Fuel Factors Checklist
1 What type of fuel(s) are we firing or co-firing? Coal Biomass Gas Oil 2 Is the fuel supply consistent? Yes No 3 Do we have two ultimate coal analysis tests to compare? Yes No HGI a.
(Hardgrove Grindability Index)
b. b. b.
Slagging index a. T250 temperature a.
4 Do we have two ash mineral analysis tests to compare? Yes No a. b. 5 Other things to check Coal supplier/mine/seam location Coal size (average & top size) Sampling method Ash fusion temperatures (oxidizing & reducing) Proximate coal analysis (w/high heating value) Crusher condition
Pulverizer System Checklist
1 Are all the mills functioning properly? Yes No 2 Are primary/secondary air flows optimized? Yes No 3 Are feeder flow rates optimized? Yes No 4 Mill temps: inlet 5 Air temps: primary outlet secondary
6 Is fuel fineness from transport pipes optimized? Yes No 7 Other things to check Horsepower per ton of coal Mill loading (typical/design capacity) Performance capacity (corrected for fineness, HGI, moisture, sizing)
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Combustion Checklist
1 Do we have good, complete combustion? Yes No 2 Oxygen levels Furnace exit Boiler exit Economizer exit 3 Air-to-fuel ratios Primary Total
4 Is fuel distribution to all burners consistently balanced? Yes No 5 Gas temperatures Furnace exit 6 Forced draft (FD) fan settings Current Damper 7 Primary air fan (or exhauster) settings Current Damper 8 Other things to check Burner belt stoichiometry (air per MMbtu) Feeder flow rates Furnace-to-windbox differential pressure Furnace exit gas profile Furnace exit O2 profile Over-fire air settings (%, flow, distribution) Secondary air flow & dampers Boiler exit velocity profile Pressure drop across windbox, furnace, convection pass, AH, backend Boiler exit
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Steam Cycle and Boiler Reliability Checklist
1 Are all controllable losses optimized? Yes No Turbine cycle heat rate Furnace heat release rate Net plant heat rate 2 Are we able to maintain design steam temperatures? Yes No 3 Do we have any air in-leakage originating in the boiler? Yes No Infiltrations between furnace & penthouse penthouse & airheater Other 4 Furnace exit gas temperature
(measured by water-cooled probe)
5 Outlet header condition assessment
(recommended every 2-5 years) (date) (date)
6 Visual boiler inspection
(recommended each outage)
7 During inspections, did we find unburned carbon on tubes in the upper furnace (above the burner belt)? Yes No 8 What is our most recent EFOR (Equivalent Forced Outage Rating)? Date Rating
9 Other mechanical issues to check Burner mechanical condition Condition of soot blowers Upper furnace/convection pass tube alignment De-superheating spray flows (superheater and reheater) Tube metal temperatures 10 Other process issues to check Turbine cycle deviations Steam/water isolation problems Feed water heater problems Long-term condenser issues Losses from combustion of moisture & hydrogen Dry gas losses
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Airheater Performance Checklist
1 Is airheater performance optimal? Yes No 2 Do we have ports available for representative testing? Yes No 3 Do we have representative performance data available? Yes No Inlet data Outlet data Oxygen Temperatures Static pressure 4 Oxygen levels Airheater inlet Airheater outlet 5 Are the gas outlet flows and/or temperatures stratified? Yes No 6 Performance results Leakage X-ratio (air-to-gas) Air-side efficiency Air-side differential pressure (P) Gas-side efficiency Gas-side differential pressure (P) Corrected no leakage exit gas temperature 7 Other things to check Recuperative and/or regenerative airheater mechanical conditions (seals, heating elements/tubes, plates, gears, turn-down, motor, diaphragm, pin racks, fasteners, soot blowers, other components) Airheater reliability Cold-end corrosion
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Selective Catalytic Converter (SCR) Performance Checklist
1 Are we experiencing ammonia slip? Yes No If yes, how much? (PPM) 2 Are we experiencing pressure drop issues? Yes No Inlet pressure 3 NOx concentration Inlet 4 Sulfur trioxide (SO3) concentration Inlet 5 SCR temperatures Inlet 6 Other things to check Ammonia distribution Ammonia flow Gas velocity distribution Bypass damper position Mercury oxidation issues Catalyst poisoning, deactivation and/or accelerated erosion Outlet Outlet Outlet Outlet pressure
Sorbent Injection (Spray Dryer) Performance Checklist
1 What type of sorbent are we using? 2 Are we over- or under-injecting? Yes No Sorbent injection rate 3 Are all the spray atomizers in service? Yes No 4 Percent solids 5 pH of injected fluid 6 Temperatures Inlet 7 Outlet gas humidity level Outlet
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Precipitator Performance Checklist
1 Are secondary voltage and current readings within normal range? Yes No
2 Gas temperatures Inlet Outlet 3 What type of fuel(s) are we firing or co-firing? Coal Biomass Gas Oil Other
4 Do we have high levels of unburned carbon in ash? Yes No How much? 5 Opacity trace trends (spikes, etc.)
6 Other things to check Primary voltage and current Spark rate Flue gas flow rate Rapper systems (mechanical, programming) Inlet temp profile Hopper collection profile O2 differential across unit Chemical injection rates upstream of ESP (SO3, NH3, etc.) ESP fly ash resistivity Particle size distribution (inlet/outlet) Hopper catch ash mineral analysis Mass loadings (inlet/outlet) Velocity distribution (inlet/outlet) Pressure differential across unit Performance of SO2 injection system (upstream of ESP) Condition/performance of data collection systems Condition/performance of economizer & airheater hoppers (upstream)
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Baghouse Performance Checklist
1 Are we experiencing opacity exceedances? Yes No
2 What is the differential pressure (P) before and after cleaning? Before After 3 Is cleaning energy sufficient? Yes No
Reverse air: inches H2O. Pulse jet: compressed air pressure (PSI)
4 Are we using an appropriate cleaning method (online or offline)? Yes No
5 Are all compartments in service? Yes No 6 Do we have hopper pluggage/high hoppers? Yes No
7 Other things to check Flue gas flow rate O2 differential across unit (air in-leakage) Hopper catch ash mineral analysis Gas temps (inlet/outlet) Inlet/outlet mass loadings Inlet/outlet particle size distribution Sorbent injection rates upstream of baghouse Appropriate air-to-cloth ratio (filter area)
R/A, 1.75:1-2.5:1 | Pulse jet, 3.25:1-4.0:1 | Shaker, 2.0:1-2.5:1
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Gas Scrubber Performance Checklist
1 Is scrubber performance consistently optimal? Yes No 2 Temperatures Inlet Outlet
3 Differential pressure (DP, P) between inlet and outlet 4 Scrubber solution pH 5 Other things to check Water makeup Scrubber efficiency Energy consumption Mist eliminator performance Large particle size (LPA) Corrosion/alloy condition
Induced Draft (ID) Fan and Stack Checklist
1 Are we using more fan than in the past? Yes No 2 Do we have two sets of stack test results to compare? Yes No
includes 02 , CO, CO2 , SO2 , NOx , temp, PM, Hg, opacity, D&Fs, HCl
a. b. 3 Fan settings Current Damper 4 Fan inlet temperature 5 Other things to check Continuous emission monitoring system (CEMS) parameters (all available)
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