1.Objectives To achieve the goal of enhanced boiler efficiencies through Efficient Boiler mai ntenance Good operation practices.

s. 2.Factors Affecting Boiler Performance Excess air control Proper water treatment programme and blow down control Draught control Boiler insulation Percentage loading of boiler Steam generation pressure and temperature Quality of fuel Periodical cleaning of boilers Periodical soot blowing 3.Performance Improvement Opportunities There are several ways of improvement opportunities : Generation Distribution Recoverable Heat from system 4.Achieving Efficiency The primary duty of the boiler operator is to achieve optimum operating efficien cy of the equipment consistent with high reliability and low cost. The steam gen erators efficiency depends on proper control of time, temperature, turbulence and oxygen. 5.GOOD OPERATION PRACTICES All fuel inputted to a boiler is converted into either usable steam or waste hea t. Simply put, Input fuel (latent energy) - steam generated (thermal energy) = heat losses thro ugh flue gas, hole, cracks, condensate, etc. Boiler efficiency is expressed by the amount of fuel needed as an input - not by the amount of steam produced or system pressure. However, the easiest way to me asure efficiency is to look at the amount of waste heat, that is, Boiler efficiency = 100 percent - heat losses. Thus, a boiler that is 75 percent efficient converts three-quarters of the input fuel into steam, but losses 25 percent of the fuel as waste heat. Factors affecting boiler efficiency are the air-to-fuel ratio and combustion eff iciency. Boiler efficiency can also be improved significantly by reusing waste h eat exiting the stack. 6.

11.Factors Affecting Boiler Periodical cleaning of boilers Periodical soot blowing Proper water treatment programme and blow down control Draft control Excess air control Percentage loading of boiler Steam generation pressure and temperature Boiler insulation Quality of fuel 12.Combustion

 Combustion occurs as fuel and air are mixed within the combustion chamber. As me ntioned earlier, the air-to-fuel ratio is important for proper combustion. Combu stion efficiency is also influenced by air leaks and the temperature of incoming air. 13.Reduce Excess Air Excess air is the result of the air-to-fuel ratio going into the boiler - this a n important factor governing boiler efficiency and affects both combustion and h eat loss. Excess air consumes energy as it is heated. Energy is then wasted as t his heated air is released up the stack. A "rule of thumb" is that boiler efficiency increases one percent for every 15 p ercent reduction in excess air or 40F reduction in stack gas temperatures . 14.However, without sufficient air, not all fuel will burn This wastes fuel and may even be dangerous. Unburned fuel will continue to move through the system, leaving behind soot. Deficient air levels may also result in the formation of carbon monoxide and smoke. Soot and carbon monoxide can accide ntally combust in areas not designed for this, which will shorten equipment life . Soot buildup also acts as an insulator, blocking some of heat transfer between combustion gas and steam generation 15. 3 Ts of Combustion Time All combustion requires sufficient Time which depends upon type of Reaction Time All combustion requires sufficient Time which depends upon type of Reaction Time All combustion requires sufficient Time which depends upon type of Reaction 16.Stoichiometric Combustion The amount of air required for complete combustion of the fuel depends on the el emental constituents of the fuel that is Carbon, Hydrogen, and Sulphur etc. Thi s amount of air is called stoichiometric air. Constituent %age by Weight Carbon 23.50 Hydrogen 3.25 Oxygen 21.75 Sulphur 0.00 Water 50.00 Ash 1.50 Nitrogen 0.00 17.Analyze flue gas Analyze flue gas to measure the amount of oxygen and the stack gas temperature, and then calculate boiler efficiency. Adjustments can then be made to optimize t he level of excess air and incoming air temperatures. 18.DCS Computer-based distributed control systems (DCS) are now common features, and ar e relatively cheap to install compared to annual operating costs. DCS automatica lly controls the fuel burner to "trim" oxygen levels as needed, keeping the airto-fuel ratio optimized. Trim systems are particularly useful when stack tempera tures are high or when fuel composition is highly variable. Payback on investmen t is usually less than one year. 19.Check and repair air leaks This should be part of routine maintenance, as recommended by the boiler manu facturer. Air infiltration can occur in the furnace, burner or stoker, and steam generation section. 20.Consider the temperature of incoming air CHigher temperatures result in better combustion efficiency. Seasonal variation in air temperatures affects excess air and boiler efficiency. This is important as seasons change and ambient air temperatures fluctuate. An oxygen trim control is beneficial to accurately control excess air when combustion air temperature changes. To improve efficiency, air can be preheated using an air economizer. One low-cos

t method is to modify the combustion air inlet so that it draws hot air released by the stack near the top of the boiler room or use flue gas recirculation onsider the temperature of incoming air 21.Preventing Heat Loss Heat loss can reach as much as 35 percent of fuel input. Most of this waste heat goes straight up the stack, like heat lost up the chimney of a fireplace. The l ower the temperature of these gases, the more efficient the system. In other wor ds, a 100 percent efficient system would, theoretically, expel flue gases at the same temperature as ambient air. In reality, the lowest temperature possible is roughly 300 F, unless a condensing heat exchanger or heat economizer is utilized . 22.An economizer recovers waste heat from the stack The heat is then usually directed to boiler feed water for preheating. Be sure t o have the boiler system cleaned and tuned before installing an economizer so th at an accurate measurement of stack gas temperature can be taken. Besides waste heat up the stack, heat can be lost in the burner and combustion c hamber. Soot on the combustion side and deposits on the water side act like insu lation, blocking some heat transfer and the efficient generation of steam. Just 1/8 inch of soot, for example, can decrease boiler efficiency by as much as 8 pe rcent 23.Reduce heat loss by keeping heat transfer surfaces clean To keep the fire-side surfaces clean, ensure there is adequate excess air to avo id soot build-up. A soot blower used periodically helps remove soot from the fir e-tubes. Water-side maintenance depends on water treatment protocols 24.Most methods for removing impurities involve the addition of chemical treatme nts Treatments should be balanced to minimize the use of chemical additives as much as possible (and thus, reduce costs) without interfering with the removal of imp urities. Clarifiers and filters also help eliminate impurities, and are worthwhi le investments. Other water treatment methods include reverse osmosis and ion ex change demineralization Besides blocking efficient heat transfer, impurities lead to energy waste becaus e of the need for periodic boiler blow down. Although blow down effectively remo ves impurities, it is also one of the largest energy wastes since it involves di scharging boiler water. This wastes both the thermal energy embodied in the wate r as well as the chemical additives used to treat the feed water. Electronic controllers can automate bottom blow-down so that it is done as infre quently as possible without allowing excessive build up of impurities. With cont inuous blow-down, discharged water can be directed through a heat exchanger to r ecover some of the thermal energy that would otherwise be lost. This heat can th en be used to preheat boiler feed water. However, the best option is to properly treat feed water correctly and minimize blow-down. 25.Effective Boiler Maintenance Boiler operation and maintenance are closely tied together. Good operation inclu des performing necessary daily and periodic maintenance. Low maintenance cost de pends on good daily operating control, given that the system and fuel are compat ible. Operating a steam generator whether it is a low-, medium-, or high-pressure desi gn is a complex undertaking. Important physical and chemical balances are necess ary for safe and efficient control. 26. Maintenance: Maintenance means maintaining the actual condition of equipment (design specifi cation & controlling parameter) for which they must be intended. The replacement of parts, repair and complete overhaul of all equipment should be done by experienced personnel only. 27. Predictive preventive maintenance

 Check for unusual noises from steam/water leakages. Check for unusual traces of water o floor. Look for valve and gland leakage Discoloration, hot spots and bulging etc. Watch the furnace for clinker & bagasse pile up. Walk arround the furnace for any hot spot or gas leak. Inspect plenum hopper/wind box for any air leakage Check position of fan and field dampers Check for leakage from safety valve at normal operating pressure Check all the drain lines. While doing soot blowing inspect for condensate, steam leaks from soot blower. 28. For Efficient maintenance From management team: Operator should have catalogue of all equipment with plant layout. Operation and maintenance manuals copy, specification list, troubleshooting gui de provided to the concern person. Cause and effect diagram, fish bone diagram should be made for any accident or f ailure of any equipment. Ensure that there should be proper communication between management (operation) team & maintenance make sure that there is no Hide and seek game. Provide all necessary measuring and repairing tools. Provide all safety gadgets 29. For Efficient maintenance From maintenance team: Team having sufficient knowledge about maintenance. Its his prime responsibility to kept manuals, document copy at proper and secu re place. Oilmen, pump operator have proper understanding & knowledge about Grease, oils ( Type, name, service period, flashing, freezing & melting point). Its their duty to place all equipment , tools & oil(grease) at proper place. Also put name tag of oil, tools etc so, that he should have clear picture of wha t he needs.

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