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Boiler Efficiency Evaluation

Efficiency Facts
Combustion Efficiency (Burner)
Heat Transfer Efficiency (Surface area)
Boiler Efficiency (Total System Efficiency)

Fuel 100%

Flue Gases 18%

Steam 75%

Boiler Efficiency

Boiler Efficiency=75% Shell Losses 2%

Ash
Unburnts 2%

Blow Down 3%

Efficiency Evaluation Method


Direct Method
Measurement of
steam & Fuel flow
only
Approximate Result

Indirect Method
Measurement of
Temp, Pr, Fuel/Flue
gas analysis,
More accurate result
Heat Loss Method
ASME/IS

DIRECT METHOD
Boiler Efficiency =

(Steam Flow)

Enthalpy)

Output X 100
Input
X (Steam Enthapy- F W

-----------------------------------------------------------------(Fuel Flow X GCV)

OR

Boiler Efficiency =Evap.Ratio X Steam


Enthalpy

INDIRECT METHOD
(As per IS: 8753)

Various Boiler Losses


1. Heat Loss in Dry Flue Gases
2. Heat Loss Due to Moisture and Hydrogen in the
Fuel
3. Heat Loss Due to Moisture in the Air
4. Heat Loss Due to Carbonmonoxide in Flue Gases

5. Surface Heat Loss Due to Radiation


6. Blowdown Losses

CONTROLLABLE & UNCONTROLLABLE LOSSES

Boundary barrier Balance

Steam
process

Fuel
tank

179.c
stack

5200kg/hr,120 .c

400kg/hr
30.c

4680kg/hr
520 kg.hr water
10% makeup water

Boiler

320.c

APH
30.c

Measurements required for thermal


energy Audit in Boiler
Fuel flow, steam/water flow
Temp & Pressure of steam
Temperature of water inlet / outlet of economizer
Draught
CO2, O2, CO , Temperature from Flue Gas
Surface Temp & Ambient Temp
Surface Area, m2
Size & dimension of boiler

Test Procedure

Plan / inform the concerned dept.


All the Instrument should be calibrated
Ensure fuel and water availability
Test at maximum steam load condition
Conduct 8 hrs minimum (1/2 or 1 hr frequently)
Water level in drum should be same at start &
end of test
Gas Sampling point should be proper
No blow down during test

Requirements in boiler

Oil level in tank


Water level in Service Tank
No leakage water
No blow down

Boiler Testing Sheet


Fuel Analysis Report
Boiler Technical Specifications

Fyrite kit

CO2, O2 in
flue gases

Combustion analysers

Contact thermometer

Infrared thermometer

RPM measurement

Tachometer

Stroboscope

BOILER PERFORMANCE TESTING


Date : 8/2/2001
Time
Fuel
Feeder
rpm

Steam Pressure - 5 to 7 kg/cm2


ID
PA
SA
(Damper position
opening)

ID
PA
SA
(Power management)
KW

O2

CO
CO2 Temp
(Flue gas analysis)

Temp

11:00
AM

21

100%

40%

50%

22

1.9

14.2

307

5.1

125

29

11.30
AM

30

50%

20%

30%

20.6

6.96

1.9

9.8

16

8.3

126

30

* At normal operatiing condition, power and flue gas measurement were taken
Then, excess air reduced by closing damper in all FD and ID secondary air fan
Fuel feeding rate is increased from 21 rpm to 30 rpm
Again power and flue gas measurement were taken
Suggesions : 1) Keep furnace draft + 5mm
2) Flue gas should be light gray at chimny top
3) keep Lowest possible damper position

Boiler Calculations

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