Trouble shooting in Boiler
operation & reduction of auxiliary
power consumption
Presented by
S. Sivakumar
AGM- O&M Contracts
Cethar Vessels Ltd, Trichy
CETHAR VESSELS LIMITED
Leading manufacture of AFBC , CFBC , WHRB for sponge iron kiln
Gas, cement kiln gas ,DG exhaust gas & supply of power plant on
EPC basis for more than two decades .
Tied up with Riley Power Inc, USA for PC fired boilers of sub critical
& super critical pressure. Collaboration with Riley / Siemens Benson
Technology for super critical PC boilers.
Collaboration with Siemens for Super Critical CFBC boilers.
Tied up with OJSC power machineries , Russia for turbine design
and Manufacturing.
Executing O & M contracts of captive power plants of any Capacity
through Cethar energy ltd.
Cethar Vessels Ltd, Trichy 2
Major projects under execution:
2x 135 MWe IPP with CFBC Boiler - M/[Link] Coal Benification
2 x 350 MWe PF Fired Boiler - M/[Link] Barath energy Ltd.
2 x 350 MWe PF Fired Boiler - M/[Link] energy Ltd.
2 x 150 MWe IPP with CFBC Boiler - M/[Link] cement
2 x 150 MWe IPP with PF Fired Boiler - M/[Link] vidhuyut
3 x 70 MWe CFBC Boiler - M/[Link] associates
65 Boilers are under execution for IPP, CPP & Co-gen
10 IPP & Captive power plants are under execution
Cethar Vessels Ltd, Trichy 3
Credentials
CVL had designed, manufactured, erected and
commissioned more than 1000 FBC boilers.
Based on our versatile experience during
operation and maintenance, we have listed few
problems faced and the causes, solution given
for the information to this elite league
Cethar Vessels Ltd, Trichy 4
Low steam generation
Identifications Causes
• Low steam pressure, low • Fuel quality
steam flow in the control
• Low air box pressure will
room
lead to high bed
temperature and
limitation in fuel feeding
• Heavy air leakage in the
system and limitation in
combustion air to
furnace.
Cethar Vessels Ltd, Trichy 5
Low steam generation
Identifications Causes
• Low steam pressure, low • Heavy flue gas leakage
steam flow in the control in the system and
room limitation in ID fan
• Fouling in evaporation
surface.
• Deposition in the
evaporator tubes due to
water chemistry
Cethar Vessels Ltd, Trichy 6
Low steam temperature
Identifications Causes
• Low steam temperature • Passing of desuper heater
indication in control control valve
room at boiler outlet and
• Low volatile fuel
turbine inlet
• Low bed temperature
operation
• Inadequate “excess air”
operation
• Fouling in super heater
Cethar Vessels Ltd, Trichy 7
High steam temperature
Identification Causes
• Steam temperature at • Low feed water
boiler outlet and turbine temperature to boiler
inlet is more
• High volatile fuel burning
• High excess of air
• Low air box pressure
• Inadequate de-super
heating
Cethar Vessels Ltd, Trichy 8
Furnace pressure fluctuation /
positive furnace pressure
Identifications Causes
• Furnace pressure • Instrument calibration and
indication variation in impulse tube attachment intact
control room
• ID fan damper malfunctioning
• Fuel input variation to furnace
• Pressure part leakage
Cethar Vessels Ltd, Trichy 9
Furnace pressure fluctuation /
positive furnace pressure
Identifications Causes
• Furnace pressure • Fouling in the gas path
indication variation in • Accumulation of ash in gas path
control room and ash chute
• Leakage in flue gas duct and
limitation of ID fan
• Erosion of ID fan impeller
Cethar Vessels Ltd, Trichy 10
Sagging of Super heaters
Identification Causes
Visual inspection during Flame impingement on
shut down super heater during start
up.
Frequent lifting of Drum
safety valve
Over heating of super
heater coils due to boiler
operation with clinker
Cethar Vessels Ltd, Trichy 11
Sagging of Super heaters
Identification Causes
Visual inspection during Compartment transfer
shut down without adequate steam
flow
Boiler operation with more
fuel fines
Cethar Vessels Ltd, Trichy 12
Boiler operation with clinker
formation
Identification Cause
Uneven combustor bed Damage in bed
temperature thermocouples.
Load raising restriction Damage of air nozzle.
Significant variation in air Fuel nozzle damage
box pressure
Improper air fuel mixture
Cethar Vessels Ltd, Trichy 13
Low Air box pressure
Cause
Identification
FD ducting bellow leakage,
Low air box pressure with
heavy air leakage in FD
normal bed pressure and
duct, failure of air nozzle and
optimum FD airflow at
leakage in air heater.
MCR
Inspection and rectification
on the above to be taken up
Cethar Vessels Ltd, Trichy 14
Coal Jamming in PA line / Mixing
nozzle
Cause
Identification
High moisture, low PA
Bed Temperature Drop
header pressure at PA line
High negative furnace shall lead to jamming.
pressure Inspection from coal feeder
to PA line and mixing
PA line back pressure
nozzle, adequate PA
header air pressure to be
taken care
Cethar Vessels Ltd, Trichy 15
Frequent tripping of FUEL feeder
Identification Causes
• Trip alarm in DCS. Presence of any foreign
materials and cleaning.
• Bed temperature drop.
High moisture and de-
• High negative furnace choking
pressure
Feeder drive mechanical
arrangement failure and
rectification
Cethar Vessels Ltd, Trichy 16
Frequent tripping of FUEL feeder
Identification Causes
• Feeder speed showing Testing condition of motor
zero Testing the speed control
• Feeder motor over drive healthiness
load trip.
Cethar Vessels Ltd, Trichy 17
Oil firing start up failure
Causes
Identification Inspection for nozzle choke
&inadequate oil
No bed temperature rise pressure(6Ksc)
even after 2 hrs of light up Ensure optimum air box
pressure.
Ensure proper bed material
size(2.36 to 0.86).
Ensure appropriate charcoal
size and moisture free
charcoal.
Inspection of bed condition
Cethar Vessels Ltd, Trichy 18
High exit flue gas temperature
Identification Causes
• High flue gas • High excess air
temperature at the outlet
• Fouling in evaporator,
of APH
super heater and air pre
heater
Cethar Vessels Ltd, Trichy 19
High unburnt carbon in ash
Causes
Identification
• Operating the boiler with
• High % LOI in ash as
clinker
per lab report
• Inadequate air supply
• Fuel quality
• High amount of fines in
fuel
• Heavy load fluctuation and
instable furnace condition
Cethar Vessels Ltd, Trichy 20
High unburnt carbon in ash
Identification Causes
• High % of LOI in ash • Low air box pressure
• High PA pressure
• Improper distribution of
fuel in furnace
Cethar Vessels Ltd, Trichy 21
High Plant Heat Rate
• Identification • Action to be taken
• Steam leakage in boiler and • Steam leakage to be arrested
steam piping • Operating the turbine at
• Low turbine inlet steam design temperature and
pressure and temperature pressure
• Condenser low vacuum • Condenser air ingress to be
rectified
• High exhaust steam
temperature & pressure • HP heater under
performance
• Turbine inspection for
depositions
Cethar Vessels Ltd, Trichy 22
High Plant Heat Rate
Action to be taken
Identification
• Combustion system
• Low boiler efficiency heating surface area to be
• Low Feed water checked.
temperature • Rectify air ingress, flue gas
leakage are to be attended.
• High turbine wheel
chamber • Insulation condition to be
checked and rectified.
• Turbine blade failure
causes exhaust steam
temperature
Cethar Vessels Ltd, Trichy 23
Auxiliary power consumption
reduction
•After plant commissioning and stabilization the design
margin in the equipment shall be optimized by
implementing modification in the system, providing
VFD for the following equipments
Cethar Vessels Ltd, Trichy 24
Auxiliary power consumption
reduction
• Cooling water pumps
• CEP
• Boiler Feed pumps(case study given)
• Fans(case study given)
• ACC fans
Cethar Vessels Ltd, Trichy 25
Auxiliary power consumption
reduction
• Optimization of coal handling plant operation
• Optimization of AHP operating and
Compressors
• Optimization of make up water consumption and
WTP operation
Cethar Vessels Ltd, Trichy 26
Case study I :
Reported issue:
Excess coal consumption
Cethar Vessels Ltd, Trichy 27
Plant design details:
Plant capacity : 1 X 8 MWe co-gen plant
Boiler capacity : 40 TPH
Type of firing : AFBC
Steam pressure : 68 ata
Steam temperature : 495 °C
Cethar Vessels Ltd, Trichy 28
Design Fuel Analysis
Moisture : 13.98%
GCV : 6100 kcal/kg
Cethar Vessels Ltd, Trichy 29
Plant visit was made,boiler operating data,fuel input were
collected and analyzed
Cethar Vessels Ltd, Trichy 30
Boiler data:
Boiler operating capacity : 37.5 TPH
Steam pressure : 68.007 ata
Steam temperature : 495 °C
Feed water temperature : 122°C
Flue gas temperature leaving APH : 132°C
O2 in flue gas is : 4%
Cethar Vessels Ltd, Trichy 31
Fired fuel analysis and efficiency
GCV : 3950 Kcal/kg
Moisture : 31.50%
Efficiency achieved : 81.7%
Reasons for lower Efficiency:
Excess fired fuel moisture comparing to design fuel
moisture
Lower GCV of fuel comparing to design
Loss in efficiency due to the above is 3.501%
Cethar Vessels Ltd, Trichy 32
Conclusion:
Corrected efficiency is 85.2%
Fuel moisture to be controlled for achieving the
guaranteed thermal Efficiency of the boiler
Expected Fuel saving by controlling moisture is 7.6 TPD
Cethar Vessels Ltd, Trichy 33
Case study II :
Reported issue:
Excess steam temperature drop
Cethar Vessels Ltd, Trichy 34
Plant design details:
Plant capacity : 1 X 8 MWe
Boiler capacity : 40 TPH
Type of firing : AFBC
Steam pressure : 68 ata
Steam temperature at boiler O/L : 495 °C
Cethar Vessels Ltd, Trichy 35
Steam temperature at T/G I/L : 470°C
Fuel GCV as fired : 3950 Kcal/kg
Boiler efficiency : 82 %
Cethar Vessels Ltd, Trichy 36
Observation:
Design Steam temperature drop : 5°C
Excess Steam temperature drop : 20°C
Excess energy loss by steam : 1.5 TPD
Considering 335 days operation the : 502 MT/year
excess fuel consumption.
Cethar Vessels Ltd, Trichy 37
Conclusion:
Steam line insulation to be rectified.
Steam traps in steam line to be set right.
Cethar Vessels Ltd, Trichy 38
Case study III :
Reported Issue:
Low thermal Boiler efficiency
Cethar Vessels Ltd, Trichy 39
Design data:
Plant capacity : 1 X 8 MWe
Boiler capacity : 40000 kg/hr
Type of firing : AFBC
Steam pressure : 68 ata
Steam temperature : 495 °C
Cethar Vessels Ltd, Trichy 40
Feed water temperature : 126 ° C
Flue gas temperature leaving APH : 140°C
Air temperature at APH I/L : 40°C
Cethar Vessels Ltd, Trichy 41
PG TEST DATA:
Power generation : 1 X 8 MWe
Boiler capacity : 37,500
kg/hr
Steam pressure : 68 ata
Feed water temperature : 122 ° C
Flue gas temperature leaving APH : 132°C
Air temperature at APH I/L : 38°C
Cethar Vessels Ltd, Trichy 42
Achieved boiler efficiency with : 82 %
Imported coal
% O2 in flue gas : 4.5%
Cethar Vessels Ltd, Trichy 43
Parameters after 12 months of PG test:
Power generation : 8 MWe
Boiler capacity : 38,000 kg/hr
Steam pressure : 67 ata
Steam temperature : 495 ° C
Feed water temperature : 122 ° C
Flue gas temperature after APH : 159 ° C
% O2 in flue gas : 4.5%
Cethar Vessels Ltd, Trichy 44
Results:
Due to increase of flue gas temperature the following
losses have been increased.
1) Dry flue gas loss.
2) Loss due to moisture in flue gas.
3) Loss due to hydrogen in flue gas.
4) Air moisture loss.
Cethar Vessels Ltd, Trichy 45
The overall thermal efficiency reduction is 2%.
Equivalent coal consumption : 4878 kg/day.
Considering 335 day operation : 1635 MT/335day
Coal consumption
Reason:
Fouling in the cold air side of APH due to high moisture
content imported coal .
Rectification:
Periodic inspection and cleaning APH by water Jet.
Cethar Vessels Ltd, Trichy 46
CASE STUDY-IV
POWER REDUCTION OF BOILER FEEDWATER PUMP
Cethar Vessels Ltd, Trichy 47
Boiler Details
Boiler capacity : 140 Tph
Steam pressure : 86 kg/cm² (g)
Drum pressure : 98 kg/cm² (g)
Steam temperature : 510°c
Fuel : Baggasse
Type of firing : Traveling grate
Cethar Vessels Ltd, Trichy 48
Boiler Feed Pump Details
Feed pump capacity : 92.1 Cum/hr
Head : 1231 mwc
Speed : 2980 rpm
[Link] pumps : 3 (2w + 1s)
Pump driven by : Motor with VFD
Drum level control by : FCV
Cethar Vessels Ltd, Trichy 49
Existing operating data
Feed water flow : 144 M3
Feed water temperature : 140°C
Control valve opening : 35%
Pump operating speed : 2900 rpm
Feed water suction pressure : 3.5 kg/cm²
Feed water delivery pressure : 138 kg/cm
Power consumption : 790 Kw (2 pumps working)
Cethar Vessels Ltd, Trichy 50
Initially boiler feed pump was operated at constant
speeds of around 2900 rpm and drum level control was
operated by varying the feed control valve with three
element level control .
Cethar Vessels Ltd, Trichy 51
MODIFIED DATA :
Feed water flow : 144 m3/hr
Feed water temperature : 140°C
Control valve opening : 100%
Pump speed : (2675 – 2700 ) rpm
Power : 660 kw (2 pumps working)
Power saving : 790 – 660 = 130 Kw
Drum level control was implemented by VFD operation of the
feed pump .The feed control valve was kept 100 % open and
system pressure drop has been reduced from boiler feed pump to
economizer . Based on the drum level VFD speed was varied in
automatic control.
Cethar Vessels Ltd, Trichy 52
CASE STUDY-V
FD fan motor power consumption reduction
Cethar Vessels Ltd, Trichy 53
FD Fan Power Saving with VFD
Boiler Capacity : 40 TPH
Steam pressure : 68 ata
Steam Temperature : 485 +-5 Deg CEL
Type of boiler : AFBC
FD fan motor : 250kW
Speed : 1440 rpm
Fuel : Imported coal
Cethar Vessels Ltd, Trichy 54
FD Fan Power Saving with VFD
Initially FD fan was operated without VFD and
the details of operating data are given
Steam generation : 37.5 TPH
Power generation : 8 Mwe
FD fan damper opening : 38%
Fan speed : 1440 rpm
Power consumption : 195kW
O2 in flue gas : 4%
Cethar Vessels Ltd, Trichy 55
FD Fan Power Saving with VFD
Data after implementation of VFD for FD fan
Steam generation : 37.5 TPH
Power generation : 8 MWe
FD fan damper opening : 100%
Fan speed : 1250 rpm
Power consumption : 160kW
O2 in flue gas : 4%
Cethar Vessels Ltd, Trichy 56
FD Fan Power Saving with VFD
Pressure drop in the damper has been eliminated by
damper full open and the power saving was
achieved through speed control
Power saving : 35kW / hr
840 kW/Day
281400kW for 335 days
Cethar Vessels Ltd, Trichy 57
FD Fan Power Saving with VFD
Fuel saving (Plant heat rate of 4050Kcal/kWh
and fired GCV of fuel is 3950 Kcal)
---861 kg/day
--- 26 MT / month
--- 312 MT / year
---12.5 lakhs per annum
Cethar Vessels Ltd, Trichy 58
Any questions please?
Thanks
“CVL”
Cethar Vessels Ltd, Trichy 59