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Boiler Engineering

1. Plant efficiency as measured by heat rate methods covered
a. Input /Output – Btu (Kcal)/Kilowatt
b. Turbine Heat Rate /Boiler Efficiency
c. Corrected Design
d. Stack CO2 flow /kW
2. Coal Balance – Tracking
a. Stockpile inventories
b. Weighing accuracy
c. CV change – Loss
3. Input /Output Method
a. Heat Input – not as accurate as output, kW
i. Weight
1. Accuracy Handbook 44
2. Material Testing
3. Consistent vs Accurate
ii. Coal Sample
1. Mechanical is best
2. Hard work
3. High ash or moisture impacts accuracy
b. Output is accurate – kW(hr)
c. Does not Identify individual issues
d. Most common, some use mine analyses
4. Turbine Heat rate /Boiler Efficiency
a. Turbine heat rate adjusted from design
i. Input – SH/RH flow, temp, and pressure
ii. SH/RH attemperation flows
iii. Feedwater heater performance
iv. Output – Condenser conditions
v. Helps identify issues
b. Boiler Efficiency
i. Output /Input
1. Steam flow and conditions
2. Coal flow and sample
ii. Heat loss method
1. Need air heater leakage
2. Excess air
3. Coal sample for ultimate analysis
4. Exit gas conditions – Temps
5. Ash sample for LOI – carbon loss
6. Helps identify issues
7. Might be more accurate, less sensitive to flow measurement
5. CO2 method for Heat Input
a. Must measure CO2 and gas flow
b. Might not be as accurate as method (4.)
6. Heat rate cheating – what heat rate do you want
7. Questions and Answers

Heat Rate Optimisation Methods

Training Course

CLEANING BACKGROUND • History • Pre-commissioning
• In-Service
• What is the objective of cleaning? DECIDING ON CLEANING
• Waterside Surface Condition Assessment
• Effect of Boiler Age
• Deposit Types
• Impact of Planned Operating Regime DEFINING THE CLEANING CIRCUIT • Preheaters & Economizers
• Evaporators
• Superheaters
• External Steam and Water Piping
• Heat Exchangers ENGINEERING THE CIRCUIT · Achieving Flow Rates · Cleaning Circuit Layout SELECTING THE CLEANING AGENT · Acid, Inhibitor and Passivator Options · Pre-cleaning stages · Laboratory Testing and In-Situ Trials PROCESS MONITORING ASSESSING THE FINAL RESULT TYPICAL PROJECT EQUIPMENT REQUIREMENTS · Pumps, Piping and associated piping · Waste Disposal CHOOSING THE CLEANING CONTRACTOR · Writing a Specification for Bids · Assessing Bids · Supervising the Work WHAT CAN GO WRONG • Incidents from the past SUCESSFUL CLEANING • What defines a successful chemical clean

In service Chemical Cleaning Boilers

Training Course

· General Overview o History of development of CFB and FB
o Types of CFB and their characteristics • Key aspects of fluidization o Voidage, particle size, minimum fluidization velocity, transport velocity and other basic concepts · Fuel Properties and their significance for operation and performance o Coal, biomass, and waste · Overall Thermal Design o Heat balance, heat transfer and allocation of heat transfer surfaces, Influence of fuel, co-combustion · Key Design Factors o Bed, Furnace, Cyclone, Loop Seal o Fuel feed system and location o External heat exchangers · Bed Inventory and PSD Management o Pressure drop, and Pressure measurements, circulation loop · Ash Systems and Management o Bottom ash, fly ash, ash cooling, recycling · Bed Agglomeration and deposits on heat transfer surface · Control Aspects o Bed material control, Bed temperature control · Air Emissions o Type of emissions and how they are influenced, CO, NO, SO2 etc. · Part Load and Transient Operation Question & Answer, Discussion

Circulating Fluidised Bed (CFB) Boiler Fundamentals

Training Course

Causes of Boiler and HRSG Pressure Part Failures • Key Types of Failures
• Failures from Fabrication Quality issues Failures during Commissioning
• Failures from operational issues (corrosion, fatigue, overheating and others)
• Failures from Other Causes Root Cause Analysis of Tube and Pressure Part Failures • Inspection and Analysis Techniques Strategies
• Collecting Evidence and Identifying the Failure Mechanism
• Root Cause Analysis Methods Pressure Part Repair and Replacement Options · Individual Tube Replacement/Plugging/Repair · Tube Panel Replacement (Single HARP or Selected HARPS) · Tube Module Replacement Engineering, Procurement, Replacement Actions for Pressure Parts · Specification Development for replacement or upgrade and replace options · Re-Engineering Considerations · Typical Schedule and Price Issues (local or off-shore sourcing,fabrication options, construction management) · Project Supervision and Oversight Pressure Part Replacement Case Studies · Extensive Design/Fabrication Quality Issues in New Plant · Partial Replacement of Evaporator Tubes Full Replacement of Evaporator Modules Replacement of Tubes Damaged in Turbine Accidents · Partial HARP replacements Issues in Replacement Access

Boiler and HRSG Tube Failure Root Cause Analysis & Repairs

Training Course

Part 1: Boiler and Steam Generation System • Basic Steam Cycle Thermodynamics
• Overview of Design of Steam Boilers o Heat Exchanger Theory and Operation
o Heat Transfer Media
o Boiler Auxiliaries • Types of Boilers and Key Boiler Components o Fire Tube Boilers
o Water Tube Boilers
o Boiler Pressure Parts
o Types of Burners
o Fuel Types • Key Ancillary Components o Air and Exhaust System o Control and Safety Valves o Drain, Vent and Blowdown Systems o Soot Blowers o Pumps o DCS and I&C o Water Treatment • Types of Boiler Control Systems o Cascade Control System o Fuel Control System for a Boiler o Air Fuel Ratio Control o Minimum Fuel Flow Limitations o Emissions Control o Boiler Drum Level Control o Boiler Drum Pressure Control o Steam Temperature Control Part 2: Plant Operations
• Effective Startup and Shutdown Procedures
• Effective O&M Monitoring
• Assuring Boiler Water Quality
• Avoiding Pressure Part Failures
o Inspection Techniques and Strategy
• Asset Life and Reliability Management Part 3: Health and Safety in Boiler Operations
· Prevention of Unsafe Situations
· Assuring Both Safety and Efficient Operation

Part 4: Real Life Case Studies

Boiler Operation and Maintenance Essentials

Training Course

CFB Boiler Design and Operations • History of development of CFB and FB
• Types of CFB and their characteristics
• Key aspects of fluidization
• Fuel Properties and their significance for operation and performance
• Overall Thermal Design
• Key Design Factors
o Bed, Furnace, Cyclone, Loop Seal,
o Fuel feed system and location
o External heat exchangers
· Bed Inventory and PSD Management
· Ash Systems and Management
· Control Aspects
· Air Emissions
o Type of emissions and how they are influenced, CO, NO, SO2 etc.
Boiler and Plant Performance Testing
· Testing Objectives
o New Plant/Commissioning
o Operational Monitoring Over Life
· Performance Test Codes Background: ASME and EN
· Key ASME Plant Test Codes
o PTC 6, Steam Turbines
o PTC 46, Overall Plant Performance
o PTC 4, Fired Steam Generators
· Balance of Plant Testing ASME PTC (4.2, 4.3, 12.1, 12.2, 23, 8.2 etc.)
· Emissions Testing
· Test Preparation and Execution
o Instrument Installation
o Data Recording
o Dealing with Test Uncertainty
o Troubleshooting
· Applying PTC Methods to Ongoing Plant Performance Monitoring

Design & Testing of Circulating Fluidized Bed Boiler (CFB) Power Plants

Training Course

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