Steve Connor. Technical Services Consultant

Transcription

1 Steve Connor Technical Services Consultant

2 What We are Covering Today Discuss the operational drivers: Efficiency, Reliability and Safety The impact areas associated with each Possible remedies or solutions to consider Prioritizing 2

3 What s most wrong with my boiler operation? Efficiency? Reliability? Safety? 3

4 What s most wrong with my boiler operation? Efficiency? Reliability? Safety? Where do problems normally lie? What are most popular solutions? How do I prioritize them? 4

5 5 Efficiency

6 Major Market Drivers Economics 50% + COST OF OPERATION 6

7 7 Impact Areas

8 8 Popular Fuels

9 9 Hydrogen/Carbon Ratio

10 Moisture Losses Hydrogen Oxygen Water Vapor = Moisture losses!! 10

11 Fuel/Air Control Single motor & Jackshaft 11

12 12 Combustion Problems

13 Stack Losses 40 Deg. F Rise = 1% Loss BASED ON: Operating pressure Firing rate Ambient temperature 13

14 14 Excess Air Increases As The Firing Rate Decreases

15 Combustion Efficiency Every 2% Increase = 1% loss! Percent O 2 12% 10% 8% Burner Turndown 4 To 1 6% 4% 2% 0% LF 25% 50% 75% 100% Firing Rate

16 Cycling Losses Pre & Post Purge Losses 16

17 Excessive Makeup? Feed water temperature? Condensate returning? 17

18 Excessive Makeup? Feed water temperature? Condensate returning? Every 10 Deg. F increase in FW temperature = 1% increase in efficiency! 18

19 19 Motors

20 20 Reliability

21 21 Impact Areas

22 22 Reliability Issues

23 Scanner Reliability Issues 23

24 Diffuser Reliability Issues Combustion Issue 24

25 Reliability Issues Fuel/Air Ratio Control Problems Slip Deflect Wear 25

26 Reliability Issues Unstable water level 26

27 Reliability Issues Nuisance shutdowns Pump on LWCO 27

28 Reliability Issues Throat tile Liner tile 28

29 Reliability Issues Burner housing cracks or poor seals 29

30 30 Safety

31 31 Impact Areas

32 Electrical Power Low Voltage High Voltage 32

33 33 Hot Surfaces

34 34 Hot Surfaces

35 Hot Surfaces Sight port w/cooling line Lower half 35

36 Water Level Controls Main Auxiliary Gauge glass 36

37 37 Water Side Occurrence

38 Confined Spaces Firetube Boiler Watertube Boiler 38

39 39 Safety Valve Piping

40 40 Solutions

41 41 Efficiency Solutions

42 Stack Temperature Accurate thermometer 42

43 Stack Temperature + 40 Deg. F = 1% Efficiency lost 43

44 Reduce Cycling Losses can reach 10 15%! 44

45 45 High Turndown Burner

46 Fuel/Air Ratio Control Single point 46

47 Fuel/Air Ratio Control Parallel Positioning System 47

48 Excess Air Losses OXYGEN TRIM SYSTEM Compensates for atmospheric changes such as: Ambient temperature Relative humidity Barometric pressure. 48

49 Stack Economizers Noncondensing Full Condensing 49

50 Stack Economizers Noncondensing Full Condensing Every 40 Degrees Gained = 1% Saved! 50

51 Returning Condensate Deaerator High pressure receiver Every 10 degree increase = 1% Saved! 51

52 Electrical Draw High Efficiency Motors? 52

53 53 Variable Frequency Drives

54 VFD Analysis No 100% = 100% 54

55 VFD Analysis No VFD 100% = 100% 70% = 50% = 12.5% 55

56 56 Reliability Solutions

57 57 Reliability

58 Reliability Neat & Clean 58

59 Boiler Room Equipment Record Keeping Dynamic records Start up and tuning reports Repair reports Inspection reports Chemical analysis reports Boiler room log 59

60 Reliability Solutions Scanner Burner Diffuser BMS 60

61 Dry Oven Reliability Solutions Throat Tile Furnace Liner 61

62 62 Reliability Issues

63 63 Water Treatment

64 64 Water Treatment

65 65 Safety

66 Hot Surfaces Dryback Wetback 66

67 Hot Surfaces Dryback Wetback 67

68 Hot Surfaces Gun Burner Package Integral Burner Package 68

69 69 Hot Surfaces

70 70 Hot Surfaces

71

72 72 Safety Solutions

73 73 Electrical Safety

74 74 Safety Valve Piping

75 Steam Cleaver-Brooks Boiler Room Log Date Time Boiler # Operator Water visible in gauge glass Combustion check (visual) Steam pressure Feedwater pressure Feedwater temperature Flue gas temperature Burner Gas pressure Gas meter reading Oil pressure (regulated) Oil temperature Oil meter reading Atomizing air pressure Ambient air temperature Make-up water Blowdown water column Blowdown boiler Chemical analysis Comments/Observations Note: record water analysis and treatment on separate log 75

76 76 Diligent Monitoring and Recording

77 77 Evaporation Test

78 CB Level Master Features Low or no float movement High and low water alarming Column blowdown reminder Notes successful or unsuccessful LED readout of water level Test auxiliary without jumper wire Easy tie into PLC platform 78

79 Operator Training Cleaver-Brooks Boiler House Milwaukee, WI On-site Tailored programs Regional seminars Online Armstrong International Training Center 79

80 80 Troubleshooting and Repair

81 Prioritizing Efficiency Reliability Safety 81

82 Investing Capital Dollars Everybody is vying for the same bag of cash Normally a simple payback calculation Operation s Guy Facility s Guy 82

83 Investing Capital Dollars Evaluating Cost & Value NPV (Net Present Value) Time/value of money (opportunity) Discounted dollars Positive cash flow and/or profitability IRR (Internal Rate of Return) Cost of capital including tax rate Hurdle rate Competing projects 83

84 Summary Single point positioning systems tend to wear causing poor fuel/air control. A 2% increase in O2 is a 1% loss in efficiency. A parallel positioning system can remedy this problem. Excessive boiler cycling is a huge energy waster. A smaller boiler or high turndown burner may be the answer. Reliability improvement starts with a clean and organized boiler room. Burner trips are mainly caused by fouled scanners and bouncing waterlines due to improper water treatment or condensate fouling. 84

85 Summary The biggest contributors to unsafe boiler rooms are poor maintenance procedures and low water cutoff failures. Operator Training is critical. Low voltage can kill! Safe boiler rooms have excellent boiler room policies & procedures which are diligently followed including documentation. Justifying a capital spend goes beyond simple payback. Money has a time/value component as well as various opportunities for its use. NPV and IRR are critical methods for analyzing the investment for decisions & prioritizing purposes. 85

86 Questions? Steve Connor Technical Services Consultant cleaverbrooks.com 86