The t oi

The Feed Cantraller

Proceas Variabie
utput

Imvel Cantreler ( )
Tank/Vese

ramer (LTn

Control Valve
Desuperheaters are typically used to reduce
and condition the temperature of superheated
steam in power plants, which is often used as
an energy source for mechanical power

generation in steam turbines.

Some of the factors that affect the efficiency of
the boiler is a superheater pressure, water feed
temperature, steam temperature, the amount
of steam produced, the amount of fuel
consumption and calorific value fuel
combustion.
Boiler efficiency can be defined as the ratio of
the useful heat output to the total energy input.
Typical boiler efficiencies range from about
90% for the best solid biomass fuel boilers to
close to 95% for oil- and natural gas-fired
boilers, Table 3.2.
 In order to calculate boiler efficiency by this
method, we divide thetotal energy output ofa
boiler bytotal energy input given tothe boiler,
multiplied by hundred. GCV= Gross calorific
value of thefuel.
 The rate of blowdownis theintentional periodicremoval
of water from the coolingtower,boiler or any other heat
exchangers. The primary purpose of blowdown is to
maintainthe solids contentofboiler water within certain
limits. 15-Aug-2017
What is shrinking effect in boiler?

Dynamic shrink/swell is a
phenomenon that produces variations
in the level of the liquid surface in the
steam drum whenever boiler load
(changes in steam demand) occur
This behavior is strongly influenced by
the actual arrangement of steam generating tubes in the
boiler. 09-Apr-2015
What is swelling effect in boiler?

Due to this a sudden drop in boiler steam pressure will

occur. This sudden drop in pressure will lead to
vaporisation of water. Hence the formation of bubbles
inside the boiler makes the level of water looks like
increased (which in reality is not there) in the water
gauge glass. This phenomenon is known as swelling.
What controls the air-fuel mixture in a car?

On fuel injected engines, the throttle body is the part of

the air intake system that controls the amount of air
flowing into the engine, controls idle speed and houses
the throttle position sensor. The throttle body is usually
attached to the intake manifold downstream from the
mass airflow sensor.
What is furnace draft control?

Furnace draft, or negative pres- sure, is created in fuel-

fired furnaces when high temperature gases are
discharged at a level higher than the furnace open- ings.
..Furnace pressure controllers regulate and stabilize the
pressure in the working chamber of process heating
equipment.

https://energy.gov 2014/05 PDF

1.6.3 Boiler Eiciency by Direet Method: Calculation and Example
Test Data and Calculation
Water consumption and coal consumption were measured in a coal-fired boiler at hourly inter-
vals. Weighed quantities of coal were fed to the boiler during the trial period. Simultaneously
water level difference was noted to calculate steam generation during the tial period. Blow
down was avoided during the test. The measured data is given below.

Tvpe of boiler: Coal fired Boiler

Heat output data
of steam generated (output) 8 TPH
Quantity 10 kg/cm'(g)/ 180°C
Steam pressure / temperature
Enthalpy of steam(dry & Saturated
665 kCal/kg
at 1O kg/cm(9 pressure
Feed water temperature C
5
Enthalpy ot feed water 85 kCal/kg

Heat input data

Quantity of coal consumed (Input) .6TPH
GCV of coal 4000 kCal/kg

Calculation
Boiler efficiency (n):
Qx(H-hx 100
(qxGCV)
Where C =
Quantity of steam generated per hour (kg/hr)
Quantity of fuel used per hour (kg/hr)
GCV -
Gross calorific value of the fuel (kCal/kg)
h
=
Enthalpy of steam(kCal/kg)
of feed water
=
Enthalpy (kCal/kg)
Boiler efficiency (7) = 8TPHx 1000ke/Txx (665-85)x 100
1.6 4000
TPHx 1000kg/T kCal/kg
72.5%
Evaporation Ratio = 8 Tonne of steam/ 1.6 Tonne of coal
5

Bureau of Energy Effhciecney

 ot Boilers
y Tcoance ASSCssthcnt

1.6.4 Merits and Demerits of Direct Method

Merits 5/29
Plant pecople can evaluate quickly the efficiency of boilers
Requires few parameters for computation
Needs few instruments for monitoring

Demerits
Does not give clues to the operator as to why efficiency of system is lower
Does not calculate various losses accountable for various efficiency levels
Evaporation ratio and efficiency may misead, if the steam is highly wet due to water carryover

1.7 The Indirect Method Testing

1.7.1 Description
The efficiency can be measured easily by measuring all the losses occuming in the boilers using
the
principles to be described. The disadvantages of the direct method can be overcome by this
method, which calculates the various heat losses associated with boiler. The efficiency can be
arrived at, by subtracting the heat loss fractions from 100.An important advantage of this
method is that the errors in measurement do not make significant change in efficiency.
Thus if boiler efficiency is 90% , an error of 1% in direct method will result in significant
in i.e. 90 +0.9 = 89.1 to 90.9. In indirect method, 1% error in measurement
change efficiency.
of losses will result in
Efficiency = 100 (10 + 0.1) = 90 +0.1 = 89.9 to 90.1
-

The various heat losses occurring in the boiler are:

Steam Output
De Flue gas loss
s. Surface loss in fuel
Moisture in air
0 loss

Fly ash lo

Fuel Input, 100%

Boiler Fluc gas sanple

Air

8 . Botlom ash loss

OW down

Eficiency 100-(1+2+3+4+5+6+7+8) doy Indirect Method)

Bureau of Energy Efficiency

 . Ehergy Fertorimiahce Assessient ol Boilers

Thefollowing lossesare applicable to liquid, gas and solid fired boiler

LI-Loss due to dry flue gas (sensible heat)
6/29
L2-Loss due to hydrogen in fuel (H)
L3-Loss due to moisture in fuel (H,0)
L4-Loss due to moisture in air (H,0)
L5-Loss due to carbon monoxide (CO)
L6-Loss due to surface radiation, convection and other unaccounted".
Losses which are insignificant and are difficult to measure.
Thefollowinglosses are applicable to solid fuel fired boilerin addition to above
L7-Unbunt losses in fly ash (Carbon)
L8-Unburnt losses in bottom ash (Carbon)
Boiler Efficiency by indirect method = 100-(LI+ L2 + L3 + LA + L5 + L6 +L7 + L8)
Boiler drumlevel control

Boiler drum-level control is critical. Too low a level may expose boiler tubes, which overheats
and damages them. 1o0 high a level may nteriere with separating moIsture from steam, whic
reduces DOler eiciency and cames moSUrE t o tne process or turoine. Ine dum-eve
controller maintains the level at constant steam load. There are three options for drum-level
cofntrol singie-eleent, wo-eememt ana tnree-element oru-Evel cotrol.

Single-element control is the simplest but least effective fom of control (see Figure 3). A
proportional signal
the
or process variabie (Pv signal generates a correction thats proportional to
from setpoint. The Output controls the boiler's feedwater valve. Single-element
deviation
control requires one anaiog input and one analog output. Because there s no relätionsip
mp
on a single boiler supplying a relatively stable load. Also, the swell effect may render control
nadequat
Easiesttway

team

Feedwater

Iwo-element
module

eve
Figure 3: Drum-ievel control with a singie-element module

Typlcal

Feedwaterr

Single-elemer
module
eve

Figure 4: Drum-level control with a hwo-element module.

Best way

team

Water
Feedwater

nree-elehen
modue

evel

Fgure b: D r u - e v e conror wit & hree-eement moouie.

TWo-element drum-level control can best be applied to a single drum boller f the teedwater Is at

for the single-element configuration but has an added steam-flow element that provides a
density-corrected mass iow-rate signal to oontrol the teedwater 1ow. Two eements offer ighter
adjustients. This gives an immediate feedwater response to load changes while the level
cOntoier corects any moiarce Deween steam mass now and teeowater iow mat arnises

Blowdown variations caused by changes in dissolved solds.

Variation in feedwater supply pressure.

Steam leaks in the steam circuit

Three-element drum-level control is suited for handing variable feedwater pressure or multiple
DOers wiU muinpie Teedwater pumps (see Fgure b). Ine thee elements in mis 5ystem nandie
level, steam and feedwater flow. The level and steam elements correct for unmeasured
disturbances ansing trom boler Diowolown, as wel as eaks n me boier ana supermeater tubes.
Thefeedwater flow element responds rapidly to variations in feedwater demand that arise from
the steam fiow-rate feed-forward signal and feedwater pressure or fiow fluctuations.
Toachieve optimum control, both steam and feedwater flow values should be corrected for

fchatin feter rerr odamo sitatedeonroli rered

To stabilize control over a wide range of steam demand, the three-element mode acts duning
highsteam demand, but can drop back to two-element mode if the steam-fiow measurement
fails. The module reverts to single-element level control" the feedwater fiow measurement fails
ort steam demand 5 Ow.