Study on

SOOT BLOWER EFFECTIVENESS

Team Members:
1.
2.
3.
4.
5.
6.

Abhishek Kumar
D. Nagesh Rao
Atul Bramhankar
Aditya Satav
Shivendra Singh
Abhishek Sinha

Introduction:
Our study is based on 3 X 660 MW, Supercritical Steam Generators (Boilers) at TSPL.
Soot Blowing is of great importance, both in Sub-Critical and Super-Critical Steam Generators (Boilers), from 200 MW ~
800 MW. In supercritical boilers, with spiral water walls, it even becomes imperative to operate soot blowers, due to its,
ash sticking tendency.
Soot Blowing has become a very dynamic part of modern day Steam Generators (Boilers), more because of fuel variations
especially laden with high slagging coals.
We have taken up the task of Soot Blowing Effectiveness, which includes,
a)
b)
c)
d)
e)

100 % availability of all Soot Blowers (Wall Blowers + LRSBs + APH).

Reduction in SH and RH spray, at all loads.
Reduction of FEGT, (Furnace Exit Gas Temp.)
Prevention of Slagging, leading to boiler erosion and clinker formation as well.
Optimization of Soot Blowing, to contain DM water consumption.

Philosophy of Soot Blowing

The Primary purpose of Steam Generators (Boilers), is to turn Chemical Energy into Thermal Energy. Chemical Energy,
released by burning of Fuel inside furnace, the Heat released is captured by the water in the tubes to become final steam
for work done in Turbine. The Steam Generator (Boiler) system is a series of Heat Exchangers and each of them plays a
great role in optimizing Plant Heat Rate. In our case, the slagging and soot deposition can seriously hamper, heat transfer
in water walls, SH and RH tubes, resuting higher SH and RH temperatures, increased spray attemperation, high FEGT,
leading to boiler erosion and higher Dry Flue Gas Losses.
Initially, Wall Blowing was always carried out in Auto-sequence, i.e. all layers, wall blowing were operated in a particular
shift, depending upon various conditions, which led to increased DM water consumption, as the wall blowers operating
frequency were irregular.
The Wall Blowers (IR), should be considered as Preventive soot blower, which helps in suppressing FEGT, by enabling
conduction in water walls, this helps in containing FEGT lower than ash fusion temp, which later results in clinker
formation. It also results in lower heat available for convection and contains the SH and RH temp, which would require
lesser attemperation spray. The LRSBs are considered as Reactive Soot Blowers, which are located in the Upper furnace
in the convection pass and removes slagging, after it has formed, to maintain optimal SH and RH temperatures.
Study: U#2 and U#3
We have been monitoring various datas before and after Soot Blowing, on daily basis, such as, a)Load, b)Coal Flow,
c)FEGT before LTSH, LTRH, ECON, d) SH Spray CV positions and Spray, preferably at stable loads.
The Unit wise (Unit #2 and Unit #3), comparison chart of above mentioned parameters are listed in the tables on the
following dates:
Note:
i)
ii)
iii)
iv)
v)
vi)

The Load, firing and OHDR was almost constant throughout the duration of study.
Load fluctuations were frequent, hence, datas were studied only during stable load.
LRSBs can only be operated, when Load > 500 MW.
Hence, the study and analysis is based on the effects of wall blowing.
Columns, marked in RED indicates, days, when there is increase in FEGT, even after Soot Blowing, hence,
increased Spray and Dry Flue Gas Losses.
Columns, marked in GREEN indicates, days, when there is decrease in FEGT, after Soot Blowing, hence
reduced spray and Dry Flue Gas Losses.

Table No.1
UNIT # 3
Parameter

15.11.2016

16.11.2016

17.11.2016

Before SB
17:00 Hrs

After SB
21:00 Hrs

Before SB
01:00 Hrs

After SB
07:00 Hrs

Before SB
21:00 Hrs

After SB
05:00 Hrs

Load

340

345

343

343

346

358

Coal Flow

195

191

160

154

212

177

WB

LRSB

APH I, L Temp A, B

316, 319

323, 323

325, 317

330, 332

313, 305

318, 316

APH O, L Temp A, B

125, 128

129, 127

143, 124

123, 129

120, 126

116, 125

1st Stage Spray 1, 2 + CV %

31, 42 74%, 74%

43, 56 86%, 85%

55, 62 96%, 92%

52, 59 93%, 93%

25, 27 57%, 57%

12, 13 40%, 40%

2nd Stage Spray 1, 2 + CV %

1, 5.5 0%, 10%

2, 8 - 5%,
15%

3, 10 10%, 23%

2, 7 - 4%,
15%

1, 5 - 0%,
6%

0, 5 - 0%,
5%

FEGT before LTSH

445

459

463

473

438

440

FEGT before Economiser

301

305

304

308

295

296

FEGT before LTRH

391

405

405

424

395

402

Table No.2
Parameter

21.11.2016

23.11.2016

25.11.2016

Before SB
09:00 Hrs

After SB
17:00 Hrs

Before SB
00:00 Hrs

After SB
05:30 Hrs

Before SB
08:00 Hrs

After SB
14:00
Hrs

Load

660

660

348

348

667

661

Coal Flow

430

335

191

168

302

287

WB

LRSB

APH I, L Temp A, B

353, 345

348, 342

316, 316

317, 322

345, 348

352, 345

APH O, L Temp A, B

132, 139

136, 141

127, 125

119, 119

130, 132

134, 131

1st Stage Spray 1, 2 + CV

%

70, 50 50%, 50%

0, 8 - 0%,
0%

43, 47 80%, 80%

25, 26 57%, 57%

19, 33 40%, 41%

6, 7.5 1%, 1%

2nd Stage Spray 1, 2 + CV

%

0, 12 0%, 10%

0, 6 - 2%,
3.4%

2, 11 5.5%, 23%

1, 8 - 0%,
14%

0, 6 - 0%,
8%

0, 6 0%, 0%

FEGT before LTSH

489

480

439

441

498

481

FEGT before Economiser

334

330

292

292

337

327

FEGT before LTRH

425

425

399

402

422

421

Table No.3
Parameter

27.11.2016

29.11.2016

10.12.2016

Before SB
09:00 Hrs

After SB
17:00 Hrs

Before SB
10:00 Hrs

After SB
16:00 Hrs

Before SB
10:00 Hrs

After SB
18:00
Hrs

Load

657

669

666

650

660

610

Coal Flow

381

369

388

312

340

400

WB

LRSB

APH I, L Temp A, B

347, 347

343, 344

347, 352

344, 341

330, 338

336, 336

APH O, L Temp A, B

133, 139

139, 140

135, 142

142, 141

134, 134

135, 144

1st Stage Spray 1, 2 + CV

%

6, 22 32%, 32%

32, 54 52%, 52%

49, 57 55%, 55%

8, 7 - 4%,
4%

6, 15 15%, 20%

26, 11 42%, 17%

2nd Stage Spray 1, 2 + CV

%

0, 7.5 0%, 3.4%

0, 11 0%, 11%

0, 17 0%, 16%

0, 11 0%, 10%

0, 8 - 0%,
5%

8, 8 0%, 0%

FEGT before LTSH

493

487

493

480

500

499

FEGT before Economiser

333

336

339

327

344

350

FEGT before LTRH

425

411

424

418

413

414

Table No.4
Parameter

13.12.2016

14.12.2016

24.11.2016

Before SB
10:00 Hrs

After SB
17:00 Hrs

Before SB
10:00 Hrs

After SB
14:00 Hrs

Before SB
09:00 Hrs

After SB
15:00
Hrs

Load

661

654

660

663

654

645

Coal Flow

329

270

346

366

414

415

WB

LRSB

APH I, L Temp A, B

344, 340

341, 333

357, 327

357, 327

349, 346

345, 343

APH O, L Temp A, B

137, 144

126, 134

133, 141

132, 142

138, 143

137, 139

1st Stage Spray 1, 2 + CV

%

0, 10 3%, 8%

0, 9 - 2%,
7%

0, 13 0%, 12%

0, 18 6%, 16%

40, 43 50%, 50%

40, 34 43%, 43%

2nd Stage Spray 1, 2 + CV

%

63, 11 57%, 12%

50, 9 53%, 8%

78, 17 62%, 27%

75, 16 62%, 23%

0, 8 - 0%,
7%

0, 8 0%, 8%

FEGT before LTSH

507

498

502

501

492

455

FEGT before Economiser

396

345

345

348

335

335

FEGT before LTRH

418

422

416

414

425

424

Table No.5
Parameter

15.12.2016

11.12.2016

12.12.2016

Before SB
10:00 Hrs

After SB
16:00 Hrs

Before SB
10:00 Hrs

After SB
16:00 Hrs

Before SB
10:00 Hrs

After SB
14:00
Hrs

Load

660

670

640

660

650

658

Coal Flow

422

347

290

340

335

355

WB

LRSB

APH I, L Temp A, B

349, 337

354, 325

320, 310

360, 330

330, 332

335, 335

APH O, L Temp A, B

134, 138

130, 138

131, 127

146, 141

134, 141

131, 137

1st Stage Spray 1, 2 + CV

%

0, 14 0%, 14%

0, 17 0%, 15%

40, 37 72%, 72%

6.5, 47 6%, 53%

0, 6 - 0%,
0%

0, 8 0%, 4%

2nd Stage Spray 1, 2 + CV

%

12, 41 18%, 50%

22, 30 32%, 41%

0, 10 0%, 20%

0, 7 - 0%,
0%

6, 9 0.0%, 10%

9, 42 10%, 51%

FEGT before LTSH

499

493

502

503

507

498

FEGT before Economiser

347

343

348

349

350

343

FEGT before LTRH

412

411

416

413

410

413

Table N0.6
Parameter

16.12.2016

17.12.2016

18.12.2016

Before SB
10:00 Hrs

After SB
16:00 Hrs

Before SB
10:00 Hrs

After SB
16:00 Hrs

Before SB
10:00 Hrs

After SB
16:00
Hrs

Load

660

644

643

652

660

537

Coal Flow

439

440

352

385

428

325

WB

LRSB

APH I, L Temp A, B

342, 341

344, 336

349, 330

345, 332

362, 336

355, 332

APH O, L Temp A, B

131, 140

133, 137

135, 134

144, 142

131, 156

145, 142

1st Stage Spray 1, 2 + CV %

0, 15 1%, 15%

0, 31 0%, 28%

3, 21 7%, 22%

0, 8 - 0%,
5%

0, 12 0%, 13%

0, 8 0%, 9%

2nd Stage Spray 1, 2 + CV

%

67, 25 62%, 34%

7, 22 9%, 35%

67, 25 62%, 34%

42, 7 52%, 0%

79, 44 69%, 56%

73, 41 68%, 58%

FEGT before LTSH

493

498

497

500

511

484

FEGT before Economiser

348

352

342

348

356

337

FEGT before LTRH

405

397

410

413

418

406

Table No.7:

UNIT #2
Parameter

23.11.2016

26.11.2016

27.11.2016

Before SB
00:00 Hrs

After SB
05:33

Before
SB,21:40

After SB
05:28

Before
SB,09:30

After SB
16:45

Load

331

347

342

342

372

553

Coal Flow

224

257

225

248

361

337

WB

LRSB

APH I, L Temp A, B

331

327

335

328

343

331

APH O, L Temp A, B

134, 120

129, 121

127, 127

126, 124

141, 128

138, 127

1st Stage Spray 1, 2 + CV %

43, 41 80%, 88%

30, 30 60%, 68%

23, 21 60%, 60%

25, 20 62%, 60%

10, 5 15%, 10%

6, 5 3.5%, 0%

2nd Stage Spray 1, 2 + CV %

8, 12 13.0%,26%

8, 11 5.0%,26%

8, 11 0.7%,25%

8, 12 0.0%,26%

12, 4 0.0% 14%

12, 0 0.0%, 8%

FEGT before LTSH

422, 422

435, 430

416, 422

430, 434

487, 494

488, 495

FEGT before Economiser

373, 369

371, 365

371, 361

369, 365

368, 398

350, 377

FEGT before LTRH

287, 289

289, 290

290, 288

295, 292

328, 328

335, 332

Table No.8
Parameter

07.12.2016

14.12.2016

17.12.2016

Before SB
10:00 Hrs

After SB
16:00

Before SB
08:00

After SB
18:00

Before
SB,07:12

After SB
16:40

Load

614

622

585

596

531

518

Coal Flow

344

332

338

311

322

334

WB

LRSB

APH I, L Temp A, B

339

351

342, 340

344, 339

330, 338

341, 332

APH O, L Temp A, B

141, 119

139, 137

139, 123

147, 118

137, 114

140, 123

1st Stage Spray 1, 2 + CV %

40, 26 55%, 51%

9, 5 12%, 5%

20, 12 52%, 38%

24, 18 50%, 45%

28, 27 59%, 63%

58, 34 75%, 70%

2nd Stage Spray 1, 2 + CV %

12, 19 3.0%, 23%

12, 24 0.0%,24%

12, 19 9%, 23%

12, 28 0.0%,20%

12, 16 0%, 20%

11, 23 8.0%,28%

FEGT before LTSH

492, 500

476, 485

495, 503

490, 487

492, 488

474, 483

FEGT before Economiser

375, 370

373, 405

381, 400

357, 386

359, 369

371, 391

FEGT before LTRH

323, 325

322, 320

328, 319

325, 320

326, 319

316, 312

Results:
1.

U#2, soot blowing is in-effective, due to unavailability of majority of wall blowers, it is very difficult to implement
any kind of soot blowing pattern and hence, unable to optimise the FEGT, hence, increased spray and Dry flue gas
loss.

2.

U#3, Soot blowing, effectiveness is comparatively better, when proper wall blowing has been done, resulting in
considerable reduction of FEGT, Spray and Dry flue gas loss.

Suggestions:
In General, Wall Blowers are operated in Auto Sequence, in which the blowing pattern is, from bottom layer to top layer,
all in a shift.
Here, we suggest,
a)
b)
c)

Soot Blowing in Manual Mode.

From Top Layer to Bottom Layer i.e. D Layer C Layer B Layer A Layer
Layer wise wall blowing, i.e.
i)
A-shift : D + C layer
ii)
B-Shift : B + A layer
iii)
C-Shift : D + C layer and the cycle continues.
iv)
APH wall blowing to be operated in every shift, without fail.

This pattern, will ensure, effective wall blowing throughout the day, with reduction in DM water and coal consumption as
well.
The Wall Blowing pattern, suggested above, was implemented by our team and we have monitored positive results, in
U#3. We shall adopt the same fashion in U#1 and U#2, for better results.