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BOILER TYPES
FIRE TUBE
As the name implies, the
BOILERS AND THERMAL
fire is in the tubes and the
SYSTEMS;
BOILER EFFICIENCY water outside. Most of the
IMPROVEMENT small ll packaged
k d b
boilers
il
SECTION P in
buildings and industry
today are fire tube boilers
and thus are likely the
ones we will encounter.
Source: Illustration recreated for web by Technologists Inc. using graphic supplied by The Boiler Efficiency Institute, Auburn,
Alabama to PNL, for use with FEMP O&M Best Practices, as a model.
Section P - 2
Section P - 3 Section P - 4
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Section P - 5 Section P - 6
Section P - 7 Section P - 8
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MONITORING
STEAM TRAPS In a poorly maintained or non-maintained system, 20% to
30% of the steam traps are likely stuck open wasting
Purposes significant amounts of expensive steam. To locate failed
steam traps, use:
1. Reject (Return) Condensate
2. Reject Air 1. Sight (Watch the Discharge)
3. Hold Back Steam 2. Sound (Listen to the Operation Possibly Ultrasonically)
3
3. Temperature (Watch the Delta T)
Section P - 9 Section P - 10
Section P - 11 Section P - 12
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NATURAL GAS
Section P - 13 Section P - 14
Savings Percent savings Fuel consumption Soot on the fireside has a similar effect. Running good combustion
systems slightly on the excess airside ensures complete combustion
and
minimizes soot. However, soot blowers may be required, especially
for
certain fuels, and periodic brushing gas fired system, this brushing
is likely required about once a year.
Section P - 15 Section P - 16
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LOAD BALANCING
The boiler room is an interesting place. If the boiler room
operator keeps the boiler working with adequate
pressure everywhere in the plant, no one complains.
Normally, there is an extra boiler or two for back up and
load variation reasons. Therefore, there is a natural
tendency for the operator to fire all the available boilers
and run them at part load. If one goes down, the others
quickly move up and the pressure is maintained.
Boilers don't run well at low loads and each boiler has
about 3-5% skin losses, so there is a significant energy
penalty for this philosophy. Instead, profiling the
efficiency of each boiler for varying loads will yield data
that can be used to determine the optimum firing profile
for any load.
Section P - 17 Section P - 18
FLASH STEAM
BOILER BLOWDOWN
When a hot pressurized liquid is placed in
a tank with lower pressure, some flash
steam will form as the enthalpy of the
saturated liquid is reduced.
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INSULATION
Install Insulation on Steam Line(s)
BOILER AND STEAM PLANT ECMS 14.
15. Install Insulation Jacket on Steam Fitting(s)
INCREASE BOILER EFFICIENCY 16. Install Insulation on Feedwater Line(s)
1. Reduce Excess Air to Boiler(s)
17. Install Insulation on Condensate Return Line(s)
2. Provide Sufficient Air to Boiler(s) for Complete Combustion
3. Install Low Excess Air Burner (s) 18. Install Insulation on Condensate/Feedwater/Deaerator Tank(s)
4. Repair/Replace Faulty Burner (s) 19. Install Insulation on (Domestic) Hot Water Line(s)
5. Repair Natural Draft Burner(s) with Forced Draft Burner(s) 20. Install Insulation on (Domestic) Hot Water Tank
6. Install Turbulators in Firetube Boiler(s) 21. Install Insulation Jacket on Boiler Shell
7. Replace Existing Boiler(s) with New More Efficient Boiler(s) 22. Install Insulation to Reduce Heat Loss
8. Install a Condensing Boiler/Water Heater
9. Install a Pulse Combustion Boiler/Water Heater
REDUCE BOILER LOAD
10. Install a Small Boiler for Summer Operation
11. Clean Boiler(s) to Eliminate Fouling and Scale 23. Repair Steam Leak(s)
12. Improve Feedwater Chemical Treatment to Reduce Scaling 24. Repair Failed Steam Trap(s)
13. Optimize Boiler Loading When Using Multiple Boilers 25. Reduce Boiler Blowdown
26. Return Condensate to Boiler(s)
Section P - 23 Section P - 24
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Section P - 25 Section P - 26
Section P - 27 Section P - 28
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Natural Gas $
$5.80/GJ efficiencyy = 0.92 Natural Gas = ($5.80/GJ)/0.92 =
$6 30/GJ deli
$6.30/GJ delivered
e ed
Residual Fuel Oil $310/ton
(40,000 kJ/kg) efficiency = 0.88 Residual = ($310/ton)(1/1000 ton/kg) x
(1/40000 kg/kJ) x
(106 kJ/GJ)(1/0.88)
=$8.81/GJ delivered
Best Choice: Natural Gas
Section P - 29 Section P - 30
EXAMPLE PROBLEM
3. Last year a 20 GJ/hr boiler consumed 19,000 GJ of natural gas at
$8/GJ. The boiler operates at 6% O2 and 350 C STR. What is
the savings for correcting that to 3% O2?
77 - 75
% savings 0.026 or 2.6%
77
19,000GJ $8.00 $3,948
Cost savings 0.026
Year GJ yr
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4. Now, you can install an economizer that will reduce the stack
temperature rise to 200C. What is the % fuel savings for that STEAM EXAMPLES
change?
Eff 1 = 77% Eff 2 = 83%
1a. Find the enthalpy of 800 kPa (8 bar)
83 - 77 saturated steam.
% savings 7.2%
83 Using Table H = 2768.7 kJ/kg
3) What is the % excess air for 3% O2 Natural Gas?
for 800 kPa steam
Approximately 15%
What would the CO2 reading be if we measured it? 1b. Find the enthalpy of 165 C steam.
Approximately 10% Using Table H = 2762 kJ/kg
for 165C steam
Section P - 33 Section P - 34
2. How much heat is required to raise the 3. Find the amount of heat required to convert
temperature of 3000 kg of water from 20C to 3000 kg of boiler feedwater at 90C to saturated
80C? steam at 800 kPa (8 bar).
For 20C water from Table H = 83.9 For 90C water H = 376.9 (Table)
For 80C water from Table H = 334.9 For 800 kPa steam H = 2768.7 (Table)
3000 kg (334.9 83.9) kJ
x kJ
k = 3000 kg (2768.7 376.9) kJ
kg x kJ =
kg
x = 753,000 kJ
x = 7,175,400 kJ
x 0.753 GJ
x 7.18 GJ
Section P - 35 Section P - 36
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Section P - 37
Section P - 38
Section P - 39 Section P - 40
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Section P - 41 Section P - 42
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To cure these problems, boilers will have to be blown Thus, TOP BLOWDOWN IS AN EXCELLENT
down in some fashion. OPPORTUNITY FOR WASTE HEAT RECOVERY.
There is usually a top blowdown (skimming) that is often
continuous or could easily be automated by blowing The bottom or mud blowdown is usually done
down when the conductivity of the water reaches a manually, by timers, or automatically. To be
certain level. This top blowdown is relatively clean and
sure the mud is adequately removed, this
usually a small volume flow.
blowdown is usually drawn off in a large line
If the
th boiler
b il is
i producing
d i 700 kPakP steam,
t then
th this
thi
with agitation. Mud blowdown is usually not a
blowdown is saturated water at 165 C.
good candidate for heat recovery.
Section P - 45 Section P - 46
BOILER BLOWDOWN
(SEE FIGURE)
An excellent system takes the high pressure blowdown,
develops low pressure steam in the tank described and Purpose: Avoid mud build up in boiler
then runs the liquid left in the low pressure tank Problem: Very hot liquid at boiler drum pressure
through a is rejected
shell and tube heat exchanger to preheat the make up
water These systems are available commercially.
water. commercially Management:
Maintain proper BD rate
Recover heat from blowdown with a shell &
tube heat exchanger (continuous or top
blowdown)
Recover flash steam (see heat recovery Q-8)
Section P - 47 Section P - 48
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%BD = 10 x 100 = 2%
B = ppm allowed in boiler
500 - 10
Section P - 49 Section P - 50
Section P - 51 Section P - 52
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Section P - 53 Section P - 54
Section P - 55 Section P - 56
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Section P - 57 Section P - 58
Section P - 59 Section P - 60
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Section P - 61 Section P - 62
END OF SECTION P
Section P - 63 Section P - 64
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