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Transcript of Boiler Eff
A-Z of Boiler Efficiency
Boiler House Division
What’s Boiler Efficiency
Boiler Efficiency is the percentage of heat input to the boiler which which
is utilized in generating steam.is utilized in generating steam.
Boiler Efficiency = Heat in the Steam generated
Heat supplied through Fuel combustion
Measuring Boiler Efficiency
1. Direct Efficiency : % ηηηη = S (hs - FWT)
F X GCV
Where S = Steam generation in Kg/hr
hs = enthalpy of steam at op. Pr. In Kcal/kg
FWT = Feed water Temp
GCV = Gross calorific value of fuel in Kcal/kg
F = actual fuel flow in Kg/hr
Advantage:
It’s the true delivered boiler efficiency & covers all kind of losses
Disadvantage:
It doesn’t give break-up of losses
2. Indirect Efficiency :
% η = 100 - All Boiler Losses
= 100 - stack loss L1
- loss due to water and hydrogen in fuel L2- radiation loss L3-Un burnt losses(L4)
So, % ηηηη = 100 - (L1+ L2 + L3+L4)
This is far more useful, as this gives break up of allboiler losses , emphasizing which area needs more attention.
Measuring Boiler Efficiency
Measuring Boiler Efficiency
Radiation
Loss
(1-2%)
Blow-DownLoss
(2-5%)
Enthalpy Loss
(7-9%)
On-Off Losses
(0-2%)
Un burnt Losses
(0-6 %)
Stack Loss
(4-12 %)
Boiler Operating Efficiency Facts
Boiler Efficiency Data Collected from over a 100
boilers for CII
Gas Fired Boilers
50
55
60
65
70
75
80
85
90
1 2 3 4 5 6 7 8 9 10 11 12
8172.869.8IdealIn DirectDirect
Max Gap: 11%Max Gap: 11%
Oil Fired Boilers
40
45
50
55
60
65
70
75
80
85
90
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49
8477.372.2IdealIn DirectDirect
Max Gap: 12%Max Gap: 12%
Solid Fuel fired Boilers
40
45
50
55
60
65
70
75
80
85
90
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47
7864.860.9IdealIn DirectDirect
Max Gap: 18%Max Gap: 18%
Cost of Boiler operation–Oil\Gas fuels
Capital Cost
15%
Electricity
cost
10%Maint Cost
5%
Water Cost
5%
Fuel Cost
65%
Capital Cost
Fuel Cost
Water Cost
Maint Cost
Electricity cost
Cost of operation-Solid fuel
Fuel Cost
50%
Capital Cost
25%
Water Cost
5%
Maint Cost
10%
Electricity Cost
10%
Capital Cost
Fuel Cost
Water Cost
Maint Cost
Electricity Cost
What affects Fuel Bill?
• Excess Air in flue gas%
• Feed Water Temperature
• Stack temperature
• Un burnts
• Number of Boiler On-Offs
• Scaling on tubes
• Soot Deposition
• Blow down TDS
• Moisture in Fuel
What to Monitor inside Boiler House
1. Steam Flow
2. Steam Pressure
3. Fuel Flow
4. S: F ratio
5. Stack Temp
6. % O2 in Flue gas
7. Feed Water Temp
8. Blow down TDS
9. Furnace Pressure
Parameters to monitor
Variation in S:F
is ‘the’ culprit!
Losses: Cause, Effect & ControlStack Loss causesStack Loss causes
1. Excess Air
2. High Stack Temp (due to Scale/soot
Deposition)
Stack loss ControlStack loss Control
1. Keeping Air to Fuel Ratio right
2. Keeping % O2 within limit
• Oil Fired : 3-4.0 %
• Gas Fired:2-3%
• Solid Fired: 6-7%
3. Continuous monitoring of Stack Temp. Periodic tube cleaning
Losses: Cause, Effects & Control
Boiler OnBoiler On--Off Loss CausesOff Loss Causes
1. Fluctuating steam load
2. Narrow operating pressure band
Boiler OnBoiler On--Off Loss EffectOff Loss Effect
1. Combustion destabilization
2. Un burnts
3. Lower combustion efficiency
Boiler OnBoiler On--Off Loss ControlOff Loss Control
1. Changing boiler parameters according to
steam demand
2. Fuel feeding according to the load
3. Widening operating pressure band
Losses: Cause, Effects & Control
Blow down Loss CausesBlow down Loss Causes
1. Manual Blow down
2. TDS level above specified limit
Blow down EffectsBlow down Effects
1. Excess blow down is a direct loss
2. Lesser blow down leads to scale
deposition & lowers boiler efficiency
Blow down ControlBlow down Control
1. Automatic Blow down control
Losses: Cause, Effects & Control
Radiation Loss causesRadiation Loss causes
1. Fluctuating steam load
2. Radiation loss reduces with increase in
load
Enthalpy Loss causesEnthalpy Loss causes
1. Fuel Hydrogen & Moisture content
Draft Loss causes & ControlDraft Loss causes & Control
1. Air leakage through Damper due to
chimney draft
2. Reducing on-off losses
Boiler Efficiency Thumb rules
1. 2% Decrease in % O2 -----� 4% Efficiency improvement
2. 6 Deg C Increase in Feed water Temp due to condensate
recovery-------� 1% lesser Fuel Consumption
3. 20 Deg C decrease in Stack temp-------� 1% lesser Fuel
Consumption
4. 1% un burnts -------� 2% Excess Fuel Consumption
5. 3 mm soot deposition on tubes increases fuel consumption by
2%
Scope for Saving
Ideal S:F Ratio =Boiler Rated Efficiency* GCV
(Steam Enthalpy at Op. Press-FWT)
e.g. for a Furnace Oil fired Boiler
FO calorific value : 9600 Kcal/kg
FWT: 70 Deg C
Steam enthalpy : 663 Kcal/Kg @ 9 Kg (g)
Ideal S:F Ratio =0.89* 9600
(663-70)= 14.4
Boiler Rated efficiency: 89 %
If actual S:F ratio is 13
Scope of fuel saving = (13/14.4)*4.5
= 10 %
The gap calculated is between Actual & Ideal S:F.
Boiler Efficiency Steam To Fuel ratio Extra fuel consumption
89% 14.40 Not Applicable
85% 13.75 5%
80% 12.90 11%
78% 12.62 13%
Boiler Efficiency Vs Extra Fuel Consumption Boiler Efficiency Vs Extra Fuel Consumption
Copyright Forbes Marshall,
2006-07
Effimax: National Accolade
Copyright Forbes Marshall,
2006-07
What is Effimax??
SCADA based Online Boiler Efficiency Measurement System
Online Boiler Efficiency Measurement
Combustion quality monitoring
Boiler House Losses Break up
Logging & Trending of Boiler Parameters
Web Connectivity-Remote boiler
monitoring
Useful Diagnostics/Continuous
Performance Evaluation
Copyright Forbes Marshall,
2006-07
What Effimax helps in achieve??
Enhancing Boiler Efficiency
Knowing where we are??
Detailing areas of improvement
Knowing gap between ideal & actual
Efficiency
Effimax boiler data analysis
Fine tuning boiler SOP to meet loading
pattern
Fuel Bill Reduction
EFFIMAX Variants with Application
Copyright Forbes Marshall,
2006-07
Effimax 1000
Online Boiler Steam to Fuel Analyzer
What It’s? What It does?
Calculates S:F ratio
Calculates Boiler’s Direct Efficiency
Plots variation in S:F with Load
Monitors Steam Flow, Fuel Flow,
Feed Water Temp & Steam Pressure
Application
All Oil/gas fired boilers up to 2 TPH
Touch Screen Based System with PC
Connectivity
Copyright Forbes Marshall,
2006-07
Effimax 2000
Online Boiler Efficiency Analyzer
What It’s? What It does?
Calculates Boiler’s in- Direct Efficiency
Break up of all boiler losses
(Stack Loss , Blow down Loss, Enthalpy
Loss , Radiation Loss)
Monitors Steam Flow, % O2 ,
Feed Water Temp , Stack Temp, Steam
Pressure, Boiler TDS,
Application
All Solid fuel fired Boilers
Touch Screen Based System with
PC Connectivity
Automatic Blow Down control
Minute, Hourly & Daily Summary
Report
Trending of Key parameters w.r.t Load
Copyright Forbes Marshall,
2006-07
Effimax 3000
Online Boiler Efficiency Analyzer
What It’s? What It does?
Calculates Boiler’s in- Direct Efficiency
& Steam to Fuel ratio
Break up of all boiler losses
(Stack Loss , Blow down Loss, Enthalpy
Loss , Radiation Loss)
Monitors Steam Flow, Fuel Flow ,% O2
Feed Water Temp , Stack Temp, Steam
Pressure, Boiler TDS
Application
All Oil/Gas fired Boilers above 2
TPH
Touch Screen Based System with
PC connectivity
Automatic Blow Down control
Minute, Hourly & Daily Summary
Report
Trending of Key parameters w.r.t Load
Effimax Schematic
Copyright Forbes Marshall,
2006-07
Hourly Report
Analyzing Effimax reports
EffiMax User interface
Copyright Forbes Marshall,
2006-07
Hourly Report
S: F Variation
captured
Variation in % O2
captured
Variation in % O2
captured
TDS maintained in the
boiler
Variation in steam
pressure captured
Boiler SOP as per EFFIMAX Reports
O2 variation Correct blower fan settings
ImpactImpact
Un burnts & stack
loss reduction
ActionAction
Boiler pressure variation Correct Operating pressure band selection
ImpactImpact
On Off loss reduction,
Improved dryness
ActionAction
Steam Load variation Correct Fuel Feed Rate determination
ImpactImpact
Improved combustion
efficiency
ActionAction
Partial Reference List
TEXTILES
Indocount Kolhapur
Bindal Silk Surat
Welspun Gandhidham
Janaki Bhilwara
Sulzer Processor Bhilwara
Ranjan Processor Bhilwara
Sangam Processors Bhilwara
Anant Syntex Bhilwara
RSR Mohota Nagpur
Gimatex Nagpur
Shriji Prints Surat
Niharika Surat
Aishwarya Prints Surat
Alok Industries Vapi
SEP
Habib Agro Mysore
Cargill Gandhidham
Cargill Paradeep
Kanpur Edibles Kanpur
Sheel Chand Agro Rudrapur
Shri Shri Niwasji Raebareli
Astha Industries Rae bareli
Hemraj Oils Kolkata
Vaighai OIls Madurai
Amrit Banaspati Rajpura
Sita Edibles Nagpur
Partial Reference List
PHARMA
Zydus Sikkim
Zydus Baroda
Hetero Hyderabad
DRL Vizag
DRL Hyderabad
Ranbaxy Mohali
Torrent Ahmedabad
Novartis Goa
Lupin Goa,Tarapur
Cipla Kurkumbh,Baddi,Sikkim
Piramal Hyderabad
Teva UP,Canada
Biological E Hyderabad
Syngenta Goa
BREWERIES & BEVERAGES
Balaji Breweries Chennai
Millenium Breweries Aurangabad
Som Breweries Bhopal
Fosters Aurangabad
UB Mangalore
UB-KBDL Bangalore
Pepsico Fritolays Kolkata
Pepsi Malaysia
Pepsi Aurangabad
Pepsi Mumbai
Coca Cola Ahmedabad
Brindavan Bottlers Lucknow
UB Daruhera,Delhi
Tata Coffee Madurai
Partial Reference List
PAPER
Jollyboard Aurangabad
Madhya Desh Nagpur
Nithya Packaging Chennai
Modinagar Paper UP
Prolific Paper UP
Kaygaon Paper Aurangabad
Ganga Paper Pune
Banwari Paper Kashipur
Venkraft Paper Chennai
Ballavpur Paper Kolkata
Chandariya Paper Mills Kenya
Supreme Duplex Madurai
FOOD,FMCG
Nestle Malaysia
Nestle Manesar (Haryana)
Maccain Foods Ahmedabad
HUL Nashik
Haldiram Delhi,Nagpur
Dabur Delhi,Kolkata,Srilanka
P&G Baddi
Amul Dairy Baroda
Doodhsagar Ahmedabad
Sabar Dairy Ahmedabad
Boiler’s with EFFIMAX operate 5-10% more
efficiently than without it!
Boiler House DivisionForbes Marshall (P) Ltd
PB:29, Old Mumbai Pune
Highway
Kasarwadi, Pune