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Performance Improvements at the

Boardman Coal Plant


Paper IJPGC 2002-26026, presented at directly from the combustion
the: International Joint Power Generation process, Btu/hr.
Conference, June 24-26, 2002, Phoenix, FCIi = Fuel Consumption Index for
Arizona, Sponsored by ASME. an ith irreversible component
Performance improvements at the or process, Btu/hr.
Boardman Coal Plant as a result of test- FCIPower = Fuel Consumption Index for
ing and input/loss monitoring power generation, Btu/hr.
David A.T. Rodgers, P.E. g = Specific exergy, Btu/lbm.
Portland General Electric Company Gin  Total of all exergy in-flows
Boardman, Oregon 97818 and shaft powers supplied to
a thermal system, Btu/hr.

ASME Power Division Special Section


Dave_Rodgers@PGN.com
Fred D. Lang, P.E. HBC  Firing Correction (i.e., "energy
Exergetic Systems, Inc. credit"), Btu/lbmAF.
San Rafael, California 94901 HHV = As-Fired (wet-base) higher
Lang@ExergeticSystems.com heating value, Btu/lbmAF.
HHVP = As-Fired (wet-base) higher
ABSTRACT heating value corrected for
This paper presents methods and prac- constant pressure process,
tices of improving heat rate through test- Btu/lbmAF.
ing and, most importantly, through heat HNSL  Non-Chemistry & Sensible
rate monitoring. This work was preformed Heat Losses, Btu/lbmAF.
at Portland General Electrics 585 MWe HPRAct  Enthalpy of Products, actual
Boardman Coal Plant, which used two very conditions, Btu/lbmAF.
different Powder River Basin and Utah HRXAct  Enthalpy of Reactants, actual
coals ranging from 8,100 to over 12,500 conditions, Btu/lbmAF.
Btu/lbm. Such fuel variability, common HR = Unit heat rate (gross, total sys-
now among coal-fired units, was success- tem), Btu/kWh.
fully addressed by Boardmans on-line hrj = Differential heat rate associat-
monitoring techniques. ed with any jth component or
Monitoring has evolved over the past process, Btu/kWh.
ten years from a Controllable Parameters HSL  Stack Losses, Btu/lbmAF.
approach (offering disconnected guid- I = Irreversibility, Btu/lbm.
ance), to a systems approach in which fuel mAF = As-Fired fuel mass flow rate
chemistry and heating value are deter- (wet with ash), lbmAF/hr.
mined on-line, their results serving as a Q = Differential heat transfer,
bases for Second Law analysis. At Btu/hr.
Boardman, on-line monitoring was imple- TCal = Calorimetric temperature for
mented through Exergetic Systems HHV determination, F.
Input/Loss Method. Boardman was one of TRef  Reference temperature for
the first half-dozen plants to fully imple- Second Law analyses, F.
ment Input/Loss. This paper teaches WFan = Brake fan power, Btu/hr.
through discussion of eight in-plant exam- WPump = Brake pump power, Btu/hr
ples. These examples discuss heat rate Woutput = Gross electrical generation,
improvements involving both operational Btu/hr or kWe.
configurations and plant components: W = Differential shaft power,
from determining changes in coal chem- Btu/hr.
istry and composite heating value on-line; B = Boiler efficiency (HHV-based), --.
to recognizing the impact of individual C = Combustion efficiency (HHV-
rows of burners and pulverizer configura- based), --.
tions; to air leakage identifications; to A = Boiler absorption efficiency, -
examples of hour-by-hour heat rate
improvements; comparison to effluent INTRODUCTION
flows; etc. All of these cases have applica- Boardman is a 585 MWe unit burning
bility to any coal fired unit. Powder River Basin and Utah coals; coals
having remarkably different chemistries
NOMENCLATURE and heating values (varying from 8,100 to
BBTC = Useful energy flow to the over 12,500 Btu/lbm). The steam generator
working fluid, as derived was provided by Foster Wheeler, as are the
FEBRUARY 2003 | ASME Power Division Special Section 5
2 MB type and 6 MBF type pulverizers. The Understanding of steam generator per-
steam turbine is a four-flow Westinghouse formance is had from computer simula-
product, with recently upgraded LP rotors. tions principally based on: internally
The plant operates under a Westinghouse updated fuel chemistries and heating val-
WDPF Distributed Control System. ues; effluents concentrations; and energy
Exergetic Systems supplied the Input/Loss flow to the working fluid. Plant indicated
Method and its associated software (Lang, fuel flow is not used, although when found
1994-2002). The WDPF communicates consistent, as at Boardman, its compari-
with Input/Loss via an interface provided son to the computed serves as an excel-
by Real Time eXecutives, (RTX) of lent "sanity check" for general Input/Loss
Wrentham, MA. Output communications performance. Measured effluent flows are
from Input/Loss are available through both never used. Boiler efficiency, B, is
RTX, and a ModBus protocol provided by defined by dividing its definition into two
KEPware, Inc. of Yarmouth, ME. components, a combustion efficiency and
As common with most coal-fired units, boiler absorption efficiency (Lang, 2000):
traditionally Boardman's plant engineers
were monitoring only the so-called B = C A (1)
ASME Power Division Special Section

Controllable Parameters. Heat rate was To develop the combustion efficiency


determined on a monthly basis by using term, Input/Loss employs an energy bal-
totalized measured coal flow, and heating ance uniquely about the flue gas stream
value based on random samplings. To (i.e., the combustion gas path). This bal-
instigate improvement, plant engineers ance is based on the difference in enthalpy
chose to mark a bright line between a between actual products HPRAct, and actu-
Performance Monitoring Program, versus al reactants HRXAct. Actual, As-Fired,
the traditional Controllable Parameters. At Enthalpy of Reactants is defined in terms
Boardman, this meant a holistic approach of Firing Corrections: HRXAct  HRXCal +
was needed - a systems approach - imple- HBC. The term HRXCal is the gross heat
menting both the Input/Loss Method and released given complete combustion (i.e.,
follow-up testing, training and mainte- ideal products) at the calorimetric temper-
nance programs. ature, TCal. Combustion efficiency is then
The Input/Loss Method determines defined in terms which are independent of
coal chemistry, heating value and coal flow fuel flow but akin to PTC 4.1's Input-
on-line, using principally Continuous Output Method.
Emission Monitoring System (CEMS)
instrumentation. Input/Loss Methods HPRAct + HRXAct (2)
C =
include the correction of CEMS measure- HHVP + HBC
ments such that stoichiometric consisten-
cies are assured. Such consistencies are This formulation was developed to
judged against certain fuel characteristics, maximize accuracy. Typically for coal-fired
found constant for a given mined coal units, over 95% of the boiler efficiency's
(Lang, 1999), involving multidimensional numerical value is comprised of C.
optimization (Lang, 2002a). The Method Indeed, all individual terms making up C
relies on a sophisticated boiler simulator have the potential of being determined
and turbine cycle computations. Input with high accuracy. HPRAct is determined
consists of routine plant data, reference knowing effluent temperature, complete
fuel characteristics, and O2, CO2 and H2O stoichiometric balances, and accurate
effluents. Its base technology has been combustion gas and water properties.
documented in four serial ASME papers HRXAct is dependent on heating value,
(Lang, 1998 for an over-view). The ideal products and Firing Corrections,
Input/Loss Method includes use of Second HBC. The HBC term applies needed cor-
Law analyses, determining Fuel Con- rections for the reactant's sensible heats:
sumption Indices for all major compo- fuel, combustion air, limestone if used,
nents and processes (Lang, 2002b). Fuel water inleakage and energy inflows ... all
Consumption Indices indicate to the oper- referenced to TCal such that the term
ator why fuel is being consumed: for power (-HPRAct + HRXAct) is stoichiometrically
generator, and for over-coming irreversible conserved relative to a measured heating
losses; thus to minimize losses and maxi- value, HHV.
mize power generation. The boiler absorption efficiency is
INPUT/LOSS DETAILS developed from the boilers "Non-
The Input/Loss Method is a unique Chemistry & Sensible Heat Loss" term,
process which allows for complete thermal HNSL; it is the product's sensible heats of
understanding of a power plant through non-combustion processes.
explicit determinations of fuel and effluent HNSL (3)
flows, fuel chemistry including ash, fuel A  1.0
heating value and boiler efficiency. HPRAct + HRXAct
6 ASME Power Division Special Section | ENERGY-TECH
HNSL / C (4) power. An important concept is that total
= 1.0 exergy flows are destroyed when viewing an
HHVP + HBC active system interfaced with its environ-
HNSL is defined through iterative tech- ment. Thus in the process of power produc-
niques, independent of fuel flow, compris- tion exergy bound in the fuel must eventu-
ing radiation & convection losses, pulver- ally be returned to the environment, mani-
izer rejected fuel losses (or fuel prepara- fested through system losses and electrical
tion processes), and sensible heats in: bot- generation - and nothing more.
tom ash, fly ash, effluent dust and effluent Thermodynamic irreversibilities are
products of limestone. HNSL is deter- these system losses, the unrecoverable
mined using a portion of PTC 4.1's Heat- losses associated with any thermal
Loss Method. process (the loss of potential power from
With a computed boiler efficiency the the system). For a process assumed inter-
As-Fired fuel flow rate, mAF, is then back- faced with its environment, irreversibility
calculated from the traditional expression is the measure of exergy destruction asso-
of boiler efficiency, of critical importance ciated with the system relative to its envi-
ronment. Irreversibility is defined, for a

ASME Power Division Special Section


to Input/Loss Methods.
process or system, by:
BBTC (5) I = (1 TRef/T) Q W - mdg (9)
mAF =
B (HHVP + HBC) Eq.(9) is a simple accounting of a
process potential and actual powers. The
Once fuel flow is correctly determined, (1 TRef /T) Q term is the Carnot con-
stoichiometrics is then used to resolve all version of energy flow to power, via a pos-
boiler inlet & outlet mass flows, including sible motive Q heat transfer, a negative
effluent flows required for regulatory term if from the process. The Carnot con-
reporting. Unit heat rate associated with a version can be thought of as the power
power plant follows directly from Eq.(5). equivalent resultant from heat transferred
HR = mAF (HHVP + HBC)/Woutput (6) from the process directly to the environ-
ment. The W and mdg terms represent
 BBTC/(B Woutput) (7) differences between actual shaft power
(produced or supplied), and the actual
where BBTC, for a conventional coal-fired exergy change of the process (potential
plant, is the useful energy flow to the tur- power supplied or produced to the fluid),
bine cycles working fluid. Note that the thus a net lost of potential power. The sign
definition of overall boiler efficiency, com- of W is positive if power is produced
prising C and A of Eq.(1), and that of from the system. For example, if a turbine
PTC 4.1, can be demonstrated to be identi- produces +0.3980x109 Btu/hr shaft power,
cal (Lang, 2002c). from a -0.5044x109 Btu/hr decrease in
An obvious objective at Boardman, as steam exergy, assuming Q = 0.0, then
found at most coalfired units, is to deter- from Eq.(9) the irreversibility is given by
mine thermal performance in light of high- 0.1064x109 = 0.0 - 0.3980x109 - ( 0.5044 x
ly variable fuel. This is achieved through 109); always the positive difference
integration of stoichiometrics with high between potential and actual powers. This
accuracy boiler efficiency. As formulated, turbines effectiveness is 78.9% (0.3980 x
consistency is guaranteed between boiler 109/0.5044x109).
efficiency, As-Fired heating values, com- At the system level, irreversibility is a
puted fuel and effluent flows and unit heat measure of the exergy destroyed and thus is
rate. With such consistency as a bases, directly proportional to fuel consumption.
thermodynamic losses throughout the Again, of the total exergy and power inputs
system are then determined employing to a system, only irreversibilities and power
Second Law analysis. output will result. This can be expressed by
Eq.(11), where the total exergy and power
inputs to the system defines Gin.
FUEL CONSUMPTION INDICES
The maximum potential power which Gin  mAF gFuel + mAF gAir + GMisc +
could be produced or consumed by the
working fluid in any process is measured WPump + WFan (10)
by its associated change in exergy flow.
The net change for any process is: = Ii + Woutput (11)
Eq.(11) represents a clear statement of
G  mdg = mgoutlet mginlet (8) the Second Law applied to a power plant.
Exergy audits permit performance engi- From this concept the Fuel Consumption
neers to quickly determine the degree Index is developed by simply dividing
(termed effectiveness) components are con- through by Gin for individual components
suming or producing actual versus potential or processes and the power production.
FEBRUARY 2003 | ASME Power Division Special Section 7
Fuel Consumption Indices are a meas- tional Controllable Parameters method.
ure of fuel consumed; they assign thermo- The operator must only maximize FCIPower
dynamically to those individual compo- by minimizing FCIi. Since FCIs sum to
nents or processes their "fuel consump- 1000, any operational change an operator
tion". FCIs quantify the exergy and power executes is registered by a balancing
consumption of all components and among FCIs. A decrease in FCIPower must
processes relative to the total exergy and be offset by FCIi increases; or, if FCIPower
power supplied to the system; by far the pre-  0.0, a change in one or more FCIi will be
dominate term (and having the greatest off-set by other non-power FCIs.
numerical complexity) is the fuel's total Boardmans engineering staff relies on
exergy, mAF gFuel. Based on Eq.(11), FCI is the belief that their operators know the
defined for non-power components and system, they understand what executions
processes (such as combustion), and the are occurring - and with FCIs - they now
ASME Power Division Special Section

power production process by the following: have quantitative knowledge as the impact
on thermal performance. Examples of
Ii (12)
FCIi  1000 using these techniques follow (see Deihl,
Gin 1999 for a parallel study).

Woutput (13) PLANT SET-UP AND DATA TRAIN


FCIPower  1000 The on-line system implementing
Gin these principles consists of three basic
As used in Eqs.(12) & (13) the terms components. The first is the plants DCS
Gin, irreversibility and power all employ used to gather system data; it is also used
units of Btu/hr. Although FCIs are unit- to display key output parameters
less, they are arbitrarily multiplied by (FCIs, efficiencies, unit heat rate, etc.)
1000, thus FCIj = 1000 (where j repre- for operator feedback. The second compo-
sents all components and processes). nent is the Performance Monitor Server
It can be shown that individual FCIj which acts as interface between the DCS
directly lead to differential heat rates, hrj, and a "Calculational Engine". The Engine,
such that: HR = hrj. Further, it can be as the third component, runs the
shown that FCIPower also leads directly to Input/Loss Method. Within the Engine, cal-
this same classical unit heat rate, HR, as culations are completed, the results of
defined by Eqs.(6) & (7): which are key Plant Performance
Parameters, notably real time boiler effi-
HR = (1000/FCIPower) (3412.1416 + ciency, FCIs and unit heat rate. At
hrEnvir) (14) Boardman, the Engine is set up to cycle
Input/Loss Methods every two minutes
The "Environmental" differential heat based on 15 minute running averages of
rate term, hrEnvir, relates to the impact the all applicable plant data. All Engine
environment plays, thermodynamically, on results are available as output to the
the supply stream exergies; it is typically WDPF system for operator display, via a
numerically small and for sensitivity stud- ModBus interface.
ies can be considered constant (see Lang, The WDPFs database communicates
2002b). with the Calculational Engine via an RTX
When presented in a Control Room the interface. The RTX program resides in one
simplicity offered by the FCI approach is a of the DCSs MMIs. RTX both obtains
considerable improvement on the tradi- selected plant data from the WDPF data

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8 ASME Power Division Special Section | ENERGY-TECH


highway, and communicates this data to D. Thermocouples were added to existing
its own historical database (HDB) via LAN. wells at the main and reheat steam tur-
The RTX historical database resides in a bine inlets. Note, the plant now controls
separate computer acting as a server. main and reheat steam temperatures
Additionally, selected Engine results are based on these temperatures as appro-
stored in the RTXs HDB. All data, be it real priate for true turbine cycle monitoring
time plant data via WDPF, or Engine (not at the steam generator per se).
results are available to plant personnel at E. Thermocouples were added in existing
their desk-top personnel computers. This wells at the Upper and Lower
information is available as real time or his- Economizer, and at the outlet lines of
torical data. This information can be dis- the Primary Superheater.
played graphically in the form of trends, or F. At both Boiler Feed Booster Pumps
via spreadsheets. Also, Engine output is (BFBP) and Boiler Feed Pumps (BFP),
available to the WDPF data highway for thermometer wells were added at each
graphical display or trend plots offered by pumps discharge lines to facilitate indi-
WDPF. Plant operators typically choose to vidual pump testing (involving high
archive at least boiler efficiency, unit heat accuracy T measurements). Also,

ASME Power Division Special Section


rate, and FCIs in the WDPFs historian. importantly, pressure taps and wells
were added at the discharge of the
INSTRUMENTATION booster stage of the BFPs (Boardmans
Instrumentation is, of course, an superheat spray flows are unusually
important aspect of performance engineer- high, thus requiring another high accu-
ing. Indeed, instrumentation, testing and racy T measurement).
analysis are the three "legs" of the G. New steam flow orifices were added in
performance engineering "stool". the steam lines feeding the Auxiliary
Recognizing this, the Boardman staff as Turbines (which at Boardman drive
part of the installation of an on-line moni- both BFP and BFBP).
toring program, preformed a detailed H. Two flow orifices were added to monitor
review of all plant instrumentation. turbine gland seal steam flow leakages,
Boundary conditions were established for and a third flow orifice was added to
the Turbine Cycle, steam generator heat monitor Gland Steam Condenser flows.
exchangers, and plant effluents. Although With the exception of the test points
most of the required thermometer wells added to BFP and BFBP, signals from
and pressure taps were in place, some key the new instrumentation were added to
instrumentation was lacking. The follow- the plants DCS, and routinely archived
ing is a list of instrumentation added to in its Historian.
the plant as a result of the on-line moni-
toring program: EXAMPLE A: SYSTEM AIR LEAKAGE
A. Temperature and pressure instruments When modeling the plant for on-line
at both LP Turbine crossover piping monitoring, preliminary boiler analysis,
(although pressure nipples were pres- using EX-FOSS (Lang, 2002c), pointed
ent they were not tapped through!). towards unrealistically high air in-leakage.
B. Temperature and pressure instruments Initial indications required a value of more
were added at the outlet of the high than 20% air leakage. With this warning in-
pressure feedwater heater. A thermome- hand, subsequent testing on May 5, 2000
ter well and pressure tap were required. revealed a low boiler efficiency of 83.21%.
C. In the stack, there are two visible efflu- As part of the testing program, detail oxy-
ent streams due to stratified flow, thus gen and CO2 profiles at the boilers exit
to eliminate any questions when meas- were then obtained. Additionally, much
uring, an additional O2 instrument was work was put into looking for tramp air
added directly opposite the existing O2 sources.
probe. Most importantly, a stack H2O Several casing leaks were discovered,
instrument was added (by Sick Optical as well as minor sources of tramp air leak-
Co.). Although initially planned (but not age. Corrections were made or were
implemented), it became apparent that planned for a forthcoming Spring outage.
with variable moisture in the coal, it Engineering judgement and EX-FOSS
would be absolutely necessary to meas- analyses suggested that the identified in-
ure stack moisture. Although a consis- leakages could not account for the leakage
tent H2O meter was required, its required to meet stoichiometric balances.
absolute accuracy was not a require- However, two sources of leakage which
ment given Input/Loss ability to correct could account for computed results were
any effluent signal. Although the stack eventually identified. The first was the
CO2 instrument was physically present out-of-service pulverizers. It was known
as part of CEMS, its signal needed to be that the original design of the burner
added to the plants WDPF data highway. sleeve damper was not adequate. Due to
FEBRUARY 2003 | ASME Power Division Special Section 9
TABLE ONE: O2 Concentrations Before Modifications TABLE TWO: O2 Concentrations After Modifications
ASME Power Division Special Section

this, the plant operators chose to keep all With the information obtained from
burner sleeve dampers fixed in place at 3 the traverse of the exit flue and further EX-
inches open and use the outer air regis- FOSS sensitivity analyses, the plant took
ters for burner adjustment. With a pulver- its O2 probes and moved them to monitor
izer out-of-service, the only way to isolate the centroids of equal areas in the upper
secondary air to the burner was to shut the duct. To cover the centroids of equal areas
outer air registers. With a burner sleeve for the entire duct, it would require an
damper fixed in place at 3 inches open, and additional twelve O2 probes. The plant
having its associated outer air register elected not to install these additional
shut, secondary air flow could not be iso- probes, preferring to investigate the
lated in the out-of-service burners. The results of testing performed after the 2001
plant typically runs with seven mills in- spring outage.
service at full load. Thus with a mill out-of- The results of the these two modifica-
service, and its associated sleeve damper tions proved to be outstanding. The plant
fixed in place, a significant source of air in- now uses the burner sleeve dampers for
leakage was present. During the 2001 burner adjustments, and rarely adjusts
Spring outage, modifications were com- the burner air registers. Of note is the
pleted to the sleeve mechanism for all 32 reduction in Wind Box pressure. Prior to
burners allowing proper operation. Again, this modification, the Wind Box pressure
this was done for the purpose of isolating was typically 4.5 to 5.5 inwater at full
tramp air from the out-of-service mill(s). load. With the current burner sleeves
The second source of high air in-leak- opened to between 8 to 9 inches, Wind
age was found by a detailed examination of Box pressure has decreased to 1.5 to 2.0
the boilers exit flue oxygen profiles (not in-water, resulting in reduced Forced
involving plant instrumentation, but an Draft Fan loading. This load reduction is
independent mobile lab.). Table 1 presents due to a decrease Forced Draft Fan load-
Boiler O2 readings. Note the heavily strati- ing, caused by less throttling at the
fied O2 concentrations across the back of sleeve dampers. Most importantly, this
the duct; and, most significantly, in the up modification has allowed the out-of-serv-
and down directions. These readings were ice pulverizer to be effectively isolated,
obtained while the plant was controlling to thus mitigating a major source of air in-
an exit flue O2 set point of 2.8% (interest- leakage. The out-of-service burners have
ingly, operations believed they had no diffi- their sleeve dampers opened slightly for
culty maintaining this set point!). burner tip cooling.
Furthermore, the plant was using fourteen In general support of this work, Figure 1
in-situ O2 probes, thus believing that boil- illustrates a year of stack effluent data.
er O2 was well understood. The reality was Note the reduction in stack O2 and total
that half of these probes were mounted at air flow. Stack O2 decreased from approxi-
the 6 foot level and the other half at the 12 mately 7.0% to 5.5%. Stack CO2 increased
foot level, in a 22 foot deep duct. Further, from 10.66% to over 12%. Clearly this data
their mountings were located in such a indicates an increase in boiler efficiency.
way as to bias burners feeding the "front" Computed boiler efficiency after the
of the boiler. At this time, mills at the Spring 2001 outage eventually rose to
"back" of the boiler were favored for out-of- between 85.0% and 85.6%, versus the ear-
service, thus further masking air leakage lier 83.21%; accounting for typically a 2%
effects. increase in boiler efficiency.

10 ASME Power Division Special Section | ENERGY-TECH


FIGURE ONE: Results of 2001 Air Leakage Work

ASME Power Division Special Section


Another traverse of the Boilers exit O2 generator modeling, boiler efficiency cal-
was then performed. This traverse was culations could not be confirmed without
used to validate modifications completed arriving at an unrealistically high air in
during the Spring outage. Table 2 presents leakage. The end result was a notable
results and should be compared to Table 1. increase in boiler efficiency.
Note the significantly lower readings, and
their improved distributions. This traverse EXAMPLE B: BURNER
was taken while controlling an O2 set point ADJUSTMENTS - I
to 2.50%, 0.30% lower than earlier practice. The Engine computes FCIs for all
Of course, these readings do not reflect a major steam generator components, power
simple set point change, but improved air generation process and miscellaneous
in-leakage and improved controls. As con- processes. Eq.(11) states, given a system
firmation, CO2 readings taken across the is being supplied with a potential for
Air Pre-Heaters indicated a component power, that only power and losses are pro-
leakage of approximately 5%, versus the duced. FCIs indicate the distribution of
original system leakage of  20%. such power and losses through fuel con-
Obviously, burner sleeve damper modi- sumption. At Boardman, losses may occur
fications and O2 probe placements are in the following modeled components or
largely responsible for the observed processes: Primary Superheater, Finishing
improvement in boiler efficiency. It is felt Superheater, Reheater, Upper Economizer,
by the authors that modifying the O2 probe Lower Economizer, boiler water walls,
placement had the greatest impact on boil- Finishing Superheater sprays, Primary
er efficiency by improving O2 control. Superheater sprays, Stack losses, collec-
Plant controls combustion air by control- tive Turbine Cycle (non-boiler interfaced)
ling oxygen at the Boilers exit. components, and the combustion process.
Based on exit flue testing the Plant Since FCIj = 1000, an increase in a heat
was inaccurately measuring Boiler oxygen exchanger or process FCIj, must be accom-
which resulted in high combustion air. panied by a decrease in another. If FCIPower
Lowering excess air is traditional, but the increases (good), given that power is being
subtlety involved changing where Boiler more effectively produced, losses some-
oxygen was being monitored. Also, modi- where in the system have (and must have)
fying the sleeve dampers significantly decreased. Of course, a ceratin component
reduced tramp air from out-of- service FCIi could increase (higher irreversible
mills. And, with less throttling due to losses), but be just off-set by another non-
wider open sleeve dampers, there is less power component or process, e.g., the
flue gas stratification in the boiler, hence combustion process; negating any effects
a more accurate Boiler O2 determination. on FCIPower.
After this effort, combustion stoichiomet- Figure 2-3 presents an example of
rics were found consistent by EX-FOSS. changes in FCIs due to a burner requiring
Boiler efficiency improved by dogged adjustment, indicating typical data associ-
persistence to resolve stoichiometric con- ated with before and after adjustments.
sistencies. During the installation of the Typically, the Boardman plant runs with
Calculational Engine and initial steam minimal CO of approximately 6-7 ppm. In

FEBRUARY 2003 | ASME Power Division Special Section 11


FIGURE TWO-THREE: Burner Adjustments (Before and After) EXAMPLE C: BURNER
ADJUSTMENTS - II
Figure 4 illustrates another example
of adjusting burners, this time a mis-
adjustment. Note how FCI for Combustion
trended higher, with a slight decrease in
FCIPower. Obviously operators were pro-
ceeding in the wrong direction; they rec-
ognized this given a visual record. After
the adjustments were reversed, FCI for
Combustion trended lower. Computed
unit heat rate followed these trends, princi-
pally caused by changes in boiler efficiency,
representing approximately 3/4% . At the
time of this example typical boiler efficien-
cy was 84.6% as the plant was the process
of a coal conduit study (Example D); addi-
tionally, the plant was still learning how
Figure 2-3, note the correspondence best to optimize the new burner sleeve
between high CO, high Combustion FCI modifications. The 3/4%  in efficiency
and corresponding lower FCIPower - versus represented over 90 Btu/kWh improve-
these values associated with low CO. Any ment in heat rate which would of gone
increase in CO provides an immediate undetected.
indication of burner problems. Notably,
changes in FCIPower are a direct indication EXAMPLE D: COAL CONDUIT STUDY
of changes in unit heat rate via Eq.(14) . At the completion of the Spring 2001
Figure 2-3 presents results after burners outage, the plant hired Storm
were adjusted, noting the decrease in Technologies, Inc. of Albemarle, NC, as
Stack CO along with a decrease in the FCI consultants to assess pulverizer perform-
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increase in the FCIPower. borne coal), coal fineness and bulk coal

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12 ASME Power Division Special Section | ENERGY-TECH
FIGURE FOUR: Effects of Burner Mis-Adjustment FIGURE FIVE-SIX: Pulverizer Classifier Upgrade (Before/After)

ASME Power Division Special Section


flows were determined for each mill. At situation is possible, lower FCIPower values
Boardman there are four burners (at the must be investigated.
same level and boiler face) for each mill,
with eight mills there are 32 burners. Each EXAMPLE E: SENSITIVITY TO
burner has its own conduit, 32 conduits. CHANGING FUELS
As a result of this testing, flow orifices Figure 7 shows Input/Loss principle
were installed in two coal conduits. outputs during a transient in which a pul-
Additionally, the plant changed classifier verizer was taken out-of-service, and then
vanes in all pulverizers with Storm returned to service four hours later. This
Technologies recommended design. The altered the mix of low and high energy
consultant pointed out that classifier coals feeding various mills. All Engine
vanes are not only responsible for coal computations were, of course, automated,
fineness but for flow distribution. updating every 2 minutes boiler efficiency,
Naturally, it is desirable to have equal coal fuel flow, composite heating value and
flows in all conduits. Prior to the classifi- other performance parameters. At the
er installation, individual coal conduit time, the plant was running with seven
flows deviated as high as 10% to 15% from mills, six of which had 8,100 to 8,500
a mill average. After the new classifier Btu/lbm PRB coal with 30% moisture, and
vane installation, individual conduit flows with a single mill with 11,000 to 12,500
deviation was less than 5%. Btu/lbm coal having less than 10% mois-
Figure 5-6 presents the results FCI for ture. A low energy mill was lost, increas-
Combustion, FCIPower and boiler efficien- ing the computed heating value of the
cy before and after modifications. Figure composite fuel (based solely on CEMS
5-6 provides an excellent representation data, etc.). The Engines computed fuel
of the consistency of Engine computa- flow, via Eq.(5), and the plants "indicated"
tions, needed and used to evaluate the fuel flow are presented in Figure 7, as are
modifications to the classifier vanes. boiler efficiency and computed composite
Boiler efficiency improved approximately heating value.
1.40% . The classifier vane upgrade Table 3 shows typical ultimate analysis
occurred over a period of five months for the two types of coals used (the varia-
(Figure 5-6 presents sampled data using tions within each type could range from 5
relative times). to 10% in heating value). Also shown is a
Given a long installation period, other typical computed composite fuel chem-
system changes were occurring; as istry and heating value produced from the
observed in Figure 5-6, FCIPower has slight- Engine.
ly decreased indicating that heat rate Further study of the Figure 7 shows a
slightly degraded. Investigation revealed "lag" and then "lead" between the value of
that the FCI for the Turbine Cycle was computed and plants indicated coal flows.
found degraded due to higher back pres- The Engine, after solving for fuel chem-
sure, thus the cause of the slight system istry and heating value, computes fuel flow
degradation. However an improved FCI for based on heat input to the working fluid;
Combustion is consistent with a strong BBTC of Eq.(5). Such transient differences
improvement in boiler efficiency, one between calculated and indicated coal
would not expect steam generator heat flows represents effects of the working
exchangers to degrade (i.e., higher irre- fluids stored energy. During a load
versible losses) while at the same time FCI decrease, the computed fuel flow is greater
for Combustion to improve - but such a than the plants indicated since the BBTC
FEBRUARY 2003 | ASME Power Division Special Section 13
FIGURE SEVEN: Input/Loss Response to Loss of Pulverizer Transient
ASME Power Division Special Section

term "sees" effects from the stored energy Canyon coal. Two of six mills running Bear
in Deaerator and condenser (effects meas- Canyon implied 1/3 of the plants fuel was
ured boundary conditions). Conversely high energy with low moisture. With this
during return to full power, calculated fuel configuration, a higher than usual boiler
flow is less than the indicated, caused by efficiency was anticipated; however,
an incrementally higher flow actually Input/Loss computations indicated this
being added to re-establish stored ener- was not the case.
gies required of the loads. Boiler efficiency prior to the six mill
The plant burned Bear Canyon and configuration was approximately 85%.
Buckskin coals, in various combinations, After two mills were bought on line with
throughout 2001. By January 5, 2002 the high energy coal, the computed boiler effi-
plant burned the last of high energy Bear ciency was essentially the same.
Canyon coal. Figure 8 indicates the com- Obviously something was wrong. Total air
puted results during this transition; most flow remained roughly the same, but with
reasonable results are again seen. a lower computed fuel flow. Additionally,
Efficiency decreased typically 0.7% . Stack CO2 was approximately 11.67%,
Although Figures 7 and 8 both employ an Stack O2 at 6.0%. This data, with prior mon-
expanded heating value scale, they also itoring and testing experiences, indicated
demonstrate the volatile nature of mixing the plant was putting too much air into the
coals. For the days plotted in Figure 8, the plant. This was made evident by a variety of
mean change in heating value (before and
after mid-night on the 30th) was 64 TABLE THREE: Coals Burned at Boardman
Btu/lbm; however the standard deviation
of all data was 93 Btu/lbm - typically a
200 Btu/lbm range! Net heat rate during
full load, steady state conditions changed
from 9,820 to 9,876 Btu/kWh, or 56
Btu/kWh degraded. Such information is
valuable, as accurate and repeatable boiler
efficiency computations, even with vari-
able fuels, allows for consistent decisions.

EXAMPLE F: PULVERIZER PROBLEMS


On the November 14, 2001, the plant
was forced to operate with six pulverizers.
The plant maintained full load by config-
uring two mills with high energy Bear
14 ASME Power Division Special Section | ENERGY-TECH
FIGURE EIGHT: Input/Loss Response to Changing Fuels

ASME Power Division Special Section


Engine performance parameters. Trusting total air flow reading while maintaining
in the boiler efficiency result (no change), the "same" Boiler O2 set point. The impli-
operators lowered the O2 set point from cations of this error were quantified by
2.50% to 2.20%. The effects of this were dra- noting boiler efficiency, unit heat rate, and
matic. Boiler efficiency increased to the several FCIs being consistent with
approximately 86%, while Stack CO2 CEMS indications. Additional O2 probes in
increased to approximately 12%, Stack O2 the lower section of the Boiler flue were
decreased to between 5.5 and 5.6%. This again justified by this experience.
data is presented in Figure 9. A further conclusion reached, support-
Net heat rate decreased during this ed by other Input/Loss installations, is
same period from 9,856 to 9,794 that on-line heat rate can offer extremely
Btu/kWh, a 62 Btu/kWh improvement. scattered data. This is seen in Figure 9,
Another key performance parameter was although the scale is greatly expanded to
the decrease in FCI for Stack Losses. illustrate only the change in heat rate,
Further, FCIPower increased to around HR (from the start of the displayed data).
355. However, of note was the increase in However, similar observations has lead to
FCI for the Boiler. By decreasing air flow, the development of a "dynamic heat rate",
more heat absorption takes place in the
water walls of the Boiler, thus higher irre- FIGURE NINE: Sensitivity to Changed O2 Set Point
versible losses. The Boardman plant has
a rather tall furnace, typical of plants
designed for PRB coal, hence, a large rel-
ative heat. Therefore, with lower air flow
and larger heat absorption in this section
of the furnace, higher irreversible losses
would be expected. Again, this increase
was offset both by a decrease in the FCI
for Stack Losses and an increase in the
important FCIPower.
Conclusions reached included not to
trust the Boiler O2 probes given their sen-
sitivity to the given mill configuration.
With this mill configuration, Boiler O2 was
again inaccurately measured. This was
made obvious by noting the increased
Stack O2 and decreased Stack CO2 read-
ings along with a greater than expected
FEBRUARY 2003 | ASME Power Division Special Section 15
FIGURE TEN: Sensitivity to Soot Blowing
ASME Power Division Special Section

which expresses with clarity to the opera- appear in-phase due to skewness (energy
tor which direction his/her actions are dissipation) in the Reheater. At these
causing on unit heat rate - feedback tells peaks (at the highest losses), Reheat tem-
the operator of an improvement or degra- perature is minimized. When the Division
dation (Lang, 2002b). Wall is blown, more heat is removed from
the gas, followed by marked reduction in
heat being delivered to the back-pass. This
EXAMPLE G: FCI CHANGES WITH is confirmed by noting the drop in Reheat
SOOT BLOWING temperature. Second Law parameters sug-
For plant operators, one of the recur-
gest that removing soot from the Division
ring pursuits is the adequacy of soot blow-
Wall exchanger causes more heat to be
ing: Is the plant blowing too much or not
absorbed in this heat exchanger, thereby
enough? Figure 10 presents a plot of sev-
causing a greater T, thus higher irre-
eral FCIs for the boilers major heat
versible losses hence an increase in the
exchangers. Plotted are the FCIs for the
FCI for the Division Wall (as seen).
Reheater and Division Wall Superheater,
Similarly, with less heat delivered to the
also plotted is final Reheat temperature.
back-pass exchangers, a reduction occurs
Soot Blower steam flow was not plotted as
in the T across the tube surfaces reduc-
only system total use was recorded; soot
ing losses, thus a decrease in the FCI for
blowing at Boardman is continuous. Note
the Reheater.
the periodicities of the FCIs and Reheat
Note that minimal cyclic variation in
temperature. This clearly reflects soot
the FCI for the Finishing Superheater was
blowing. The outstanding question is:
observed. Given this response, operators
Where in the steam generator is soot blow-
made the decision to reduce its soot blow-
ing occurring to cause such oscillations?
ing; thus a heat rate improvement. This
The next exchanger downstream from
action was over checked by visual inspec-
the furnace is the Division Walls followed
tion and noting no appreciable change in
by the Finishing Superheater. After the
the FCI pattern.
Finishing Superheater, combustion gases
are split to the Reheater and the Primary
Superheater/Upper Economizer heat EXAMPLE H: INCREMENTAL HEAT
exchangers (or back-pass); such split is RATE CHANGES
governed through dampers as a function of Boardman employs two Forced Draft
final Reheat temperature. Damper controls Fans used for excess air and two Primary
are slow moving. As seen in Figure 10, Air Fans for fuel transfer. Each fan uses its
losses in the Reheater are generally out of inlet vanes as a means to control: Forced
phase with losses (FCIs) in the Division Draft Fans control Boiler oxygen; and the
Wall exchanger; although their peaks Primary Air Fans control primary air duct
16 ASME Power Division Special Section | ENERGY-TECH
FIGURE ELEVEN: Fan Difference Heat Rate and FCI Changes to FIGURE TWELVE: Measured and Computed Effluent Flows
Load Reduction

ASME Power Division Special Section


pressure. Fans are run at full speed, throt- by a decreasing FCIPower, an increasing
tling their vanes. FCI for the Turbine Cycle and degrading
Figure 11 illustrates the sensitivity of heat rate. This evidence lead to the
irreversible losses incurred by the fans heaters removal from service and inves-
due to load changes. Figure 11 plots net tigative testing: all tubes were tested,
heat rate, gross power, FCI for the Fan and drain and isolation valves were inspected,
its corresponding component heat rate for and vents were checked for blockage.
the Fans, hrFan . As shown in Figure 11, Nothing was found. Three months later,
with a reduction in plant output, FCI for during a minor outage, plant personnel
the Fan increases. As expected the fan opened the main condenser finding Heater
continues to run at full speed with #2 expansion joints were entirely missing!
increased throttling due to reduced air Evidently an expansion joint failed due to
demand. Of interest is the increase in the fatigue, resulting in its total destruction
Fans differential heat rate, hrFan, whose with debris critically damaging adjacent
increases can be translated as a cost in expansion joints. Indeed, all expansion
fuel and power associated with load reduc- joints in that section of the condenser
tion of 5 Btu/kWh is indicated. were damaged that for the Deaerator. The
DAs protective shrouding was destroyed
EXAMPLE I: COMPARISON OF along with an expansion joint penetration.
EFFLUENT FLOWS All was repaired, with Heater #2 extraction
A long-standing objective of Input/Loss lines being sealed.
technology has been to replace direct In Figure 13-14 note the consistency in
measurements of effluent flows, now prac- FCI data, heater temperature data and heat
ticed by the power industry, with computed rate. Daily averaged heat rate degraded
flows based on consistent boiler efficiency, from 9768 Btu/kWh on 1/26 to 9868
fuel flows and the same stoichiometrics as Btu/kWh on 1/29 (100 Btu/kWh or 1.02%);
used to compute boiler efficiency; thus FCI for Power degraded from 350.9 to
consistent with unit heat rate. Figure 12 346.9 (1.14%), and FCI for the Turbine
illustrates Boardmans regulatory reported Cycle degraded from 106.7 to 111.4
effluent flows (based on direct measure- (4.40%) over the same time - all consisten-
ments) versus those computed by cy computed by the Performance Monitor.
Input/Loss. Observed is a 16.4% difference. FCI for the Turbine Cycle clearly points to
The measured is high - as has been higher irreversible losses. Obviously, a
observed and reported by others. These feedwater heater failure leads to a degrad-
flows are volumetric rates using EPA ed heat rate, but by isolating the #2 extrac-
defined standard conditions (of 68 F and tion its steam passes to the last stages of
14.6959 psiA). the LP turbine producing additional
power. The effect between 1/26, before the
EXAMPLE J: TURBINE CYCLE EFFECTS failure and after repairs was a net 32
On January 27, 2002 the plant experi- Btu/kWh improvement.
enced difficulties with Feedwater Heater What is noteworthy is how this failure
#2 (2nd lowest pressure heater). Plant per- was quantified both thermodynamically
sonnel first noted Heater #2 level control and financially. Although the problem was
problems which was immediately con- repaired during a short outage, in the
firmed by an increasing FCI for the Turbine future knowing the sensitivities of compo-
Cycle. Figure 13-14 illustrates a decreas- nent FCIs, cost of heat rate degradation,
ing tube-side outlet temperature, tracked cost of repairs and cost of lost generation,
FEBRUARY 2003 | ASME Power Division Special Section 17
FIGURE THIRTEEN-FOURTEEN: Heater #2 Failure (Before/After) ACKNOWLEDGMENTS
It is important to recognize the
Boardman plant operators and its engineer-
ing staff for their outstanding contributions.
Particularly helpful have been Marc
Andreason, Randy Curtis, Dean Mason and
Wayne Oren who implemented plant modifi-
cations, conducted testing projects, main-
tained a plant with 0.25% water loss,
installed instrumentation and maintained
the Performance Monitoring system - all
leading to the improvements cited.

REFERENCES
Lang, F.D., US Patents 5367470, 5790420,
and US patents & Patent Cooperation
ASME Power Division Special Section

Treaty applications pending, 1994-


more logical decisions can be made as to 2002.
investigation techniques and operational Lang, F.D., "Monitoring and Improving
alternatives. Expansion joints will be Coal-Fired Power Plants Using the
replaced during Spring 2002 outage. Input/Loss Method (Part I)", Am.
Society of Mech. Engrs., 1998-IJPGC-
CONCLUSIONS Pwr-33, pp.789-797.
Burning coal to produce power is a Deihl, B., and Lang, F.D., "Practical
complicated process. If we as an industry Experience with the Input/Loss
are to monitor and improve electrical pro- Method as Applied to a CFB Power
duction using a minimum of fuel we must Plant", Am. Society of Mech. Engrs.,
thoroughly understand the process. 1999-IJPGC-Pwr-34, p75-86.
North America, and the world, is blessed
with an abundance of coal. However, the Lang, F.D., and Lang, A.F., "Monitoring and
power industry can not continue to Improving Coal-Fired Power Plants
assume that cheap fuel justifies cursory Using the Input/Loss Method - Part II",
understanding. The pressures for Am. Society of Mech. Engrs., 1999-
improved boiler efficiency given this IJPGC-Pwr-34, pp.373-382.
represents an immediate reduction in Lang, F.D., "Monitoring and Improving
emissions come from throughout socie- Coal-Fired Power Plants Using the
ty, from regulators, from environmental- Input/Loss Method - Part III", Am.
ists and from the financial sector. Society of Mech. Engrs., 2000-
Process understanding comes about by IJPGC2000-15079 (CD).
quantifying key performance parameters Lang, F.D., "Monitoring and Improving
... and dogged persistence. To act on this Coal-Fired Power Plants Using the
information, requires real time access to Input/Loss Method - Part IV,
consistent, system-oriented information Preliminary", Am. Society of Mech.
(not "data"), and a dedicated staff. Engrs., 2002a-IJPGC2002 (to be pub-
This paper has demonstrated some of lished).
the tools, and their sensitivities, which are
now available to power plant engineers. At Lang, F.D., "Fuel Consumption Index for
Boardman, we have improved boiler effi- Proper Monitoring of Power Plants -
ciency in a permanent fashion, and, more Revisited", Am. Society of Mech.
importantly, we have assisted operators by Engrs., 2002b-IJPGC2002 (to be pub-
giving them the analytical tools for contin- lished).
uous feedback. The value to Boardman Lang, F.D., EX-FOSS: A Program for
operators of having a consistent tool, as is Monitoring and Analysis of Fossil-Fired
the Input/Loss Method, has proven invalu- Boilers, Exergetic Systems, Inc., San
able when coupled with testing and con- Rafael, CA. (Jan. 2002c, Ver.2.7, Mod.65,
tinual training. first published 1983). ET

ASM E Membership Information


For information on how to join the ASME, go to
http://www.asme.org/divisions/power/membership/
or call 800.977.0474 and well fax you an Express Application form.
18 ASME Power Division Special Section | ENERGY-TECH
Call For Papers
International Conference of Power Engineering 03 (ICOPE-03). November 9-13, 2003,
International Conference Center, Kobe Port-Island, Kobe, Japan
Organized and Sponsored by the Power of Energy System Division of The Japan Society of
Mechanical Engineers. Co-Organized by the Power Division of The American Society of Mechanical
Engineers and The Chinese Society of Power Engineering
Objective
The Conference aims to provide a platform for promoting collaborations among professional
societies and enhancing technical exchanges in the power engineering community. The
Conference will include technical sessions, special lectures, social activities, and exhibition.
Scope and Topics
ICOPE will cover both fundamental and applied topics in power engineering including:
1. Power Systems 7. Generators 12. Renewable Energy
2. Distributed Energy 8. Components, Equipment 13. Waste to Energy

ASME Power Division Special Section


Systems and Auxiliaries 14. Fuel Cells
3. Fuel Utilization 9. Operations and 15. Economics
4. Advanced Combustion Maintenance 16. Emerging Technologies
Technology 10. New Materials for Energy 17. Others (power-related
5. Boilers Systems topics)
6. Turbines 11. Environmental Protection

Steering Committee
Chairman Prof. Terushige Fujii
Kobe University
Co-Chairman Mr. William C. Stenzel
Consultant, Sargent & Lundy, LLC
Prof. Kefa Cen
Zhejiang University
Members Mr. Toshikazu Ikegami, Secretary General
Mitsubishi Heavy Industries, Ltd.
Dr. Yutaka Kawata, Chair of General Affairs
Mitsubishi Heavy Industries, Ltd.
Mr. Ryohei Shirai, Chair of Financial Affairs
The Kansai Electric Power Co., Inc.
Dr. Kenji Mori, Chair of Scientific Committee
Kawasaki Heavy Industries, Ltd.
Dr. Yoshinori Hisazumi, Chair of Social Program Committee
Osaka Gas Co., Ltd.
Abstract Submission
Submissions are welcome by authors from any country. Authors are strongly requested to
attend the Conference and to present their papers in oral sessions individually. Initial screening
will be based on the abstracts. Authors willing to present their papers should submit 4 copies of
400 words abstracts in English, containing the following: title of paper, names, affiliations and
complete addresses (with the phone and fax numbers, and e-mail addresses), two to five represen-
tative keywords, and an abstract summarizing the objectives, main findings and results. Abstracts
should be submitted by mail to either the following:
USA: Impor
ta
Prof. David Y.S. Lou, J.K. Ludwickson Apri nt Dates
Distinguished Professor and Chairman l 19,
2003 for Au
400 w thors
Department of Mechanical Engineering May ords abstra
University of Nebraska-Lincoln 1, 20 ct due
Notific 03
104N Walter Scott Engineering Center Jun at ion of
e 21, abstra
Lincoln, NE 68588-0656, USA 2003 ct acc
eptanc
Full-le e
Phone: 402-472-2375, Fax: 402-472-1465 July ng th ma
19, 2 nuscrip
E-mail: dlou1@unl.edu 0 03 t du e
Notific
ation
All full-length manuscripts will be peer reviewed. All script of full
accept -le ngth m
accepted papers will be published in the Conference Aug ance anu-
ust 1
Proceedings that will be available at the Conference site. Camer 6, 2003
a-read
Also the papers of JSME members will be endorsed for registr y man
at uscrip
publication in the JSME International Journal upon co-aut ion of at lea ts and
pre-
hors w s
reviewers recommendation. ith reg t one of the
istratio
Detailed information about the conference, including location, n fee d
ue
travel, accommodation, abstract submission, proceedings, venues, registration,
etc. can be found at the web page of the ICOPE-03:
http://www.jsme.or.jp/pes/ICOPE-03.
FEBRUARY 2003 | ASME Power Division Special Section 19

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