INDEX

1. INTRODUCTION ...................................................................................................... 1
2. TYPE OF BOILER
4
2.1 Fire tube boiler
2.2 Water tube boiler
2.3 Packedage Boiler
2.4 Fluidized Bed Boiler
2.4.1 Atmospheric Fluidized Bed combustion (AFBC) boiler
2.4.2 Pressure Fluidized bed combustion (PFBC) boiler
2.4.3 Atmospheric circulating fluidized bed combustion Boiler
2.5 Pulverized fuel Boiler
2.6 Waste Heat Boiler

3. BOILER
INDUSTRY.10
3.2 Rakhoh Boiler pvt. Ltd.
3.2 Location
3.3 Testing facility

4. ASSESSMENT OF A BOILER..12
4.1 Performance Evaluation of Boiler

4.1.1 Heat Balance
4.1.2 Boiler Efficiency
4.1.3 Direct method of determining boiler efficiency
4.1.4 Indirect method of determining boiler efficiency
4.2 Boiler Blow Down
4.2.1 Type of blow down
4.2.2 Blow down calculation
4.2.2 Benefits of blow down control
4.3 Boiler feed water treatment
4.3.1 Deposit Control
4.3.2 Internal Water treatment
4.3.3 External water treatment
4.3.4 Recommended Boiler and Feed water quality

5. ENERGY EFFICIENCY OPPORTUNITIES ................................................... 21
5.1 Stack temp control
5.2 Feed water Preheating using economizers
5.3 Combustion Air preheating
5.4 Incomplete Combustion
5.5 Excess Air Control
5.6 Radiation and Convection heat loss minimization
5.7 Automatic Blow down control
5.8 Reduction of sealing and soot losses
5.9 Reduction of Boiler steam pressure
5.10 Variable speed control for fans, blower and pumps
5.12 Controlling boiler loading
5.12 Proper Boiler scheduling
5.13 Boiler Replacement


6. OPTION CHECKLIST .......................................................................................... 28
6.1 Periodic task and check outside of the boiler
6.2 Boiler :- Extra items for steam raising and hot water boiler

6.3 Boiler room and plant room
6.5 Water and steam
6.5 Boiler water
6.6 Blow down procedure

7. WORKSHEETS AND OTHER TOOLS .............................................................. 33
7.1 Worksheet
7.1.1 Boiler performance
7.1.2 Data collection sheet
7.2.3 Fuel Analysis sheet
7.2 Boiler Periodic Check list
7.3 General Rules

8.CONCLUSION ......................................................................................................... 39

APPENDIX

BIBLIOGRAPHY

CHAPTER1
INTRODUCTION
This section briefly describes the Boiler and various auxiliaries in the Boiler
Room.
A boiler is an enclosed vessel that provides a means for combustion heat to be
transferred to water until it becomes heated water or steam. The hot water or steam under
pressure is then usable for transferring the heat to a process. Water is a useful and
inexpensive medium for transferring heat to a process. When water at atmospheric
pressure is boiled into steam its volume increases about 1,600 times, producing a force
that is almost as explosive as gunpowder. This causes the boiler to be an equipment that
must be treated with utmost care.
The boiler system comprises of: a feed water system, steam system and fuel
system. The feed water system provides water to the boiler and regulates it automatically
to meet the steam demand. Various valves provide access for maintenance and repair.
The steam system collects and controls the steam produced in the boiler. Steam is
directed through a piping system to the point of use. Throughout the system, steam
pressure is regulated using valves and checked with steam pressure gauges. The fuel
system includes all equipment used to provide fuel to generate the necessary heat. The
equipment required in the fuel system depends on the type of fuel used in the system.
The water supplied to the boiler that is converted into steam is called feed water.
The two sources of feed water are: (1) Condensate or condensed steam returned from the
processes and (2) Makeup water (treated raw water) which must come from outside the
boiler room and plant processes. For higher boiler efficiencies, an economizer preheats
the feed water using the waste heat in the flue gas.




CHAPTER2
TYPES OF BOILER

This section describes the various types of boilers: Fire tube boiler, Water tube
boiler, Packaged boiler, Fluidized bed combustion boiler, Stoker fired boiler, Pulverized
fuel boiler, Waste heat boiler and Thermic fluid heater.

2.1 FIRE TUBE BOILER
In a fire tube boiler, hot gases pass through thetubesand boiler feed water in the
shell side is converted into steam. Fire tube boilers are generally used for relatively small
steam capacities and low to medium steam pressures. As a guideline, fire tube boilers are
competitive for steam rates up to 12,000 kg/hour andpressures up to 18 kg/cm2.
Fire tubeboilers are available for operation with oil, gas or solid fuels. For
economic reasons,most fire tube boilers are of packaged construction (i.e.
manufacturer erected) for all fuels.










2.2 Water Tube Boiler
In a water tube boiler, boiler feed water flows through the tubes and enters the
boiler drum. The circulated water is heated by the combustion gases and converted into
steam at the vapour space in the drum. These boilers are selected when the steam demand
as well as steam pressure requirements are high as in the case of process cum power
boiler / power boilers.
Most modern water boiler tube designsare within the capacity range 4,500
120,000 kg/hour of steam, at very high pressures. Many water tube boilers are of
packaged construction if oil and /or gas are to be used as fuel. Solid fuel fired water
tube designs are available but packaged designs are less common.
The features of water tube boilers are:
Forced, induced and balanced draft provision help to
improve combustion efficiency.
Less tolerance for water quality calls for water treatment
plant.
Higher thermal efficiency levels are possible


2.3 Packaged Boiler
The packaged boiler is so called because it comes as a complete package. Once
delivered to a site, it requires only the steam, water pipe work, fuel supply and electrical
connections to be made to become operational. Package boilers are generally of a shell
type with a fire tube design so as to achieve high heat transfer rates by both radiation and
convection.
The features of packaged boilers are:
Small combustion space and high heat release rate resulting in faster evaporation.

Large number of small diameter tubes leading to good convective heat transfer.
Forced or induced draft systems resulting in good combustion efficiency.
Number of passes resulting in better overall heat transfer.
Higher thermal efficiency levels compared with other boiler.













These boilers are classified based on the number of passes - the number of times
the hot combustion gases pass through the boiler. The combustion chamber is taken, as
the first pass after which there may be one, two or three sets of fire-tubes. The most
common boiler of this class is a three-pass unit with two sets of fire-tubes and withthe
exhaust gases exiting through the rear of the boiler.




2.4 Fluidized Bed Combustion (FBC) Boiler
Fluidized bed combustion (FBC) has emerged as a viable alternative and has
significant advantages over a conventional firing system and offers multiple benefits
compact boiler design, fuel flexibility, higher combustion efficiency and reduced
emission of noxious pollutants such as SO
2
and NO
2
. The fuelsburnt in these boilers
include coal, washer rejects, rice husk, biogases& other agricultural wastes. The fluidized
bed boilers have a wide capacity range- 0.5 T/hr to over 100 T/hr.When an evenly
distributed air or gas is passed upward through a finely divided bed of solid particles such
as sand supported on a fine mesh, the particles are undisturbed at low velocity. As air
velocity is gradually increased, a stage is reached when the individual particles are
suspended in the air stream the bed is called fluidized.
With further increase in air velocity, there is bubble formation, vigorous
turbulence, rapid mixing and formation of dense defined bed surface. The bed of solid
particles exhibits the properties of a boiling liquid and assumes the appearance of a fluid
bubbling fluidized bed.
If sand particles in a fluidized state are heated to the ignition temperatures of coal,
and coal is injected continuously into the bed, the coal will burn rapidly and the bed
attains a uniform temperature. The fluidized bed combustion (FBC) takes place at about
840
0
c to 950
0
c. Since this temperature is much below the ash fusion temperature,
melting of ash and associated problems are avoided.
The lower combustion temperature is achieved because of high coefficient of heat
transfer due to rapid mixing in the fluidized bed and effective extraction of heat from the
bed through in-bed heat transfer tubes and walls of the bed. The gas velocity is
maintained between minimum fluidization velocity and particle entrainment velocity.
This ensures stable operation of the bed and avoids particle entrainment in the gas stream.
Most operational boiler of this type is of the Atmospheric Fluidized Bed
Combustion. (AFBC). This involves little more than adding a fluidized bed combustor to
a conventional shell boiler. Such systems have similarly being installed in conjunction
with conventional water tube boiler.
Coal is crushed to a size of 1 10 mm depending on the rank of coal, type of fuel
fed to the combustion chamber. The atmospheric air, which acts as both the fluidization
and combustion air, is delivered at a pressure, after being preheated by the exhaust fuel
gases. The in-bed tubes carrying water generally act as the evaporator. The gaseous
products of combustion pass over the super heater sections of the boiler flowing past the

economizer, the dust collectors and the air pre-heater before being exhausted to
atmosphere.
2.4.1Pressurized Fluidized Bed Combustion (PFBC) Boiler
In Pressurized Fluidized Bed Combustion (PFBC) type, a compressor supplies the
Forced Draft (FD) air and the combustor is a pressure vessel. The heat release rate in the
bed is proportional to the bed pressure and hence a deep bed is used to extract large
amounts of heat. This will improve the combustion efficiency and sulphur dioxide
absorption in the bed. The steam is generated in the two tube bundles, one in the bed and
one above it. Hot flue gases drive a power generating gas turbine. The PFBC system can
be used for cogeneration (steam and electricity) or combined cycle power generation. The
combined cycle operation (gas turbine & steam turbine) improves the overall conversion
efficiency by 5 to 8 percent.

2.4.2Atmospheric Circulating Fluidized Bed Combustion Boilers
(CFBC)
In a circulating system the bed parameters are
maintained to promote solids elutriationfrom the bed.
They are lifted in a relatively dilute phase in a solids riser,
and a down-comerwith a cyclone provides a return
path for thesolids.There are no steam generation tubes
immersedin the bed. Generation and superheating of steam
takes place in the convection section, water walls,
at the exit of the riser.CFBC boilers are generally more
economical than AFBC boilers for industrial application
requiring more than 75 100 T/hr of steam. For large units,
the taller furnace characteristics of CFBC boilers offers
better space utilization, greater fuel particle and sorbent
residence time for efficient combustion and SO
2
capture,

and easier application of staged combustion techniques
for NO
2
control than AFBC steam generators.
2.5 Pulverized Fuel Boiler
Most coal-fired power station boilers use pulverized coal, and many of the larger
industrial water-tube boilers also use this pulverized fuel. This technology is well
developed, and there are thousands of units around the world, accounting for well over 90
percent of coal-fired capacity.

The coal is ground (pulverized) to a fine powder, so that less than 2 percent is
+300 micrometre (m) and 70-75 percent is below 75 microns, for a bituminous coal. It
should be noted that too fine a powder is wasteful of grinding mill power. On the
other hand, too coarse a powder does not burn completely in the combustion chamber and
results in higher unburnt losses.

The pulverized coal is blown
with part of the combustion air into the
boiler plant through a series of burner
nozzles. Secondary and tertiary air
may also be added. Combustion takes
place at temperatures from 1300-1700
C, depending largely on coal
grade.Particle residence time in the
boiler is typically 2 to 5 seconds, and
the particles must be small enough for
completecombustion to have taken
place during this time.

This system has many
advantages such as ability to fire varying quality of coal, quick responses to changes in
load, use of high pre-heat air temperatures etc.One of the most popular systems for firing
pulverized coal is the tangential firing using four burners corner to corner to create a
fireball at the centre of the furnace.




2.6 Waste Heat Boiler
Wherever the waste heat is available
atmedium or high temperatures,
a waste heat boiler can be installed economically.
Wherever the steam demand is more than the steam
generated during waste heat, auxiliary fuelburners
are also used.If there is no direct use of steam,
the steam may be let down in a steam turbine- generator
setand power produced from it.It is widely used in the heat
recovery from exhaust gases from gas turbineand diesel engine.















CHAPTER3
BOILER INDUSTRY
RAKHOH INDUSRIES PVT.LTD




This section gives the details about RAKHOH INDUSRIES PVT.LTD. Its
the location, mode of transport, capacity and establishment of plant.



3.1 RAKHOH Boilers

RAKHOH is a 30 years old an ISO 9001:2008 Certified Companyby TUV
NORD. It is inprocess of obtaining U STAMP, S STAMP AND R STAMP
THESAME WILL BE AN ADDED FEATHER TO THERE CAP and will further
improve of capabilities to cater the Domestic as well as International market. It is
engaged in manufacturing of wide range of Steam boilers with fuel range
consisting of furnace Oil, LDO, Heavy Fuel Oil, Natural gas and solid fuels like
Coal, Wood, Baggase, Rice Husks etc. It also manufacture Waste Heat
Recovery Systems, Thermic Fluid heaters, Thermic Fluid Steam boiler & Hot
Water Boilers, Coded Pressure Vessels, Storage Tanks, Structural, Water Tube
Boiler Components like, Convection Tubes, Headers, Super Heater Coils,
Economizer Coils, Drums, Boiler accessories like Economizers, Air pre-heaters,
Wind Turbine equipments, carriers and High capacity Tower and Nacelle Lifting
Jigs etc.




3.2 Location

Company is located in the heart of Punes Industrial Area with apresent working
area of 1,00,000 Sq. ft. and is managed andcontrolled by experienced technocrats each of
them follows the corporate philosophy, to achieve the desired goal and also satisfy the

customers.The mainmanufacturing unit of RAKHOH is located at MIDC
Bhosari,Pimrichinchwad,Pune.
3.3. Testing facility
a) Facilities available in house
1). Hydraulic Test up to 500 Kg / Cm2.
2). Pneumatic Test: up to 100 PSI
3). Dye Penentrant Test
4). Soap Bubble Test.
5). Hardness Test.

b) Facilities available on contract
(Lloyds / IBR approved agency)

1. Radiography
2. Ultrasonic Test
3. Magnetic Test
4. Chemical Test
5. Physical Test
6. Heat- Treatment
7. Mechanical Testing
8. Normalizing
9. Sand Blasting


Rakhoh truly adherers to it tagline
WHEN IT COMES TO FUEL ECONOMY. ITS RAKHOH














Heat loss due to dryflue gas
Heat loss due to stem in flue gas
Heat loss due to moisture in fuel
Heat loss due to moisture in air
Heat loss due to unburnt in residue
Heat loss due to radiation & other
unaccounted loss
Heat in steam
Fuel

CHAPTER 4
ASSESSMENT OF A BOILER

This section describes the Performance evaluation of boilers (through the direct
and indirect method including examples for efficiency calculations), boiler blow down,
and boiler water treatment.

4.1. Performance Evaluation of a Boiler
The performance parameters of a boiler, like efficiency and evaporation ratio,
reduces with time due to poor combustion, heat transfer surface fouling and poor
operation and maintenance. Even for a new boiler, reasons such as deteriorating fuel
quality and water quality can result in poor boiler performance. A heat balance helps us
to identify avoidable and unavoidable heat losses. Boiler efficiency tests help us to find
out the deviation of boiler efficiency from the best efficiency and target problem area for
corrective action.
4.1.1 Heat balance
The combustion process in a boiler can be described in the form of an
energy flow diagram. This shows graphically how the input energy from the fuel
is transformed into the various useful energy flows and into heat and energy loss
flows.
12.7% 8.1%
100% BOILER 1.7%
0.3%
2.4%
0.3%
73%
Figure12.TypicalLossesfromCoalFiredBoiler



The thickness of the arrows indicates the amount of energy contained in the
respective A heat balance is an attempt to balance the total energy entering a boiler
against that leaving the boiler in different forms. The following figure illustrates the
different losses occurring for generating steam
The energy losses can be divided in unavoidable and avoidable losses. The goal of a
Cleaner Production and/or energy assessment must be to reduce the avoidable losses, i.e.
to improve energy efficiency. The following losses can be avoided or reduced:
Stack gas losses: Excess air (reduce to the necessary minimum which depends
from burner technology, operation, operation (i.e. control) and maintenance).
Stack gas temperature (reduce by optimizing maintenance (cleaning), load; better
burner and boiler technology).
Losses by unburnt fuel in stack and ash (optimize operation and
maintenance; better technology of burner).
Blow down losses (treat fresh feed water, recycle condensate)
Condensate losses (recover the largest possible amount of condensate)
Convection and radiation losses (reduced by better insulation of the boiler).


Definition of Boiler Efficiency is The percentage of the total absorption heating
value of outlet Steam in the total supply heating value.In other word, it is a rate how
the boiler runs efficiently.
There are two method of assessing boiler efficiency:
1.The Direct Method: The energy gain of the working fluid (Water and Steam) is
compared with the energy content of the boiler fuel.
2.The indirect Method: The efficiency is the difference between the losses and the
energy input.








Methodology

A. Direct Method of determining boiler efficiency
This is also known as input output method due to that fact that it need only the useful
output (steam) and the heat input (i.e. fuel) for evaluating the efficiency.
This efficiency can be evaluated using the formula:
Boiler efficiency = (heat output/heat input) *100
Boiler efficiency = (Q *(h
g
h
f
))/ (q*GCV)*100
Parameters to be monitored for the calculation of boiler efficiency by direct method are:
Quantity of steam generated per hour (Q) in kg/hr.
Quantity of fuel used per hour (q) in kg/hr.
The working pressure (in kg /cm2(g) and superheat temperature (C) , if any
The temperature of feed water (C
0
)
Type of fuel and gross calorific value of the fuel (GCV) in kcal/ kg of fuel
Boiler efficiency = {Q
g
*(hg- h
f
) / q* GCV} * 100
and where
H
g
Enthalpy of saturated steam in kcal/kg of steam
H
f
Enthalpy of feed water in kcal/kg of water

Example
Find out the efficiency of the boiler by direct method with the the data given
below:
Type of boiler: - coal fired
Quantity of steam (dry) generated 10TPH
Steam pressure (gauge)/temp 10kg/cm
2
(g)/180 C
Quantity of cola consumed 2.25TPH
Feed water temperature 85
GCV of coal 3200kcal/kg

Enthalpy of steam at 10 kg/cm
2
pressure 665kcal/kg
Enthalpy of feed water 85 kcal/kg
Boiler efficiency
= [8*(665-85)*1000] / [1.8* 3200*1000]*100 = 80%

It should be noted that boiler may not generate 100% saturated dry steam, and there may
be some amount of wetness in the steam


Advantage of direct method
Plant workers can evaluate quickly the efficiency of boiler
Require few parameters for computations.
Needs few instrument for monitoring.
Easy to compare various evaporation accountable for various efficiency level.

Disadvantage of direct method
Does not give clue to the operator as to why efficiency of the system is lower
Does not calculate various losses accountable for various efficiency level



B. Indirect Method

The reference standards for Boiler Testing at Site using indirect method namely
British Standard, BS 845: 1987 and USA Standard is ASME PTC-4-1 Power Test
Code Steam Generating Units.
The Indirect method is also called as heat loss method. The efficiency can be
arrived at, by subtracting the heat loss fractions from 100. The standards do not include
blow down loss in the efficiency determination process. A detailed procedure for
calculating boiler efficiency by indirect method is given below. However, it may be
noted that the practicing energy mangers in industries prefer simpler calculation
procedures .


The principle losses that occur in a boiler are:
Loss of heat due to dry flue gas.
Loss of heat due to moisture in fuel and combustion air.
Loss of heat due to combustion of hydrogen.
Loss of heat due to radiation.
Loss of heat due to unburnt.

In the above, loss due to moisture in fuel and the loss due to combustion of hydrogen
are dependent on the fuel, and cannot be controlled by design.

The data required for calculation of boiler efficiency using indirect method are:

Ultimate analysis of fuel (H2, O2, S, C, moisture content, ash content).
Percentage of Oxygen or CO2 in the flue gas.
Flue gas temperature in C
0
(Tf).
Ambient temperature in C
0
(Ta) & humidity of air in kg/kg of dry air.
GCV of fuel in kcal/kg.
Percentage combustible in ash (in case of solid fuels).
GCV of ash in kcal/kg (in case of solid fuels).


Solution :

1)Theoretical air requirement
= [(11.6*C) +{ 34.8 * (H
2
O
2
/8)}+ (4.35*S)]/100 kg/kg of fuel

2)Excess Air supplied (EA) = (O
2
%)/(21- O
2%
)* 100


3)Actual mass of air supplied/ kg of fuel (AAS)
= {1 + EA/100} x theoretical air


4) Estimate all heat losses

a) Percentage heat loss due to dry flue gas
= {[m*C
p
*(T
f
-T
a
)]/ GCV of fuel} *100

Where,
m = mass of dry flue gas in kg/kg of fuel
m = Combustion products from fuel: CO2 + SO2 + Nitrogen in fuel + Nitrogen
in the actual mass of air supplied + O2 in flue gas.
(H2O/Water vapor in the flue gas should not be considered)
Cp = Specific heat of flue gas (0.23 kcal/kg C
0
)


b) Percentage heat loss due to evaporation of water formed due to H2 in fuel
= {9* H
2
*{584+ C
p
(T
f
T
a
)}*100/ GCV of fuel

Where,
H
2
kg of H
2
in 1 kg of fuel
Cp Specific heat of superheated steam (0.45 kcal/kg 0C)


c) Percentage heat loss due to evaporation of moisture present in fuel
= (M * {584 + C
p
(T
f
-T
a
)}/ GCV of fuel *100

Where,
M Kg of moisture in 1kg of fuel
Cp Specific heat of superheated steam (0.45 kcal/kg)
0
C


d) Percentage heat loss due to moisture present in air
= {AAS * humidity factor * C
p
* (T
f
-T
a
)}*100/GCV of fuel

Cp Specific heat of superheated steam (0.45 kcal/kg)


e) Percentage heat loss due to unburnt in fly ash
= (Total ash collected /kg of fuel burnt* GCV of fly ash)/
GCV of fuel*100


f) Percentage heat loss due to unburnt in bottom ash
= (Total ash collected /kg of fuel burnt* GCV of bottom ash)/
GCV of fuel *100


g) Percentage heat loss due to radiation and other unaccounted loss
The actual radiation and convection losses are difficult to assess because of
particular emissivity of various surfaces, its inclination, air flow pattern etc. In a
relatively small boiler, with a capacity of 10 MW, the radiation and unaccounted losses
could amount to between 1% and 2% of the gross calorific value of the fuel, while in a
500 MW boiler, values between 0.2% to 1% are typical. The loss may be assumed
appropriately depending on the surface condition.








5) Boiler efficiency and Boiler evaporation ratio

Efficiency of boiler = 100- (a+b+c+d+e+f+g)

Evaporation ratio = heat utilized for steam generation/Heat addition to steam.
Evaporation ratio means kilogram of steam generated per kilogram of fuel consumed.
Typical Ex: Coal fired boiler: 6 (1 kg of coal can generate 6 kg of steam)
Oil fired boiler: 13(1 kg of oil can generate 13 kg of steam)

However, this figure will depend upon type of boiler, calorific value of the fuel and
associated efficiencies.




Example:
The following are the data collected for a typical oil fired boiler. Find out
the efficiency of the boiler by indirect method and Boiler Evaporation ratio.


Type of boiler : Oil fired

Ultimate analysis of Oil
C: 84.0 % H2: 12.0%
S: 3.0 % O2: 1.0 %
GCV of Oil : 1020kcal/kg
Steam Generation Pressure: 7kg/cm2 (g)
-saturated
Enthalpy of steam : 660 Kcal/kg
Feed water temperature: 60oC
Percentage of Oxygen in flue gas: 7
Percentage of CO2 in flue gas : 11
Flue gas temperature (Tf : 220 0C
Ambient temperature (Ta): 27 0C
Humidity of air: 0.018 kg/kg of Dry air


Solution:-

Step-1: Find the theoretical air requirement

= [(11.6*C) + {34.8*(H
2
-O
2
/8)} + (4.35*S)]/100 kg/kg of oil
= [(11.6*84) + {34.8*(12-1/8)} + (4.35*3)]/100 kg/kg of oil

= 14 kg of air /kg of fuel
Step-2: Find the %Excess air supplied

Excess air supplied (EA) = (O
2
%)/ (21-O
2%
)*100
= 7 %/( 21-7)*100
= 50%



Step-3: Find the Actual mass of air supplied

Actual mass of air supplied /kg of fuel = [1 + EA/100] x Theoretical Air
(AAS) = [1 + 50/100] x 14
= 1.5 x 14
= 21 kg of air/kg of oil




Step-4: Estimation of all losses


i. Dry flue gas loss

Percentage heat loss due to dry flue gas = {m*C
p
*(T
f
-T
a
)}/GCV of fuel * 100
m= mass of CO2 + mass of SO2 + mass of N2 + mass of O2
m = (0.84*44/12) + (0.03*64)/32+ (21*77)/100+ ((21-4)*(23/100)7)
m= 21 kg /kg of oil
= (21*0.23*(220-27))/10200*100
=9.57%


ii. Heat loss due to evaporation of water formed due to H2 in fuel
=[(9*H
2
*{584+C
p
(T
f
-T
a
)})/GCV of fuel] /100
Where,
H
2
percentage of H
2
in fuel
= [(9*12*{584+0.45(220-27)})/10200] /100
=7.10%


iii. Heat loss due to moisture present in air

= [(AAS*humidity *C
p
*(T
f
T
a
))/GCV of fuel]/100
= [(21*0.018*0.45*(220-27)/10200]*100
=0.322



iv. Heat loss due to radiation and other unaccounted losses

For a small boiler it is estimated to be 2%






5) Boiler Efficiency and boiler evaporation ratio

i. Heat loss due to dry flue gas: 9.14%
ii. Heat loss due to evaporation of water formed due to H2 in fuel: 7.10 %
iii. Heat loss due to moisture present in air: 0.322 %
iv. Heat loss due to radiation and other unaccounted loss: 2%



Boiler Efficiency

= 100- [9.14+7.10+0.322+2]
= 100 18.56 = 81 (app)


EvaporationRatio

=Heatutilizedforsteamgeneration/Heatadditiontothesteam
=10200x0.83/(660-60)
=14.11(comparedto13foratypicaloilfiredboiler)










CHAPTER
5
ENERGY EFFICIENCY
OPPORTUNITIES


This section includes energy efficiency opportunities related to combustion, heat
transfer, avoidable losses, auxiliary power consumption, water quality and blow down.
Energy losses and therefore energy efficiency opportunities in boilers can be related to
combustion, heat transfer, avoidable losses, high auxiliary power consumption, water
quality and blow down.
The various energy efficiency opportunities in a boiler system can be related to:
1. Stack temperature control
2. Feed water preheating using economizers
3. Combustion air pre-heating
4. Incomplete combustion minimization
5. Excess air control
6. Radiation and convection heat loss avoidance
7. Automatic blow down control
8. Reduction of scaling and soot losses
9. Reduction of boiler steam pressure
10. Variable speed control for fans, blowers and pumps
11. Controlling boiler loading
12. Proper boiler scheduling
13. Boiler replacement


These are explained in the sections below.



5.1 Stack Temperature Control
The stack temperature should be as low as possible. However, it should not be so
low that water vapour in the exhaust condenses on the stack walls. This is important in
fuels containing significant sulphur as low temperature can lead to sulphur dew point
corrosion. Stack temperatures greater than 200C indicates potential for recovery of
waste heat. It also indicates the scaling of heat transfer/recovery equipment and hence the
urgency of taking an early shut down for water / flue side cleaning.


5.2Feed Water Preheating using Economizers

Typically, the flue gases leaving a modern 3-pass shell boiler are at temperatures of
200 to300
o
C. Thus, there is a potential to recover heat from these gases. The flue gas exit
temperature from a boiler is usually maintained at a minimum of 200
o
C, so that the
sulphuroxides in the flue gas do not condense and cause corrosion in heat transfer
surfaces. When a clean fuel such as natural gas, LPG or gas oil is used, the economy of
heat recovery must be worked out, as the flue gas temperature may be well below 200
o
C.
The potential for energy savings depends on the type of boiler installed and the fuel
used. For a typically older model shell boiler, with a flue gas exit temperature of 260
o
C,
an economizer could be used to reduce it to 200
o
C, increasing the feed water temperature
by 15
o
C. Increase in overall thermal efficiency would be in the order of 3 percent. For a
modern 3-pass shell boiler firing natural gas with a flue gas exit temperature of 140
o
C a
condensing economizerwould reduce the exit temperature to 65
o
C increasing thermal
efficiency by 5 percent.



5.3Combustion Air Preheating

Combustion air preheating is an alternative to feed water heating. In order to
improve thermal efficiency by 1 percent, the combustion air temperature must be raised
by 20
o
C. Most gas and oil burners used in a boiler plant are not designed for high air-
preheat temperatures.Modern burners can withstand much higher combustion air preheat,
so it is possible to consider such units as heat exchangers in the exit flue as an
alternative to an economizer, when either space or a high feed water return temperature
make it viable.




5.4Incomplete Combustion Minimization

Incomplete combustion can arise from a shortage of air or surplus of fuel or poor
distribution of fuel. It is usually obvious from the colour or smoke, and must be corrected
immediately.In the case of oil and gas fired systems, CO or smoke (for oil fired systems
only) with normal or high excess air indicates burner system problems. A more frequent
cause of incomplete combustion is the poor mixing of fuel and air at the burner. Poor oil
fires can result from improper viscosity, worn tips, carbonization on tips and deterioration
of diffusers or spinner plates.With coal firing, unburned carbon can comprise a big loss.
It occurs as grit carry-over or carbon-in-ash and may amount to more than 2 percent of
the heat supplied to the boiler. Non-uniform fuel size could be one of the reasons for

incomplete combustion. In chain grate stokers, large lumps will not burn out completely,
while small pieces and fines may block the air passage, thus causing poor air distribution.
In sprinkler stokers, stoker grate condition, fuel distributors, wind box air regulation
and over-fire systems can affect carbon loss. Increase in the fines in pulverized coal also
increases carbon loss.



5.5Excess Air Control

The table below gives the theoretical amount of air required for combustion of
various types of fuel.Excess air is required in all practical cases to ensure complete
combustion, to allow for the normal variations in combustion and to ensure satisfactory
stack conditions for some fuels. The optimum excess air level for maximum boiler
efficiency occurs when the sum of the losses due to incomplete combustion and loss due
to heat in flue gases is minimized. This level varies with furnace design, type of burner,
fuel and process variables. It can be determined by conducting tests with different air fuel
ratios.

THEORETICAL COMBUSTION DATA
COMMON BOILER FUELS
(National Productivity Council, field experience)

Fuel kg of air req./kg
of fuel
CO
2
percent in flue gas
achieved in practice
Solid Fuels
3.3

10-12
Bagasse
Coal (bituminous) 10.7 10-13
Lignite 8.5 9 -13
Paddy Husk 4.5 14-15
Wood 5.7 11.13


Liquid Fuels


13.8


9-14
Furnace Oil
LSHS 14.1 9-14



TYPICAL VALUES OF EXCESS AIR
LEVELS FOR DIFFERENT FUELS
(National Productivity Council, field
experience)

Fuel Type of Furnace or
Burners
Excess Air
(percent by
wt)
Pulverized coal Completely water-cooled furnace for
slag-tap or dry-ash removal
15-20
Partially water-cooled furnace for
dry-ash removal
15-40
Coal Spreader stoker 30-60
Water-cooler vibrating-grate stokers 30-60
Chain-grate and traveling-grate
stokers
15-50
Underfeed stoker 20-50
Fuel oil Oil burners, register type 15-20
Multi-fuel burners and flat-flame 20-30
Natural gas High pressure burner 5-7
Wood Dutch over (10-23 percent through
grates) and Hofft type
20-25
Bagasse All furnaces 25-35
Black liquor Recovery furnaces for draft and soda-
pulping processes
30-40



Controlling excess air to an optimum level always results in reduction in flue gas
losses; for every 1 percent reduction in excess air there is approximately 0.6 percent rise
in efficiency.

Various methods are available to control the excess air:
1. Portable oxygen analyzers and draft gauges can be used to make periodic readings
to guide the operator to manually adjust the flow of air for optimum operation.
Excess air reduction up to 20 percent is feasible.
2. The most common method is the continuous oxygen analyzer with a local
readoutmounted draft gauge, by which the operator can adjust air flow. A further
reduction of 10- 15 percent can be achieved over the previous system.
3. The same continuous oxygen analyzer can have a remote controlled pneumatic

damper positioner, by which the readouts are available in a control room. This
enables an operator to remotely control a number of firing systems
simultaneously.
4. The most sophisticated system is the automatic stack damper control, whose
costis really justified only for large systems.




5.6 Radiation and Convection Heat Loss
Avoidance

The external surfaces of a shell boiler are hotter than the surroundings. The surfaces
thus lose heat to the surroundings depending on the surface area and the difference in
temperature between the surface and the surroundings.
The heat loss from the boiler shell is normally a fixed energy loss, irrespective of the
boiler output. With modern boiler designs, this may represent only 1.5 percent on the
gross calorific value at full rating, but will increase to around 6 percent, if the boiler
operates at only 25 percent output.Repairing or augmenting insulation can reduce heat
loss through boiler walls and piping.



5.7 Automatic Blow down Control
Uncontrolled continuous blow down is very wasteful. Automatic blow down controls
can be installed that sense and respond to boiler water conductivity and pH. A 10 percent
blow down in a 15 kg/cm2 boiler results in 3 percent efficiency loss.


5.8 Reduction of Scaling and Soot Losses
In oil and coal-fired boilers, soot build-up on tubes acts as an insulator against heat
transfer. Any such deposits should be removed on a regular basis. Elevated stack
temperatures may indicate excessive soot build-up. Also same result will occur due to
scaling on the water side. High exit gas temperatures at normal excess air indicate poor
heat transfer performance. This condition can result from a gradual build-up of gas-side
or waterside deposits. Waterside deposits require a review of water treatment procedures
and tube cleaning to remove deposits.
An estimated 1 percent efficiency loss occurs with every 22
o
C increase in stack
temperature.

Stack temperature should be checked and recorded regularly as an indicator of soot
deposits. When the flue gas temperature rises to about 20
o
C above the temperature for a
newly cleaned boiler, it is time to remove the soot deposits. It is therefore recommended
to install a dial type thermometer at the base of the stack to monitor the exhaust flue gas
temperature.
It is estimated that 3 mm of soot can cause an increase in fuel consumption by 2.5
percent due to increased flue gas temperatures. Periodic off-line cleaning of radiant
furnace surfaces, boiler tube banks, economizers and air heaters may be necessary to
remove stubborn deposits.





5.9 Reduction of Boiler Steam Pressure

This is an effective means of reducing fuel consumption, if permissible, by as much
as 1 to 2 percent. Lower steam pressure gives a lower saturated steam temperature and
without stack heat recovery, a similar reduction in the temperature of the flue gas
temperature results.
Steam is generated at pressures normally dictated by the highest pressure /
temperature requirements for a particular process. In some cases, the process does not
operate all the time, and there are periods when the boiler pressure could be reduced. But
it must be remembered that any reduction of boiler pressure reduces the specific volume
of the steam in the boiler, and effectively derates the boiler output. If the steam load
exceeds the rerated boiler output, carryover of water will occur. The energy manager
should therefore consider the possible consequences of pressure reduction carefully,
before recommending it. Pressure should be reduced in stages, and no more than a 20
percent reduction should be considered.





5.10 Variable Speed Control for Fans, Blowers and
Pumps

Variable speed control is an important means of achieving energy savings. Generally,
combustion air control is affected by throttling dampers fitted at forced and induced draft
fans. Though dampers are simple means of control, they lack accuracy, giving poor
control characteristics at the top and bottom of the operating range. In general, if the load
characteristic of the boiler is variable, the possibility of replacing the dampers by a VSD
should be evaluated.

5.11 Controlling Boiler Loading

The maximum efficiency of the boiler does not occur at full load, but at about two-
thirds of the full load. If the load on the boiler decreases further, efficiency also tends to
decrease. At zero output, the efficiency of the boiler is zero, and any fuel fired is used
only to supply the losses. The factors affecting boiler efficiency are:
1. As the load falls, so does the value of the mass flow rate of the flue gases
through thetubes. This reduction in flow rate for the same heat transfer area
reduces the exit flue gas temperatures by a small extent, reducing the sensible heat
loss.
2. Below half load, most combustion appliances need more excess air to burn
the fuelcompletely. This increases the sensible heat loss.

In general, efficiency of the boiler reduces significantly below 25 percent of the rated
load and operation of boilers below this level should be avoided as far as possible.




5.12Proper Boiler Scheduling

Since, the optimum efficiency of boilers occurs at 65-85 percent of full load, it is
usually more efficient, on the whole, to operate a fewer number of boilers at higher loads,
than to operate a large number at low loads.




5.13Boiler Replacement

The potential savings from replacing a boiler depend on the anticipated change in
overall efficiency. A change in a boiler can be financially attractive if the existing boiler
is:
1. Old and inefficient
2. Not capable of firing cheaper substitution fuel
3. Over or under-sized for present requirements
4. Not designed for ideal loading conditions

The feasibility study should examine all implications of long-term fuel availability
and company growth plans. All financial and engineering factors should be considered.
Since boiler plants traditionally have a useful life of well over 25 years, replacement must
be carefully studied.

CHAPTER
6

OPTION CHECKLIST




This section includes the most common options for improving a boilers energy
efficiency.


6.1Periodic tasks and checks outside of the boiler
1. All access doors and plate work should be maintained air tight with effective
gaskets.
2. Flue systems should have all joints sealed effectively and be insulated where
appropriate.
3. Boiler shells and sections should be effectively insulated. Is existing insulation
adequate?If insulation was applied to boilers, pipes and hot water cylinders
several years ago, it is almost certainly too thin even if it appears in good
condition. Remember, it was installed when fuel costs were much lower.
Increased thickness may well be justified.
4. At the end of the heating season, boilers should be sealed thoroughly, internal
surfaceseither ventilated naturally during the summer or very thoroughly sealed
with tray of desiccant inserted. (Only applicable to boilers that will stand idle
between heating seasons)




6.2 Boilers: extra items for steam raising and hot
water boilers

1. Check regularly for build-up of scale or sludge in the boiler vessel or check TDS
of boiler water each shift, but not less than once per day. Impurities in boiler
water are concentrated in the boiler and the concentration has limits that depend
on type of boiler and load. Boiler blow down should be minimized, but consistent
with maintaining correct water density. Recover heat from blow down water.
2. With steam boilers, is water treatment adequate to prevent foaming or
priming andconsequent excessive carryover of water and chemicals into the
steam system?

3. For steam boilers:- are automatic water level controllers operational? The
presence of inter-connecting pipes can be extremely dangerous.
4. Have checks been made regularly on air leakages round boiler inspection
doors, orbetween boiler and chimney? The former can reduce efficiency; the
latter can reduce draught availability and may encourage condensation, corrosion
and smutting.
5. Combustion conditions should be checked using flue gas analyzers at least
twice perseason and the fuel/air ratio should be adjusted if required.
6. Both detection and actual controls should be labeled effectively and checked
regularly.
7. Safety lockout features should have manual re-set and alarm features.
8. Test points should be available, or permanent indicators should be fitted to oil
burners to give operating pressure/temperature conditions.
9. With oil-fired or gas-fired boilers, if cables of fusible link systems for shutdown
due to fire or overheating run across any passageway accessible to personnel, they
should be fitted above head level.
10. The emergency shut down facility is to be situated at the exit door of the boiler
house.
11. In order to reduce corrosion, steps should be taken to minimize the periods when
water return temperatures fall below dew point, particularly on oil and coal fired
boilers.
12. Very large fuel users may have their own weighbridge and so can operate a direct
checkon deliveries. If no weighbridge exists, occasionally ask your supplier to run
via a public weighbridge (or a friendly neighbor with a weighbridge) just as a
check? With liquid fuel deliveries check the vehicles dipsticks?
13. With boiler plant, ensure that the fuel used is correct for the job. With solid fuel,
correct grading or size is important, and ash and moisture content should be as the
plant designeroriginally intended. With oil fuel, ensure that viscosity is correct at
the burner, and check the fuel oil temperature.
14. The monitoring of fuel usage should be as accurate as possible. Fuel stock
measurementsmust be realistic.
15. With oil burners, examine parts and repairs. Burner nozzles should be changed
regularly and cleaned carefully to prevent damage to burner tip.
16. Maintenance and repair procedures should be reviewed especially for burner
equipment,controls and monitoring equipment.
17. Regular cleaning of heat transfer surfaces maintains efficiency at the highest
possible level.
18. Ensure that the boiler operators are conversant with the operational procedures,
especiallyany new control equipment.
19. Have you investigated the possibility of heat recovery from boiler exit gases?
Modern heat exchangers/ remunerators are available for most types and sizes of
boiler.
20. Do you check feed and header tanks for leaking make up valves, correct
insulation or loss of water to drain?
21. The manufacturer may have originally provided the boiler plant with insulation. Is
thisstill adequate with todays fuel costs? Check on optimum thickness.

22. If the amount of steam produced is quite large, invest in a steam meter.
23. Measure the output of steam and input of fuel. The ratio of steam to fuel is the
main measure of efficiency at the boiler.
24. Use the monitoring system provided: this will expose any signs of deterioration.
25. Feed water should be checked regularly for both quantity and purity.
26. Steam meters should be checked occasionally as they deteriorate with time due to
erosion of the metering orifice or pilot head. It should be noted that steam meters
only give correct readings at the calibrated steam pressure. Recalibration may be
required.
27. Check all pipe work, connectors and steam traps for leaks, even in inaccessible
spaces.
28. Pipes not in use should be isolated and redundant pipes disconnected.
29. Is someone designated to operate and generally look after the installation? This
work should be included in their job specification.
30. Are basic records available to that person in the form of drawings,
operationalinstructions and maintenance details?
31. Is a log book kept to record details of maintenance carried out, actual combustion
flue gas readings taken, fuel consumption at weekly or monthly intervals, and
complaints made?
32. Ensure that steam pressure is no higher than need be for the job. When night load
is materially less than day load, consider a pressure switch to allow pressure to
vary over a much wider band during night to reduce frequency of burner cut-out,
or limit the maximum firing rate of the burner.
33. Examine the need for maintaining boilers in standby conditionsthis is
often anunjustified loss of heat. Standing boilers should be isolated on the fluid
and gas sides.
34. Keep a proper log of boiler house activity so that performance can be measured
against targets. When checking combustion, etc. with portable instruments, ensure
that this is done regularly and that load conditions are reported in the log:
percentage of CO
2
at full flame/half load, etc.
35. Have the plant checked to ensure that severe load fluctuations are not caused by
incorrect operation of auxiliaries in the boiler house, for example, ON/OFF feed
control, defective modulating feed systems or incorrect header design.
36. Have hot water heating systems been dosed with an anti-corrosion additive and is
this checked annually to see that concentration is still adequate? Make sure that
this additives NOT put into the domestic hot water heater tank, it will contaminate
water going to taps at sinks and basins.
37. Recover all condensate where practical and substantial savings are possible.


6.3 Boiler rooms and plant rooms

1. Ventilation openings should be kept free and clear at all times and the opening
area should be checked to ensure this is adequate.

2. Plant rooms should not be used for storage, airing or drying purposes.
3. Is maintenance of pumps and automatic valves carried out in accordance with
the manufacturers instructions?
4. Are run and standby pump units changed over approximately once per month?
5. Are pump isolating valves provided?
6. Are pressure/heat test points and/or indicators provided on each side of the pump?
7. Are pump casings provided with air release facilities?
8. Are moving parts (e.g. couplings) guarded?
9. Ensure that accuracy of the instruments is checked regularly.
10. Visually inspect all pipe work and valves for any leaks.
11. Check that all safety devices operate efficiently.
12. Check all electrical contacts to see that they are clean and secure.
13. Ensure that all instrument covers and safety shields are in place.
14. Inspect all sensors, make sure they are clean, unobstructed and not exposed to
unrepresentative conditions, for example temperature sensors must not be
exposed to direct sunlight nor be placed near hot pipes or a process plant.
15. Ensure that only authorized personnel have access to control equipment.
16. Each section of the plant should operate when essential, and should preferably
be controlled automatically.
17. Time controls should be incorporated and operation of the whole plant should,
preferably, be automatic.
18. In multiple boiler installations, isolate boilers that are not required on the waterside
and, ifsafe and possible, on the gas side. Make sure these boilers cannot be fired.
19. Isolation of flue system (with protection) also reduces heat losses.
20. In multiple boiler installations the lead/lag control should have a change round
facility.
21. Where possible, reduction of the system operating temperature should be made with
devices external to the boiler and with the boiler operating under a normal constant
temperature range.


6.4Water and steam
1. Water fed into the boilers must meet the specifications given by the
manufacturers. The water must be clear, colorless and free from suspended
impurities.
2. Hardness nil. Max. 0.25 ppm CaCO3.
3. pH of 8 to 10 retard forward action or corrosion. pH less than 7 speeds up
corrosion due to acidic action.
4. Dissolved O2 less than 0.02 mg/l. Its presence with SO2 causes corrosion
problems.

5. CO2 level should be kept very low. Its presence with O2 causes corrosion,
especially in copper and copper bearing alloys.
6. Water must be free from oilit causes priming


6.5Blow down (BD) procedure

A conventional and accepted procedure for blowing down gauge is as follows:
Close water lock
Open drain cock (note that steam escapes freely)
Close drain cock
Close steam cock
Open water cock
Open drain cock (note that water escapes freely)
Close drain cock
Open steam cock
Open and then close drain cock for final blow through.

Operators should blow these down regularly in every shift, or at least once per day
where boilers are steamed less than 24 hours a day.







6.5 Boiler water
1. Water must be alkalinewithin 150 ppm of CaCO3 and above 50 ppm of CaCO3
at pH.
2. Alkalinity number should be less than 120.
3. Total solids should be maintained below the value at which contamination of
steam becomes excessive, in order to avoid cooling over and accompanying
danger of deposition on super heater, steam mains and prime movers.
4. Phosphate should be no more than 25 ppm P2 O5.
5. Make up feed water should not contain more than traces of silica. There must be
less than 40 ppm in boiler water and 0.02 ppm in steam, as SiO2. Greater amounts
may be carried to turbine blades.
6. Water treatment plants suitable for the application must be installed to ensure
water purity, and a chemical dosing arrangement must be provided to furthe





control boiler water quality. Blow downs should be resorted to when
concentration increases beyond the permissible limits stipulated by the
manufacturers.
7. Alkalinity should not exceed 20 percent of total concentration. Boiler water level
should be correctly maintained. Normally, 2 gauge glasses are provided to ensure
this.




















Maximum Boiler Water Concentrations
recommended by the American Boiler
Manufacturers Association

Boiler Steam Pressure (ata) Maximum Boiler Water
Concentration (ppm)
0-20 3500
20-30 3000
30-40 2500
40-50 2000
50-60 1500
60-70 1250
70-100 1000

CHAPTER 7
WORKSHEETSANDOTHERTOOLS



This section includes worksheets (Boiler Performance; Data Collection Sheet
;FuelAnalysis Sheet) and other tools (Boiler Performance Checklist ; Rules of Thumb;
Dos and Donts)



7.1 Worksheets
7.1.1.Worksheet Boiler:- BOILER PERFORMANCE

No. Parameter reference Units Readings
1
Ultimate Analysis

Carbon
percent 48.54

Hydrogen
percent 3.35

Oxygen
percent 4.42

Sulphur
percent 0.27

Nitrogen
percent 0.88

Moisture
percent 9

Ash
percent 33.66
2 GCV of Fuel K Cal/kg
4200
3 Oxygen in Flue Gas percent
7
4 Flue Gas Temperature(Tf)
0
C

230
5 Ambient Temperature(Ta)
0
C

30
6 Humidity in Air Kg/kg of dry
air
0.018
7 Combustible in Ash percent
17.91
8 GCV of Ash K Cal/kg
452.95(Fly ash)
600 (Bottom ash)

600

9 Excess Air
Supplied(EA)(O2x100)/
(21O2)
percent
31.25
10 Theoretical air requirement (TAR)
[11xC+{34.5x(H2O2/8)}+4.32xS]/100
kg/kg of fuel
6.316
11 Actual mass of air supplied
{1+EA/100}x theoretical air
kg/kg of fuel
9.474
12 Percentage heat loss due to dry flue gas
{k x (TfTa)}/percentCO2
Where,K (Seigertconst.)
= 0.65 for Coal
= 0.56 for Oil
= 0.40forNG
percent
13
13 Percentage heat loss due to evaporation of
water formed due to H2 in fuel
[9xH2{584+0.45(TfTa)}]/GCV of Fuel
percent
4.89
14 Percentage heat loss due to evaporation
of moisture present in fuel
[M x{584+0.45x(TfTa)}]/GCV of Fuel
percent
1.68
15 Percentage heat loss due to moisture present in
air
{AASxHumidityx0.45(TfTa)x100}/GCV of
Fuel
percent
1.2983
16 Percentage heat loss due to combustibles in ash
{Ash x(100
CombInAsh)xGCVofAshx100}/GCV of Fuel
percent
8.42
17 Total Losses percent
31.28

18 Efficiency percent
68.72

7.1.2 Worksheet Boiler 3 : FUEL ANALYSIS SHEET
No. Parameter reference Units Readings
1
Ultimate Analysis

Carbon
Percent 48.54

Hydrogen
percent 3.35

Oxygen
percent 4.42

Sulphur
percent 0.27

Nitrogen
percent 0.88

Moisture
percent 9

Ash
percent 33.66
2 GCV of Fuel K Cal/kg
4200




7.1.3 Boiler Periodic Checklist


Boiler Periodic Checklist

System

Daily

Weekly


Monthly


Annual

BD and Water
Treatment

Check BD
valves.Do not
leak.BD is not
excessive
-
Make sure
solids do
Not buildup.
-
Feed Water
System
Check and
correctUnsteady
water level.
Ascertain
Cause ofunsteady
water
level,contaminant
s over
load,malfunction
etc.
Check controls by
Stopping the
feed water pump
and
Allow control to
stop fuel
Nil Condensate
receiver, de-aerator
system pumps.

Flue Gases Check temp. at
two
different points
Measure temp.
andCompare
composition at
Selected firings
andAdjust
recommendedvalve
s.
Same as
weekly.
Compare
with previous
readings.
Same as weekly
Record
references.

Combustion Air
Supply

Check
adequate
Openings exist
in air inlet.
Clean
passages.


Burners

Check control sare
Operating
properly. May
need cleaning
Several times a day

Clean burners ,pilot
assemblies, check
condition of spark
gap of electrode
burners.

Same as
weekly

Same as weekly,
Clean and
recondition

Boiler operating
Characteristics


Observe flame
Failure and
characteristics of
the flame


Relief Valve


Check for leakages


Remove and
Recondition

Steam Pressure

Check for excess



Loads which will
Cause
excessive
variation in
Pressure



Fuel System

Check pumps,
Pressure
gauges,
transfer lines.
Clean them

Clean and
Recondition system

Belt for gland
Packing

Check
damages.
Check
gland
packing
for
Leakages
andpropercom
pression


Air leaks in water
Side and
fireside
surfaces


Clean surface as per
manufacturers
recommendation
annually

Air leaks


Check for leaks
Around access
openings and flame

Refractories on
fuel side


Repair

Elec. System



Clean panels
Outside

Inspect panels
inside

Clean ,repair
Terminals and
contactsetc.

Hydraulic and
Pneumatic valves

Clean
equipment,
Oil spillages
to bear rested
and air
Leakstrobe
avoided

Repair all defects
And check for
proper operation

7.2.General rules (Rules of Thumb)

5percentreductioninexcessairincreasesboilerefficiencyby1percent(or1percentre
duction ofresidualoxygeninstackgasincreasesboilerefficiencyby1percent).
22Creductioninfluegastemperature increasestheboiler efficiencyby1percent.
6Criseinfeedwatertemperaturebroughtaboutbyeconomizer/condensaterecover
ycorrespondstoa1percentsavingsinboilerfuelconsumption.
20Cincreaseincombustionairtemperature,pre-heatedbywaste heat
recovery,resultsina1percentfuelsaving.
A3mmdiameterholeinapipecarrying7kg/cm
2
steamwouldwaste32,650litersoffu
eloil peryear.
100mofbaresteampipewithadiameterof 150 mm
carryingsaturatedsteamat8kg/cm2wouldwaste25000litersfurnace oilinayear.
70 percent of heat losses can be reduced by floating a layer of 45 mm
diameterpolypropylene(plastic)ballsonthesurfaceofa90Chotliquid/condensate.
A0.25mmthickairfilmoffersthesameresistancetoheattransferasa330mmthickCopp
erwall.
A3mmthicksootdepositonaheattransfersurfacecancausea2.5percentincreaseinf
uelconsumption.
A1mmthickscaledepositonthewatersidecouldincreasefuelconsumptionby5to8per
cent.











CHAPTER8

CONCLUSION AND DISCUSSION

A case study on boiler efficiency manufactured by RAKHOH INDUSTRIES
PVT.LTD ,PUNE have been presented. From the case study following conclusion are
drawn:
1.Boiler efficiency is 68.72 %.
2. 2% of heat is unaccounted during process.
3. Percentage heat loss due to dry flue gas is 13 %.
4. Percentage heat loss due to evaporation of water formed due
toH2 in fuel is 4.89 %.
5.Percentage heat loss due to evaporation of moisture present in fuel
is 1.68 %.
6. Percentage heat loss due to moisture present in air is 1.29 %.
7. Percentage heat loss due to combustibles in ash is 8.42 %.
8. Total losses are 31.28% .



It is clear from the above efficiency that the energy transferred in form heat
from fuel to the water has a difference of about 10%. So there is scope to improve
the efficiency of boiler.

Suggestions:-
1. Coal of higher grade must be used.
2. Coal must be dried before feeding for firing.
3. Moisture in the air supplied must be removeed by using air preheater or
using one more air preheater.
4. Quantity of excess air must be optimized.
BIBLIOGRAPHY


REFERENCES BOOKS
1. THERMAL ENGINEERING by R.K GUPTA
2. THERMAL ENGINEERING BY R.S KHURMI AND R.K GUPTA
3. EFFICIENT OPERATION OF BOILER BY NATIONA PRODUCTIVITY
COUNCIL


WEB SEARCH
www.beeindia.org
www.energyefficiencyasia.org
www.rakhoh.com
www.energy-efficiency.org