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NEWSLETTER
About 40 participants from various Indian thermal power plants have participated in
the workshop. During the workshop, comprehensive boiler testing procedures and
performance improvement opportunities are discussed. Some of them are Boiler
combustion & performance optimisation, typical plant challenges, applying the
essentials in combustion optimisation, Pulverizers and optimisation techniques,
fuel & ash quality impacts, air heater performance, performance improvement
opportunities in power plant auxiliaries and case studies implemented in Indian
thermal power plants.
During the workshop, an exclusive interaction session was also organised for the
participants to discuss about specific problems in their Power plants. Some the
concepts discussed during the workshop related to Boiler combustion &
performance optimisation are covered in the article presented by Mr Stephen K
Storm in Power plant efficiency News letter -1 published during March 2010.
Overall, the programme was well received by the participants from Indian thermal
power plants and majority of them rated as excellent. Based on the feedback from
the participants, as part of the information dissemination programme CII-Godrej
GBC is planning to organise similar workshops on other aspects of thermal power
plants in future.
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Optimization of soot blowers for Increase in auxiliary steam consumption due to
F
unnecessary soot blowing operation
performance improvement in
Thermal power plants Optimizing the conventional soot blowing system
Background
The conventional soot blowing system in a typical 210 MW
The boiler performance including its ability to meet full thermal power generating unit, consists of 56 blowers
load, auxiliary power consumption, net plant heat rate, arranged in four elevations. Out of four rows, three rows
availability of the unit, operation and maintenance cost are installed above the firing zone and one row below the
etc. are affected significantly by the fuel characteristics. firing zone.
Coal firing in the furnace form different kinds of deposits
on the boiler tubes. To improve the performance and This system operates sequentially once in eight hours. All
thermal efficiency of the boiler, it is important to remove soot blowers are operated three times a day. This
the deposits periodically and maintain the heating surface operation requires about 3.30 Tons of steam per cycle.
clean. In conventional wall blowing system, the Boiler operator
can optimize the soot blowing system and keep the
Boilers are designed such that the radiation and furnace free of ash deposits or without much slagging by
convective zone heat transfer surfaces absorb the the following guidelines.
released heat proportionately. Any deviation in heat
transfer in radiation and convection zones, will affect the
function of feed water preheating in the economizer, 1. Provide more excess air if found slagging
steam super heating in LT super heater, platen super
heater and final super heater. This will result in reduction in
boiler operating efficiency. 2. Keep all the wall blowers in operating condition
and operate them on need based rather than
Wall Blowing System conventional system
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The degree, pattern and the periodicity of ash deposits on Operation of Smart wall blowing system
the water walls of boiler furnace mainly depends on type &
quantity of coal fired, mills in operation, burner tilt, excess The heat flux changes continuously depending on the
air, etc. Smart wall blowing system activates the blowers thickness and heat transfer properties of the deposits. The
automatically for cleaning the ash deposits considering actual heat flux is measured continuously by the heat flux
the above variations. In Smart system, the SH spray is kept sensor and monitored with the dynamic set point.
within certain level. Smart system keeps the boiler furnace
clean for better heat absorption by water walls which in The super-heater spray requirement triggers the
turn reflects on the SH spray. operation. The High and low super-heater sprays are set
to desired values. The system either starts or stops the
Smart wall blowing system consists of an electronic logic blowing sequence when the spray crosses the highest /
system interfaced with existing normal blowing system. lowest set points respectively.
The system consists of water wall heat flux sensors
installed in between the wall blowers. These sensors have When there is a reduction in the heat flux below the
built in thermocouples. dynamic set value of a particular sensor the adjacent two
blowers are actuated automatically. The sequence of heat
flux comparison with the set values and the blower by
SWBS establishes automatic operation of wall blowers to passing/ blowing continues in a sequential manner from
achieve optimum heat absorption in the furnace and wall to wall until the SH spray flow reaches the low set
reduces supherheater & reheater spray. The operation is point.
controlled based on super heater spray flow and furnace
heat absorption at different zones. The blowing operation resumes in auto mode when the
SH spray flow crosses the high set point with a
The heat flux sensors are installed in between the wall comparison of heat flux with the set point. The system
blowers in four elevations. There are eight heat-flux maintains super heater spray flow within a narrow band.
sensors in each wall and totally 32 sensors are mounted The trend of super heater spray control with conventional
on four sides of the water wall. The typical arrangement of blowing system and SWBS is shown below.
the heat-flux sensor is shown below:
TIME IN MINUTES
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Benefits of the project About CII & CII Godrej GBC
The benefits of the smart wall blowing system are as CII is a non-government, not-for-profit, industry led and
below. industry managed organization, playing a proactive role in
India's development process. Founded over 113 years
1. Avoids accumulation of deposits ago, it is India's premier business association, with a direct
membership of over 6500 organizations from the private
2. Maintains net total furnace heat absorption at as well as public sectors, including SMEs and MNCs, and
optimum level an indirect membership of over 90,000 companies from
3. Improves heat rate / cycle efficiency around 350 national and regional sectoral associations.
4. Lowers peak furnace gas temperatures Government of Andhra Pradesh, CII and House of Godrej
with the technical support of USAID have launched the CII-
5. reduces the steam consumption by about 55-60% Sohrabji Godrej Green Business centre to offer much
compared to conventional wall blowing system need “Green Services” to Indian industry.
6. Reduces opacity excursion & improves flame
stability Cll-Godrej GBC is a Centre of Excellence in Energy
Efficiency, Green Buildings, Renewable Energy, Water,
7. Lowers thermal Nox due to reduced gas Environment & Recycling and Climate Change activities in
temperature India.
8. Offers less wear & tear of equipment, steam
requirement, auxiliary consumption and CII-Godrej GBC is promoting the concept of “Make Indian
operational cost thermal power plants world class”. The main objective is
facilitating continuous performance improvement in
Financial Analysis thermal power plants and there by achieving world class
standards. As part of this, CII-Godrej GBC is also
The annual savings achieved in a 210 MW unit is facilitating development of service providers network for
Rs 52.5 Lakhs. This will vary significantly depending Indian thermal power plants.
upon the coal characteristics and the site conditions.
Supported by USDOE, NETL & USAID/India
The approximate investment required for installation of
Smart wall blowing system is Rs 265 Lakhs. The U. S. Department of Energy (DOE), National Energy
Technology Laboratory (NETL) USA and the India Mission
Replication potential of the U.S. Agency for International Development
(USAID/India) are supporting the initiatives of CII-Godrej
This project has high replication potential in majority of the GBC for development of service providers network for
captive and utility thermal power plants in India. Indian thermal power plants.
Considering the present installed capacity of the coal This technical bulletin has been developed as part of the
based thermal power plants in India and the typical information dissemination programme for the
operating conditions the replication potential of development of service providers network for Indian
installation of smart wall blowing system is about thermal power plants.
Rs 7500 Lakhs.
S Karthikeyan
s.karthikeyan@cii.in Survey No 64, Kothaguda Post, Near HITEC City,
Ranga Reddy Dist., Hyderabad - 500 084
Tel: +91 40 23112971-73, Fax: +91 40 23112837
www.greenbusinecentre.com
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