ta) x 100
GCV of fuel
= { 20.74 x (0.018)x(0.448 x (220-27) x 100 = 0.31 %
10200
4. % Heat loss due to radiation & Un - accounted loss (Hu)

= 2 %( assumed for a small boiler )
Boiler Efficiency ( Indirect Method) :
ID = 100 - ( Hg + Hmh+ Hm+ Hr + Hua) %
= 100 – ( 9.46 + 7.14 + 0.31 + 2.0 ) %
= 81 %

Boiler Performance

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BOILER EFFICIENCY

 What are the factors for poor efficiency?

 How Efficiency testing helps to improve

PRELIMINARY DATA COLLECTION :

(A) BY DIRECT METHOD ( D) :

= E. R. X ( Enthalpy in Steam - Enthalpy in feed water ) X 100%

Therefore, Boiler Efficiency (Direct ) ;

 Heat output data

 Boiler efficiency (D) = 8 TPH x1000Kg/Tx (665–85) x 100

7. Fly ash loss

Efficiency = 100 – (1+2+3+4+5+6+7+8)

Data requirement for measuring Boiler Efficiency

 Boiler Efficiency ( Indirect Method) :

o Flue gas temperature (Tf) : 220 0C

=13.82 kg of air/kg of oil

Step-4: Estimation of all losses ( Hg )

2. % Heat loss due to Moisture &Hydrogen (Hmh) :

3. % Heat loss due to Moisture in air ( Hma)

4. % Heat loss due to radiation & Un - accounted loss (Hu)

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