Conditions causing Poor

Performance of Boiler
• Non-Optimum Reheat or Superheat
steam temperatures.
• Higher than design economizer exit gas
temperature or furnace exit gas
temperature caused by poor combustion.
• Higher than design Re heater or Super
heater De-Superheating spray flows.
 Conditions causing Poor
Performance of Boiler
• Fly ash Unburned Carbon or Loss on
Ignition greater than 5% for Eastern
Bituminous Coals or greater than 1% for
Western or Lignite Coals.
• High Bottom Ash Loss on Ignition.
• Non-Optimum utilization or distribution
of primary air, secondary air and over fire
air, if applicable.
 Conditions causing Poor
Performance of Boiler
• Increased auxiliary horsepower
consumption by coal pulverizers and fans
• Reductions in capacity factors due to
excessive furnace or convection pass
slagging or fouling.
• Excessive boiler setting air in-leakage.
• Excessive air heater leakage.
• Increased cycle losses with increased
sootblowing due to non-optimum
combustion.
 Conditions causing Poor
Performance of Boiler
• Excessive pulverizer spillage on vertical
spindle, roll and race and ball bearing
type pulverizers. Reductions in capacity
factors due to pulverizer or fan capacity
limitations.
• Reductions in capacity factors due to
Superheater or Reheater tube
overheating and/or coal-ash corrosion.
Requirements For Achieving
Optimum Conditions
• Furnace exit must be oxidizing,
preferably 3% excess O2.
• Minimal air in-leakage between the
furnace exit and economizer exit.
• Pulverizer fineness of >75% passing
200 Mesh and <0.3% remaining on 50
Mesh.
• Secondary (combustion) air balanced
to within ±5% between burners
Requirements For Achieving
Optimum Conditions
• Optimum windbox to furnace
differential, typically 100mm w.c. at
full load.
• Optimum Pulverizer Primary Air to
Fuel Ratio. In most cases, air to fuel
ratio of 1.8 to 1 on roll and race and
ball bearing type pulverizers, and 1.4
to 1 on attrition and ball tube
pulverizers.
Requirements For Achieving
Optimum Conditions
• Fuel balanced between each
pulverizers fuel lines to within ±10%
deviation from the mean.
• Pulverized coal line dirty airflow
balanced between each pulverizers
fuel lines within ±5%.
• Pulverized coal line clean air
velocities balanced to ±2% of the
mean.
Requirements For Achieving
Optimum Conditions
• Coal line minimum velocities of 17
Mps.
• Burner mechanical tolerances with
±6mm (circular burners), burner
buckets stroked and synchronized to
within ±2° (tangentially fired).
• Primary airflow metered and
controlled to ±3% accuracy.
 Requirements For Combustion
Optimisation Programme
• Boiler testing to identify opportunities for
improved unit heat rate.
• Comprehensive inspections of the boiler,
burners, pulverizers and auxiliaries to
identify and address opportunities related to
mechanical tolerances.
• Technical direction of outage repairs to
ensure mechanical tolerances are optimized
as well as training of maintenance personnel
in achieving optimum mechanical tolerances.
Requirements For Combustion
Optimisation Programme
• Design new or calibration of existing air
flow measurement elements to facilitate
optimum management and control of
primary air, secondary air and overfire air
(when applicable).
• Curtain or boundary air incorporated into
some low NOx burner systems must also
be precisely measured and controlled.
Requirements For Combustion
Optimisation Programme
• Modifying existing equipment (pulverizers,
boiler heating surfaces, fans, burner
components) to meet challenges of switching
fuels or changing status of unit between
cyclic and non-cyclic.
• Boiler tuning and testing to achieve all
"pre-requisites" for optimum combustion.
Requirements For Combustion
Optimisation Programme
• "Awareness" training of boiler
operators, maintenance personnel and
engineering personnel to sustain long
term improvements achieved through
combustion optimization during day to
day operation. Usually termed a
"Performance Preservation Program".
COMBUSTION OPTIMIZATIONGUIDELINES -
SUMMARY

• Secondary Air Balancing

• Burner Tilt Timing
• Fuel Balancing
• Reduce Air-In-Leakage
• Control Primary Air Flow
Unit Generating Capacity Limitations
From Inadequate Fan Performance
• Higher ambient temperatures result in less
stack draft.
• ID fan capacity limitation may result in load
reduction or inability to maintain desired
excess air levels.
• Low excess air due to fan capacity limitation
can result in
– Increased slagging and fouling propensity
– High Flyash Loss On Ignition
– Superheater and Reheater tube overheating
– High boiler exit gas temperature
 Common conditions contributing to
inadequate fan capacity
• Excessive inlet cone gap & overlap clearance
• Excessive boiler setting air in-filtration
• Pre-spinning condition at the fan inlet
• Non-Optimum damper or pre-spin vane stroke
and/or synchronization
• Excessive air heater leakage
• High air heater pressure differential due to
non-optimum air heater soot
 Excessive inlet cone to fan wheel gap
or insufficient overlap clearance
• Allow gas to circulate around
the fan wheel, reducing
capacity and fan efficiency.
Gap clearance should be 6 to
12 mm around the inlet bell
circumference at operating
temperature. Clearance
measured "cold" during
inspection are slightly
different when the fan is
operating at a typical
temperature of 145°C.
 Ensure the mating surfaces between sections of
the inlet box-scroll interface are tightly sealed
and the interface plate is free of holes.
• A 35-50mm
differential in static
pressure between the
fan outlet and inlet is
typical.
• Holes or gaps in the
interface plate will
allow circulation
between the outlet or
scroll side and the inlet
reducing fan capacity
 Non-optimum damper stroking
• Dampers should be
stroked with internal
position verification
of full damper
opening.
• An external key stock
indicator or scribe
mark should be
present to verify
internal damper
position from the
outside.
 Test Procedure For Collecting An
ASME Fineness Sample
• Sample locations are
positioned correctly with
regard to bends and
restrictions. Ideally, test
taps should be located in a
vertical run of piping, 10
diameters upstream and
downstream from the
nearest disturbance. A
minimum of two taps, 90°
apart, is required. Taps
should not be located at
the discharge of an
exhauster.
 Test Procedure For Collecting An
ASME Fineness Sample
• Traverse points collected from
equal area test grid
• Traverse points are sampled for
equal time intervals. This is
necessary for calculation of
total recovered sample (A
fineness test is said to be
representative when the sum of
the samples totals between 90 -
110% of the indicated feeder
flows). Collection of a timed
sample allows for determination
of relative pipe-to-pipe fuel
balance.
 Test Procedure For Collecting An
ASME Fineness Sample
• Traverse points are sampled for equal time
intervals. This is necessary for calculation of total
recovered sample (A fineness test is said to be
representative when the sum of the samples totals
between 90 - 110% of the indicated feeder flows).
Collection of a timed sample allows for
determination of relative pipe-to-pipe fuel
balance. Recovered fuel flow per pipe is
calculated using the following equation:)
 Test Procedure For Collecting An
ASME Fineness Sample
Fuel Flow lbs/Hr per burner line
=
gms sampled per pipe 1lb 60min pipe area sft
---------------------------- ---- -------- ---------------
Sample time in min. 453.6 1Hr. Tip area

0.0021 sft
 Procedure to collect coal samples
using the ASME Coal Sampler :
Insert the sample probe into the dustless connector,
open the ball valve, and slide the probe in to the first
port (probe completely inserted) with the flag of
probe (sample tip) in the direction of flow. Turn the
tip of the probe into the flow, turn on and adjust the
aspirating air to achieve/maintain 10 psi, and start
the stopwatch. Sample each traverse point for 10
seconds (total burner line sample time of 4 minutes,
assuming a 24 point traverse grid). Upon completion
of the last traverse point, cut off the air, and remove
the probe. Repeat the process for each port.
 Procedure to collect coal samples
using the ASME Coal Sampler : :
• After completing traverses of each test port on a
designated burner line, empty the sampling jug
and the filter canister into a labeled Ziploc bag.
Repeat the process for each burner line on the
pulverizer.
• Once all burner lines on the pulverizer have been
tested, weigh the samples and calculate an
individual burner line fuel flow and sum the results
to determine (%) recovery. If the cumulative
recovery is not between 90% - 110% of the feeder
indication, then repeat traverse again increasing
and/or decreasing the extraction diff. Pr. until
desired recovery is achieved.
 Coal Sieving Procedure
• Air drying of sample is recommended if high
moisture (>10%) coal is being fired or sieving is
not performed immediately after sample
extraction
• Prevents the coagulation of sample on top of
sieve screens which prevents particles to pass
through screens and results in non-
representative coal fineness
• ASTM D-197 specifies drying at 10° – 15°C
above room temperature with (1) to (4) air
changes per minute until weight loss is less than
0.1% difference.
 Coal Sieving Procedure
• Remove 50 grams of coal from the sample. This
is done by using an ASTM riffler or by
“rolling” the sample (usually between 200 g
and 800 g).
• Shake the sample through a series of 50, 100,
140 and 200 Mesh U.S. Standard sieves
• Record the weight of coal residue on each
screen and coal in the bottom pan (passing 200
Mesh). Great care should be taken in weighing
coal sample residue on each screen. Residue on
50 Mesh will be very small and must be
weighed accurately to yield representative data.
Coal Sieves and Calculations
• Wt of test sample 50g
• Wt.of residue on 50 mesh R 1g
• Wt.of residue on 100 mesh R 2g
• Wt.of residue on 140 mesh R 3g
• Wt.of residue on 200 mesh R 4g
• Wt.of residue in pan R 5g
 Coal Sieves and Calculations

• % Passing 50 mesh ( 50-R1) *100/50

• % Passing 100 mesh {50-(R1+R2)} *100/50
• % Passing 140 mesh {50-(R1+R2+R3)} *100/50
• % Passing 200 mesh {50-(R1+R2+R3+R4)} *100/50
 VOLUMETRIC FLYASH SAMPLE
COLLECTION AND ANALYSIS
• According to the ASME Test Code PTC 38
“Determining the Concentration of Particulate
Matter in a Gas Stream”; ideally test tap layout
should be such that sampling access ports and
traverse points are selected to permit sampling in
zones of equal areas. The traverse grid should
facilitate a minimum of one traverse point for
every 9 ft² of duct area. For example a 12’ × 18’
duct with a cross-sectional area of 216 ft² will
require a minimum of (24) traverse points.
 VOLUMETRIC FLYASH SAMPLE
COLLECTION AND ANALYSIS
• The traverse grid should be located in a straight
run of ductwork (constant cross-sectional area),
preferably a vertical run in order to minimize
stratification of the medium. In addition, the
traverse grid should be located a minimum of
eight (8) duct diameters downstream and two (2)
duct diameters upstream from the nearest flow
disturbance. Since these criteria are often
impossible to meet, test taps are generally
located in the “best possible” location. This is
acceptable if all parties involved in the testing
agree. Adequacy of probe access, lighting, power
facilities, etc. should also be considered when
choosing a location
Volumetric Fly ash Sample Collection
and Analysis

Example of Equal Area Sampling Grid

Typical locations for collection of a fly ash sample
Procedure for Sieving a Flyash
Sample
 Procedure for Burning a Fly ash
Sample for L.O.I. Determination
• Equipment
• A small oven capable of maintaining temperatures
between 150 - 815 °C
• A set of ceramic crucibles for burning the ash
• A set of pincers or tongs for handling the crucibles
• A highly accurate scale(balance) for measuring the
ash samples; the scale should have a readability of
0.1 mg with a repeatability of + 0.1 mg.
 Procedure for Burning a Flyash
Sample for L.O.I. Determination

• Label each of the crucibles.

• Preheat the crucibles to 150 °C for
approximately 15 minutes.
• Weigh each crucible while hot(Wc).
• Add one gram of the ash to be burned to
the crucible as it remains on the scale and
record the “sample and crucible” weight.
 Procedure for Burning a Flyash
Sample for L.O.I. Determination

• Insert the crucible with the sample into

the oven and leave it for 1 hour at
between 150 - 260 °C.
• Remove the crucible with sample and
reweigh and record it, comparing the
weight to the initial weight.
• Any difference in the two is the amount
of water driven off.
 Procedure for Burning a Flyash
Sample for L.O.I. Determination

• Replace the crucible w/sample in the oven

at 150 - 260 °C and leave it for 30 minutes.
• Remove, weigh, and record the crucible
w/sample.
• Continue this process until the weight
remains constant.
• RECORD THIS WEIGHT(WCSD).
 Procedure for Burning a Flyash
Sample for L.O.I. Determination

• Replace the crucible w/sample in the

oven and cook the sample at 815 °C for
three (3) hours.
• Remove, weigh, and record the crucible
w/sample weight.
• Replace the crucible w/sample and cook
at 815 °C for 30 minutes.
 Procedure for Burning a Flyash
Sample for L.O.I. Determination

• Remove, weigh, and record the crucible

w/sample weight.
• Any difference indicates that there is still
carbon present in the ash.
• Continue this procedure until the weight
remains constant(WCSFW).
 Procedure for Burning a Flyash
Sample for L.O.I. Determination
• Once the weight no longer changes, the flyash
L.O.I. can be calculated using the following
equation:
• WCSD = Crucible w/sample (dried) weight
• WCSFW = Crucible w/sample (final weight)
• WC = Crucible weight
• % Flyash L.O.I.
= {[(WCSD - WC) - (WCSFW - WC) × 100]} ÷
WCSD