Trouble shooting in Boiler

operation & reduction of auxiliary

power consumption

Presented by

S. Sivakumar
AGM- O&M Contracts
Cethar Vessels Ltd, Trichy
 CETHAR VESSELS LIMITED

Leading manufacture of AFBC , CFBC , WHRB for sponge iron kiln

Gas, cement kiln gas ,DG exhaust gas & supply of power plant on
EPC basis for more than two decades .

Tied up with Riley Power Inc, USA for PC fired boilers of sub critical
& super critical pressure. Collaboration with Riley / Siemens Benson
Technology for super critical PC boilers.

Collaboration with Siemens for Super Critical CFBC boilers.

Tied up with OJSC power machineries , Russia for turbine design

and Manufacturing.

Executing O & M contracts of captive power plants of any Capacity

through Cethar energy ltd.

Cethar Vessels Ltd, Trichy 2

 Major projects under execution:

 2x 135 MWe IPP with CFBC Boiler - M/s.Aryan Coal Benification

 2 x 350 MWe PF Fired Boiler - M/s.Ind Barath energy Ltd.



 2 x 350 MWe PF Fired Boiler - M/s.Meenakshi energy Ltd.

 2 x 150 MWe IPP with CFBC Boiler - M/s.Shree cement

 2 x 150 MWe IPP with PF Fired Boiler - M/s.Vandana vidhuyut

 3 x 70 MWe CFBC Boiler - M/s.Jayprakash associates

65 Boilers are under execution for IPP, CPP & Co-gen

10 IPP & Captive power plants are under execution



Cethar Vessels Ltd, Trichy 3

 Credentials

CVL had designed, manufactured, erected and

commissioned more than 1000 FBC boilers.
Based on our versatile experience during
operation and maintenance, we have listed few
problems faced and the causes, solution given
for the information to this elite league

Cethar Vessels Ltd, Trichy 4

 Low steam generation
Identifications Causes
• Low steam pressure, low • Fuel quality
steam flow in the control
• Low air box pressure will
room
lead to high bed
temperature and
limitation in fuel feeding
• Heavy air leakage in the
system and limitation in
combustion air to
furnace.

Cethar Vessels Ltd, Trichy 5

 Low steam generation
Identifications Causes
• Low steam pressure, low • Heavy flue gas leakage
steam flow in the control in the system and
room limitation in ID fan
• Fouling in evaporation
surface.
• Deposition in the
evaporator tubes due to
water chemistry

Cethar Vessels Ltd, Trichy 6

 Low steam temperature
Identifications Causes
• Low steam temperature • Passing of desuper heater
indication in control control valve
room at boiler outlet and
• Low volatile fuel
turbine inlet
• Low bed temperature
operation
• Inadequate “excess air”
operation
• Fouling in super heater

Cethar Vessels Ltd, Trichy 7

 High steam temperature
Identification
• Steam temperature at
boiler outlet and turbine
inlet is more
Cethar Vessels Ltd, Trichy
Causes
• Low feed water
temperature to boiler
• High volatile fuel burning
• High excess of air
• Low air box pressure
• Inadequate de-super
heating
8
 Furnace pressure fluctuation /
positive furnace pressure

Identifications Causes
• Furnace pressure • Instrument calibration and
indication variation in impulse tube attachment intact
control room
• ID fan damper malfunctioning
• Fuel input variation to furnace
• Pressure part leakage

Cethar Vessels Ltd, Trichy 9

 Furnace pressure fluctuation /
positive furnace pressure
Identifications Causes
• Furnace pressure • Fouling in the gas path
indication variation in • Accumulation of ash in gas path
control room and ash chute
• Leakage in flue gas duct and
limitation of ID fan
• Erosion of ID fan impeller

Cethar Vessels Ltd, Trichy 10

 Sagging of Super heaters
Identification Causes
 Visual inspection during  Flame impingement on
shut down super heater during start
up.
 Frequent lifting of Drum
safety valve
 Over heating of super
heater coils due to boiler
operation with clinker

Cethar Vessels Ltd, Trichy 11

 Sagging of Super heaters
Identification Causes
 Visual inspection during  Compartment transfer
shut down without adequate steam
flow
 Boiler operation with more
fuel fines

Cethar Vessels Ltd, Trichy 12

 Boiler operation with clinker
formation
Identification Cause
 Uneven combustor bed  Damage in bed
temperature thermocouples.
 Load raising restriction  Damage of air nozzle.
 Significant variation in air  Fuel nozzle damage
box pressure
 Improper air fuel mixture

Cethar Vessels Ltd, Trichy 13

 Low Air box pressure
Cause
Identification
 FD ducting bellow leakage,
 Low air box pressure with
heavy air leakage in FD
normal bed pressure and
duct, failure of air nozzle and
optimum FD airflow at
leakage in air heater.
MCR
 Inspection and rectification
on the above to be taken up

Cethar Vessels Ltd, Trichy 14

Coal Jamming in PA line / Mixing
nozzle
Cause
Identification
 High moisture, low PA
 Bed Temperature Drop
header pressure at PA line
 High negative furnace shall lead to jamming.
pressure Inspection from coal feeder
to PA line and mixing
 PA line back pressure
nozzle, adequate PA
header air pressure to be
taken care

Cethar Vessels Ltd, Trichy 15

 Frequent tripping of FUEL feeder
Identification Causes
• Trip alarm in DCS. Presence of any foreign
materials and cleaning.
• Bed temperature drop.
High moisture and de-
• High negative furnace choking
pressure
Feeder drive mechanical
arrangement failure and
rectification

Cethar Vessels Ltd, Trichy 16

 Frequent tripping of FUEL feeder
Identification
• Feeder speed showing
zero
• Feeder motor over
load trip.
Causes
Testing condition of motor
Testing the speed control
drive healthiness

Cethar Vessels Ltd, Trichy 17

 Oil firing start up failure
Causes

Identification  Inspection for nozzle choke

&inadequate oil
 No bed temperature rise pressure(6Ksc)
even after 2 hrs of light up  Ensure optimum air box
pressure.
 Ensure proper bed material
size(2.36 to 0.86).
 Ensure appropriate charcoal
size and moisture free
charcoal.
 Inspection of bed condition

Cethar Vessels Ltd, Trichy 18

 High exit flue gas temperature
Identification Causes
• High flue gas • High excess air
temperature at the outlet
• Fouling in evaporator,
of APH
super heater and air pre
heater

Cethar Vessels Ltd, Trichy 19

 High unburnt carbon in ash
Causes
Identification
• Operating the boiler with
• High % LOI in ash as
clinker
per lab report
• Inadequate air supply
• Fuel quality
• High amount of fines in
fuel
• Heavy load fluctuation and
instable furnace condition

Cethar Vessels Ltd, Trichy 20

 High unburnt carbon in ash
Identification
• High % of LOI in ash
Causes
• Low air box pressure
• High PA pressure
• Improper distribution of
fuel in furnace

Cethar Vessels Ltd, Trichy 21

 High Plant Heat Rate
• Identification • Action to be taken

• Steam leakage in boiler and • Steam leakage to be arrested

steam piping • Operating the turbine at
• Low turbine inlet steam design temperature and
pressure and temperature pressure

• Condenser low vacuum • Condenser air ingress to be

rectified
• High exhaust steam
temperature & pressure • HP heater under
performance
• Turbine inspection for
depositions

Cethar Vessels Ltd, Trichy 22

 High Plant Heat Rate
Identification
• Low boiler efficiency
• Low Feed water
temperature
• High turbine wheel
chamber
Cethar Vessels Ltd, Trichy
Action to be taken
• Combustion system
heating surface area to be
checked.
• Rectify air ingress, flue gas
leakage are to be attended.
• Insulation condition to be
checked and rectified.
• Turbine blade failure
causes exhaust steam
temperature
23
 Auxiliary power consumption
reduction

•After plant commissioning and stabilization the design

margin in the equipment shall be optimized by
implementing modification in the system, providing
VFD for the following equipments

Cethar Vessels Ltd, Trichy 24

 Auxiliary power consumption
reduction
• Cooling water pumps
• CEP
• Boiler Feed pumps(case study given)
• Fans(case study given)
• ACC fans

Cethar Vessels Ltd, Trichy 25

 Auxiliary power consumption
reduction
• Optimization of coal handling plant operation

• Optimization of AHP operating and

Compressors

• Optimization of make up water consumption and

WTP operation

Cethar Vessels Ltd, Trichy 26

 Case study I :

Reported issue:

Excess coal consumption

Cethar Vessels Ltd, Trichy 27

Plant design details:

Plant capacity : 1 X 8 MWe co-gen plant

Boiler capacity : 40 TPH

Type of firing : AFBC

Steam pressure : 68 ata

Steam temperature : 495 °C

Cethar Vessels Ltd, Trichy 28

Design Fuel Analysis

Moisture : 13.98%
GCV : 6100 kcal/kg

Cethar Vessels Ltd, Trichy 29

Plant visit was made,boiler operating data,fuel input were
collected and analyzed

Cethar Vessels Ltd, Trichy 30

Boiler data:

Boiler operating capacity : 37.5 TPH

Steam pressure : 68.007 ata

Steam temperature : 495 °C

Feed water temperature : 122°C

Flue gas temperature leaving APH : 132°C

O2 in flue gas is : 4%

Cethar Vessels Ltd, Trichy 31

 Fired fuel analysis and efficiency

GCV : 3950 Kcal/kg

Moisture : 31.50%

Efficiency achieved : 81.7%

Reasons for lower Efficiency:

Excess fired fuel moisture comparing to design fuel

moisture

Lower GCV of fuel comparing to design

Loss in efficiency due to the above is 3.501%

Cethar Vessels Ltd, Trichy 32

Conclusion:

Corrected efficiency is 85.2%

Fuel moisture to be controlled for achieving the

guaranteed thermal Efficiency of the boiler

Expected Fuel saving by controlling moisture is 7.6 TPD

Cethar Vessels Ltd, Trichy 33

 Case study II :

Reported issue:

Excess steam temperature drop

Cethar Vessels Ltd, Trichy 34

Plant design details:

Plant capacity : 1 X 8 MWe

Boiler capacity : 40 TPH

Type of firing : AFBC

Steam pressure : 68 ata

Steam temperature at boiler O/L : 495 °C

Cethar Vessels Ltd, Trichy 35

Steam temperature at T/G I/L : 470°C

Fuel GCV as fired : 3950 Kcal/kg

Boiler efficiency : 82 %

Cethar Vessels Ltd, Trichy 36

Observation:

Design Steam temperature drop : 5°C

Excess Steam temperature drop : 20°C

Excess energy loss by steam : 1.5 TPD

Considering 335 days operation the : 502 MT/year

excess fuel consumption.

Cethar Vessels Ltd, Trichy 37

Conclusion:

Steam line insulation to be rectified.

Steam traps in steam line to be set right.

Cethar Vessels Ltd, Trichy 38

 Case study III :
Reported Issue:

Low thermal Boiler efficiency

Cethar Vessels Ltd, Trichy 39

Design data:

Plant capacity : 1 X 8 MWe

Boiler capacity : 40000 kg/hr

Type of firing : AFBC

Steam pressure : 68 ata

Steam temperature : 495 °C

Cethar Vessels Ltd, Trichy 40

Feed water temperature : 126 ° C

Flue gas temperature leaving APH : 140°C

Air temperature at APH I/L : 40°C

Cethar Vessels Ltd, Trichy 41

PG TEST DATA:

Power generation : 1 X 8 MWe

Boiler capacity : 37,500

kg/hr

Steam pressure : 68 ata

Feed water temperature : 122 ° C

Flue gas temperature leaving APH : 132°C

Air temperature at APH I/L : 38°C

Cethar Vessels Ltd, Trichy 42

Achieved boiler efficiency with : 82 %
Imported coal

% O2 in flue gas : 4.5%

Cethar Vessels Ltd, Trichy 43

Parameters after 12 months of PG test:

Power generation : 8 MWe

Boiler capacity : 38,000 kg/hr

Steam pressure : 67 ata

Steam temperature : 495 ° C

Feed water temperature : 122 ° C

Flue gas temperature after APH : 159 ° C

% O2 in flue gas : 4.5%

Cethar Vessels Ltd, Trichy 44

Results:

Due to increase of flue gas temperature the following

losses have been increased.

1) Dry flue gas loss.

2) Loss due to moisture in flue gas.

3) Loss due to hydrogen in flue gas.

4) Air moisture loss.

Cethar Vessels Ltd, Trichy 45

The overall thermal efficiency reduction is 2%.

Equivalent coal consumption : 4878 kg/day.

Considering 335 day operation : 1635 MT/335day

Coal consumption

Reason:

Fouling in the cold air side of APH due to high moisture

content imported coal .

Rectification:
Periodic inspection and cleaning APH by water Jet.

Cethar Vessels Ltd, Trichy 46

 CASE STUDY-IV

POWER REDUCTION OF BOILER FEEDWATER PUMP

Cethar Vessels Ltd, Trichy 47

 Boiler Details

Boiler capacity : 140 Tph

Steam pressure : 86 kg/cm² (g)
Drum pressure : 98 kg/cm² (g)
Steam temperature : 510°c
Fuel : Baggasse
Type of firing : Traveling grate

Cethar Vessels Ltd, Trichy 48

 Boiler Feed Pump Details

Feed pump capacity : 92.1 Cum/hr

Head : 1231 mwc
Speed : 2980 rpm
No.of pumps : 3 (2w + 1s)
Pump driven by : Motor with VFD
Drum level control by : FCV

Cethar Vessels Ltd, Trichy 49

 Existing operating data

Feed water flow : 144 M3

Feed water temperature : 140°C
Control valve opening : 35%
Pump operating speed : 2900 rpm
Feed water suction pressure : 3.5 kg/cm²
Feed water delivery pressure : 138 kg/cm
Power consumption : 790 Kw (2 pumps working)

Cethar Vessels Ltd, Trichy 50

Initially boiler feed pump was operated at constant
speeds of around 2900 rpm and drum level control was
operated by varying the feed control valve with three
element level control .

Cethar Vessels Ltd, Trichy 51

 MODIFIED DATA :

Feed water flow : 144 m3/hr

Feed water temperature : 140°C
Control valve opening : 100%
Pump speed : (2675 – 2700 ) rpm
Power : 660 kw (2 pumps working)
Power saving : 790 – 660 = 130 Kw

Drum level control was implemented by VFD operation of the

feed pump .The feed control valve was kept 100 % open and
system pressure drop has been reduced from boiler feed pump to
economizer . Based on the drum level VFD speed was varied in
automatic control.

Cethar Vessels Ltd, Trichy 52

 CASE STUDY-V

FD fan motor power consumption reduction

Cethar Vessels Ltd, Trichy 53

 FD Fan Power Saving with VFD
 Boiler Capacity : 40 TPH
 Steam pressure : 68 ata
 Steam Temperature : 485 +-5 Deg CEL
 Type of boiler : AFBC
 FD fan motor : 250kW
 Speed : 1440 rpm
 Fuel : Imported coal
Cethar Vessels Ltd, Trichy 54
 FD Fan Power Saving with VFD
 Initially FD fan was operated without VFD and
the details of operating data are given
 Steam generation : 37.5 TPH
 Power generation : 8 Mwe
 FD fan damper opening : 38%
 Fan speed : 1440 rpm
 Power consumption : 195kW
 O2 in flue gas : 4%
Cethar Vessels Ltd, Trichy 55
 FD Fan Power Saving with VFD
 Data after implementation of VFD for FD fan
 Steam generation : 37.5 TPH
 Power generation : 8 MWe
 FD fan damper opening : 100%
 Fan speed : 1250 rpm
 Power consumption : 160kW
 O2 in flue gas : 4%
Cethar Vessels Ltd, Trichy 56
 FD Fan Power Saving with VFD
 Pressure drop in the damper has been eliminated by
damper full open and the power saving was
achieved through speed control
 Power saving : 35kW / hr
 840 kW/Day
 281400kW for 335 days

Cethar Vessels Ltd, Trichy 57

 FD Fan Power Saving with VFD
 Fuel saving (Plant heat rate of 4050Kcal/kWh
and fired GCV of fuel is 3950 Kcal)
 ---861 kg/day
 --- 26 MT / month
 --- 312 MT / year
 ---12.5 lakhs per annum

Cethar Vessels Ltd, Trichy 58

Any questions please?

Thanks

“CVL”
Cethar Vessels Ltd, Trichy 59