EXPERIMENT NO-3 OBIECT:*- To Study the performance parameters of boiler INTRODDUCTION: - time, due to ‘maintenance. Deterioration oF boiler. Efficiency testing st efficiency. jo reduces Performance ofthe boiler, like efficien®y and evaporation rat poor combustion, heat transfer fouling and poor operation and vest quality and water quality also leads poor performance helps us to find out how far he boiler ‘ciiclency drifts away from the bes PURPOSE OF THE PERFORMANCE TEST: = «To find out the efficiency of the boiler ‘To find out the Evaporation ratio formance test is to determine actual Ps design values or norms. Its an in 'n boiler efficiency and energy effici ‘The purpose of the per! boiler and compare it with and season-to-season variations i PERFORMANCE TERMS AND DEFINITIONS: - 1. Boiler Efficiency, = x 100 erformance and efficiency of the idicator for tracking day-to-day jency improvements. _ Heat in steam out ats) Heat in Fuel Input (kCals) x 100 2. Evaporation Ratio = SS of Steam Generation ‘Quantity of fuet Consumption REFERENCE STANDARDS: - [ASME Standard: PTC-4-1 Power Test Code for Steam Generating Units This consists of 8 part One: Direct method (also called as Input -output method) + Part Two: Indirect method (also called as Heat loss method) 18975: Standard for Boiler Efficiency Testing ost standards for computation of boiler efficiency ji including IS 8753 and BSB4 Gevgned for spt messuent of belerfsieney. variably al these api inte bow down a loss inthe efeiency determination process sain ,_ Basal Boer efficieny canbe tested by the following methods: rect Method: Where the energy gain of the worki / 2 mp ih ene ceed atictolir ial est . The Indirect Method: Where the effic it The nel ciency isthe difference between the losses andTHE DIRECT METHOD TESTIN This is also known as ‘input-output method’ due to the fact that it needs only the ee i ‘aaa ‘nd the heat input (ie. fuel) for evaluating the efficiency. This efficiency can evaluated using the formula Heat out Heat input «100 Boiler Efficiency, 1 Boiler Efficiency = Steam flow rate x (team cahalpy Feed water enthspy Foe ing rate x Gros calonfic vale THE INDIRECT METHOD TESTING: - The efficiency can be measured easily by measuring all the losses occurring in the boilers using the principles to be described, The disadvantages ofthe direct method can be overcome by this method, which calculates the various heat losses associated with boiler. The efficiency an be arived at, by subtracting the heat los fractions from 100.An important advantage of itis method is thatthe errors in measurement do not make significant change inefficiency Thus if boiler efficiency is 90% , an error of 1% indirect method will result insignificant change in efficiency. i, 90+ 0.9 = 89.1 to 90.9, In indirect method, 1% error in ‘measurement of losses will result in Efficiency = 100 (10+ 0. 1)=9020.1 = 89.910 90.1 The various heat losses occurring in the boiler are:Steam Output Flue gas loss Loss isture in (uel Fuel Input, 100% A Tir "C58 Botom ash oss Blow down Efficiency = 100 - (1+2+3+4+5+6+7+8) (by Indirect Method) The following losses are applicable to liquid, gas and solid fired boiler Ly-Loss due to dry flue gas (sensible heat) L,-Loss due to hydrogen in fuel (H2) Ly — Loss due to moisture in fuel (H20) L4 — Loss due to moisture in air (H20) Ls —Loss due to carbon monoxide (CO) Le —Loss due to surface radiation, convection and other unaccounted*. *Losses which are insignificant and are difficult to measure. ‘The following losses are applicable to solid fuel fired boiler in addition to above Ly —Unburnt losses in fly ash (Carbon) Lg — Unburnt losses in bottom ash (Carbon) Boiler Efficiency by indirect method = 100 -(L1 +L2+L3 + L4+L5+L6+L7+ L8)Boiler Efficiency by Indirect Method: Calculation Procedure and Formula: - ‘The various losses associated with the operation of a boiler are discussed below with required formula, 1, Heat loss due to dry flue gas mxC,x(Tf-Ta) — x 100 GCV of fuel % Heat loss due to dry flue gas Mass of dry flue gas in kg/kg of fuel Combustion products from fuel: CO, + SO. + Nitrogen in fuel + Nitrogen in the actual mass of air supplied + O, in flue gas. (H,0/Water vapour in the flue gas should not be considered) Specific heat of flue gas in kCal/kg*C Flue gas temperature in °( Ambient temperature in °C 2. Heat loss due to evaporation of water formed due to H2 in fuel (%) 9x Ha x {584 +C, (T)-T,)} x 100 GCV of fuet kg of hydrogen present in fuel on | kg basis Specific heat of superheated steam in kCallkg' Flue gas temperature in °C Ambient temperature in °C Latent heat corresponding to partial pressure of water vapour 3. Heat loss due to moisture present in fuel L, M x {584 +C, (T;-T,)} X 100 GCV of fuel kg moisture in fuel on | kg basis Specific heat of superheated steam in kCaVkg°C Flue gas temperature in °C Ambient temperature in °C Latent heat corresponding to partial pressure of water vapour4. Heat loss due to moisture present in air AAS x humidity factor x C, x (Ty-T,) x 100 ly = Where AAS Actual mass of air supplied per kg of fuel Humidity factor kg of water/kg of dry air c Specific heat of superheated steam in kCal/kg?C q Flue gas temperature in °C Ambient temperature in °C (dry bulb) 5. Heat loss due to incomplete combustion: %CO x 5744 Ls — a. aeaeeee «FCC % CO + % CO, GCV of fuel Ls % Heat loss due to partial conversion of C to CO co Volume of CO in flue gas leaving economizer (%) co, Actual Volume of CO; in flue gas (%) c Carbon content kg / kg of fuel or ‘When CO is obtained in ppm during the flue gas analysis CO formation (M..) CO (in ppm) x 10% x M, x 28 M, Fuel consumption in kg/hr Ls = Mag x 5744* * Heat loss due to partial combustion of carbon. 6. Heat loss due to radiation and convection: Le = 0548 x [ (T,/ 55.55)! - (T, / 55.55)" + 1.957 x (T, -T,)' x sq.tt of {(196.85 V,, + 68.9) / 68.9] where it Radiation loss in W/m? Vn Wind velocity in mis v Surface temperature (K) T, = Ambient temperature (K) 7. Heat loss due to unburnt in fly ash (%). Total ash collected / kg of fuel burnt x G.C.V of fly ash x 100 i i GCV of fuel8, Heat loss due to unburnt in bottom ash (%) Total ash collected per kg of fuel burnt x G.C.V of bottom ash x 100 ee Ee ie GCV of fuel HEAT BALANCE: Having established the magnitude of all the losses mentioned above, a simple heat balance would give the efficiency of the boiler. The efficiency is the difference between the energy input to the boiler and the heat losses calculated. BOILER HEAT BALANCE: Input/Output Parameter kCal/kg of fuel | % Heat Input in fuel = 100 ‘Various Heat losses in boiler 1. Dry flue gas loss = 2. Loss due to hydrogen in fuel 3. Loss due to moisture in fuel = 4, Loss due to moisture in air = 5. Partial combustion of C to CO = 6. Surface heat losses = 7. Loss due to Unburnt in fly ash = 8. Loss due to Unburnt in bottom ash | = Total Losses = Boiler efficiency = 100 - (1+2+3+4+5+6+7+8)