Energy Efficiency is one of the major pillars towards achieving g Net-Zero by reducing Green House Gas (GHG) emission and thereby Global Warming.
Hence it is of utmost importance that Boilers must be periodically tested for their performance assessment and compared with the design performance.
Corrective actions to be taken by implementing cleaner technologies, Fuel switching, High efficiency burners etc.
Performance of the boilers depends mainly on efficiency and evaporation ratio.
Both the above parameters diminish with time, due to following reasons:
Improper combustion,
Fouling of heat transfer areas
Poor operation and maintenance (O&M) practices.
Other factors are:
Deteriorating of fuel quality
Boiler water quality.
Efficiency testing is the best way to find out how far the boiler efficiency deteriorated from the best efficiency point and how energy efficiency/energy performance can be improved.
Here are best ways to test boiler efficiency for performance evaluation, on-site.
Why Boiler performance test is required?
To find out the efficiency of the boiler
To find out the Evaporation ratio of the boiler.
What is the purpose of performance tests?
The purpose of the performance test is to determine actual performance and efficiency of the boiler and compare it with design values or norms.
Hence It is an indicator for keeping track of day-to-day and seasonal variations in boiler efficiency and energy efficiency improvements.
Procedure for Boiler performance test:
Establish a baseline measurement. And this is the First & critical step.
Operate the Boiler at full load for approx. 1 hour and stabilize
Indirect method of efficiency calculation is also known as heat loss efficiency calculation method.
Boiler indirect Efficiency = 100 – Losses
Standard is ASME PTC-4-1 issued for calculating boiler efficiency by indirect method.
The standards do not include blow down loss in the efficiency determination process.
In a simple way, following are the losses from a boiler
Percentage heat loss due to dry flue gas
Percentage heat loss due to evaporation of water formed due to H2 in fuel
Percentage heat loss due to evaporation of moisture present in fuel (H2O)
Percentage heat loss due to moisture present in air.(H2O)
Loss due to Carbon Monoxide (CO)
Loss due to surface radiation, Convection and other unaccounted losses.
Percentage heat loss due to unburnt in fly ash (Carbon)
Percentage heat loss due to unburnt in bottom ash (Carbon)
## losses mentioned in sl. no. 7 & 8 are specifically applicable solid fuel fired boilers in addition to the all other lossess mentioned above.
Finally, Boiler Efficiency by indirect method = 100 - Losses.
The efficiency test does not account for:
Blow down loss: The amount of energy wasted by blow down varies over a wide range.
Soot blower steam: The amount of steam used by soot blowers is variable that depends on the type of fuel.
Auxiliary equipment energy consumption: The combustion efficiency test does not account for the energy usage by auxiliary equipment, such as burners, fans, and pumps.
Standby losses: Stand by losses are the losses which occurs during firing intervals.
When the boiler is operating under a steady load then efficiency test to be carried out.
Therefore, Standby losses will not be reflecting.
FOR MORE DETAILS AND CONSULTANCY PLESAE LEAVE A COMMENT .
Bibek Roy
An experienced power plant professional having more than 34 years of experience in India & abroad. Certified Lead auditor for QMS, EHSMS. Certifed Energy auditor from BEE. A trainer, coach and auditor. An evangelist for sustainability.
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