Boiler and Coal Mill Testing

Techniques to Optimize
Combustion

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 The Thirteen Prerequisites For Optimum Combustion
1. Furnace exit must be oxidizing, preferably 3%
2. Fuel lines balanced to each burner by “Clean Air” test ±2% or better.
3. Fuel lines balanced by “Dirty Air” test, using a Dirty Air Velocity Probe, to ±5%
or better.
4. Fuel lines balanced in fuel flow to ±10% or better.
5. Fuel line fineness shall be 75% or more passing a 200 mesh screen. 50 mesh
particles shall be less than 0.1%.
6. Primary airflow shall be accurately measured & controlled to ±3% accuracy.
7. Over-fire air shall be accurately measured & controlled to ±3% accuracy
8. Primary air/fuel ratio shall be accurately controlled when above minimum.
9. Fuel line minimum velocities shall be 3,300 fpm
10. Mechanical tolerances of burners and dampers shall be ±1/4” or better
11. Secondary air distribution to burners should be within ±5% to ±10%.
12. Fuel feed to the pulverizers should be smooth during load changes and
measured and controlled as accurately as possible. Load cell equipped
gravimetric feeders are preferred.
13. Fuel feed quality and size should be consistent. Consistent raw coal sizing of
feed to pulverizers is a good start.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 13 Prerequisites are essentially the boiler “inputs”
Boiler Inputs need to be verified by Field Tests
Fuel lines balanced to
each burner by “Clean Over fire air shall be
Air” test ±2% or better. accurately measured &
controlled to ±3%
Fuel lines balanced in accuracy.
fuel flow to ±10% or
better. Furnace exit must be
Fuel lines balanced by oxidizing preferably, 3%.
“Dirty Air” test, using a Secondary air distribution to
Dirty Air Velocity burners should be within ±5%
Probe, to ±5% or to ±10%.
better.
Fuel line minimum Mechanical tolerances
velocities shall be of burners and dampers
3,300 fpm. shall be ±1/4” or better.
Fuel line fineness shall Fuel feed to the pulverizer should
be 75% or more passing be smooth during load changes
a 75 Micron screen. 300 and measured and controlled as
Micron particles shall be accurately as possible. Load cell
less than 0.3%. equipped gravimetric feeders are
preferred.
Primary air/fuel ratio shall
be accurately controlled Fuel feed quality and size should
when above minimum. be consistent. Consistent raw
coal sizing of feed to pulverizer is
Primary airflow shall be a good start.
accurately measured &
controlled to ±3%
accuracy.
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 About 70% of the 13 Prerequisites are essentially the boiler “inputs” are Pulverizer Related
Some of these mill related “inputs” were recently quantified on CPB2

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Mill & Fuel Line Performance Measurements

1. Clean Air: Air going through the fuel lines without any fuel, at normal
operating temperature and pressures. With the absence of fuel this is
considered a clean environment.

2. Dirty Air: Air and Fuel mixture going through the fuel lines. Coal and Air
mixture in the burner lines is considered a dirty environment.

3. Isokinetic: Is when the “dust laden” flow entering the collection nozzle is
equal to the velocity of the flow in the fuel line

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Purpose of Clean Air Testing

1. Establish similar system resistance for each burner line on a balanced air
flow basis.
2. Provide a correlation between fuel line “dirty air” and clean air velocities
3. Clean air balancing is an integral part of air to fuel ratio balancing which
incorporates air, as well as fuel balancing.
4. To ensure the minimum fuel line velocity is maintained after optimization of
primary air flow to improve flame stability at lower loads and reduced fuel
line plugging.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Equations Used in Clean Air Testing Data Analysis

!" =
! /0P + /0 2 + /0 N .....
-". ", '()*+(&+ !"#$%&

'(
'&-$K/01 =)*+, ! "#$%& !
!
34
54 +
72$ + &$°S
89:*;#<(! ) = ! 1!B2 ! $B$&D(F*BH"# !
72$ + S .LBL.0 ,-

A%&D()*+,2,-.%/M1%,A%&D()*+
!,8%.)M*)D4,6/D7,*5%,3%M4,,=, !"##!
-.%/M1%,A%&D()*+

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Performing Clean Air Test

!"#$
+I-..LI-
%&'&(F*

M1&'O*+I-..LI-

%&'&(F*+I-..LI-

P45*STFO(T-*
8'T19-&-I

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Dirty Airflow and Isokinetic Coal Sampling
The Isokinetic coal sampling process is a three step process

• Finally Extract a
Coal sample
• Determine Isokineticily, to
velocity pressure determine fuel flow
and for utilization of
• Determine static and flow the representative
pressure and sample for fineness
temperature in analyses.
fuel line

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Coal Sampling Definitions
• Holding the Velocities is critical in order to obtain an representative sample.

Notice how the particles

Notice how the particles Notice how the particles
are flowing into the
are being pulled into the are being pushed away
sampler at the same
sampler at a higher rate from the sampler tip due to
rate as the coal is
than the pipe velocity. its obstruction.
flowing through the pipe.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Why Perform Isokinetic Coal Sampling ?

1. Ascertain relative pipe-to-pipe fuel balance.

2. Quantify individual fuel line air to fuel ratios.
3. Quantify pulverizer air to fuel ratios
4. Quantify individual fuel line velocity and
airflow.
5. Ascertain pipe-to-pipe airflow balance.
6. Ascertain pipe-to-pipe fuel flow balance.
7. Quantify fuel line temperature and static
pressure.
8. Obtain representative fuel sample for coal
fineness analysis.
9. To determine Mill HP/Ton

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Mill Testing Conditions

The Isokinetic coal sampling process will only yield accurate results
under proper testing conditions. Several of the conditions are as
follows:

1. Mill fuel controls in manual at steady state for as long as possible

prior to testing.
2. All air controls settled out at respective flows and/or temperatures.
3. Correct number of ports per distance from nearest bend in fuel line
(either upstream or downstream)
4. No obstructions to flow inside pipe near testing location. See pictures
below of “Ideal” and “Unacceptable”.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Arrangement of test connections

10 Diameter Upstream 5 Diameter Upstream

5 Diameters Downstream 2 Diameters Downstream

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Proper Orientation of Test Ports

Note: Test taps need to be

centered on the plane created by
Typical heavy coal the axis of pipe before and after
laden area due to the bend to ensure a
the centrifugal representative sample
acceleration of the
coal from the bend

Typical heavy coal laden area

due to the centrifugal
acceleration of the coal from
the bend

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Horizontal vs. Vertical Runs for Testing
Stratification following an elbow

Horizontal Coal Pipe

Fine
Particles
Fine Particles

Coarse
Particles
Higher Kinetic Energy of
larger particles causes
stratification

Flow

Flow

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Three Steps to Isokinetic Sampling

In all the isokinetic coal sampling process is a three step process:

1. Determine static pressure and temperature in fuel line

2. Determine velocity pressure
3. Finally extract a n isokinetic coal sample through representative test ports

Install coal line test taps to facilitate insertion of the sampling probes.
Ideally, coal line test taps should be located in a vertical run of piping
between five and ten diameters downstream or upstream of the nearest
obstruction (i.e. elbow, orifice plate, flange, isolation value, etc.) Two test
ports, 90° apart, per pipe are required at a minimum.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Static Pressure & Temperature Probe

1 ¼ Full Ported
Ball Valve

Dustless
Connector

Static Tap and Connection

Digital Manometer

Type “K” Thermocouple

Lead and Digital
Coal/Air Thermometer

Mixture

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Dirty Airflow Testing Probe & measurement
Low
pressure High pressure
connection 47.9% 47.9%
connection
43.3 % 43.3%
[Link]-N-O

CD#EA CD#EA
C!#!A C!#!A
!B#"A !B#"A
38.2 %
!"#"A 38.2%
!"#"A
"PA "PA
32.24C#CA
% 32.2%
4C#CA

Flow direction 25.0 % 25.0%

Pointer [Link]-

14.4 % 14.4 % [Link]

=SRLN-I
[Link]

Low pressure tip

GSN-9..-LRW.U-OR-GNL;-.[Link]=NFU=F-I.>?.[Link].
.............[Link]@.[Link]=FG;.USFGN#

High pressure
Flow baffle HLMU=FG;.[Link].L.4"[Link].=LO;-[Link]-
tip

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Dirty Airflow Measurement
Traverse points on the dirty air probe
are marked on an equal area grid in
accordance to ASME Performance
Test Code for traversing circular
ducts. Taking into account the test
ports, nipples & dustless connector.

Dirty air velocities must be measured

in each fuel line to establish proper
sampling rate (∆P) for the isokinetic
sampler and to determine airflow in
each fuel line. The dirty air probe is a
field proven device, which allows the
measurement of airflow in a dust-
laden environment with a minimum of
probe stoppage.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Dirty Airflow Equations

Velocity Pressure is the 1st thing that

0N =
! 0N4 + 0N P + 0N 2 ////////
is needed to be found before Coal ."/'"- '()*+,)&,'!"#$%&
Sampling can begin.

34
Bp = Barometric Pressure (“Hg) 54 +
72$ + &$°S
89:*;#<(! ) = ! 1!B2 ! $B$&D(F*BH"# !
Sp = Static Pressure (“w.c.) 72$ + °S .LBL.0 ,-

'(
'&K$/012- = -)*+, ! "#$%& !
!
A%&D()*+ " ,-%M1.% A%&D()*+
7%1625%-)1*)D623#42 =2 !!""#
,-./A%&D()*+

Volumetric Flow (Q) = velocity (Fpm) x pipe cross—sect. area (ft3)

Mass Flow (W) = Q x 60 min/hr. x Density

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Performing Isokinetic Coal Sampling

Differential pressure is 2nd equation needed to begin sampling.

This finds the sample rate at which the coal will be pulled from
the fuel line.
Calculate the sampler orifice differential pressure based on the
dirty air velocity traverse. Sampler differential is monitored by a
standardized orifice and an inclined manometer. The average
square root velocity head (velocity pressure) observed by the
dirty air probe is entered into the following formula:

(
"& = &%"#$ ! $"% "# )
!
!!!

● Relationship of velocity pressure and coal sampler orifice differential for

reference

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Performing Isokinetic Coal Sampling

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Isokinetic
Coal Sampler

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Performing Isokinetic Coal Sampling

Determine sample weight in each of the sample bags,

record on the data sheet and perform fineness analysis on
all coal samples. Sample drawing of sieve and scale on
right.
Place 50 grams of coal on stacked 50, 100, 140 and
200 mesh sieves and shake for 20 minutes

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Combustion Airflow Distribution & Control
Combustion Air Flow Paths
• Primary Air
• Secondary Air – Inner
• Secondary Air – Outer
• Secondary Air – OFA
• Tramp Air – In-Leakage*
* Expected < 2% of total theoretical air
Over-Fire Air
(15 - 20%)

Secondary Air
(55%-65%)

Primary
Airflow
(15%-20%)

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Airflow can be measured accurately with airfoils but periodic calibration is needed

q Measurement of velocity pressure at discrete points which sensitive to stratification or turbulence

caused by structural components.

q Leaks in internal sensing manifolds are difficult to detect.

q Ash plugging characteristics tend to cause inaccurate flow measurement rather than loss of airflow
signal.
Wednesday, CLP Coal-Fired Boiler Testing &
August 4, 2011 Performance
Airflow measurement by venturi is less problematic and can be more accurate

q Sensing taps are on top and out of the gas

stream preventing plugging and leakage.

q Extremely low maintenance and easy to

calibrate.

q Highest accuracy and minimizes temperature

stratification.

Wednesday, CLP Coal-Fired Boiler Testing &

August 4, 2011 Performance
Precise measurement & management of all airflow inputs to the boiler is ideal

Wednesday, CLP Coal-Fired Boiler Testing &

August 4, 2011 Performance
 Forward/Reverse Probe

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Fecheimer Probe

Used to measure air or gas

flow when the directional
element of flow is not known
(primarily fan performance
tests)

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Fan Inlet Measurements

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Overview of Fan Testing ASME PTC 11
• Procedure
– Two traverse planes are required to
determine fan pressure and specific
energy
• Inlet and outlet boundaries of the fan
– Only one test plane is needed to determine
flow rate; however, if two are available then
both should be utilized
– If there is more than one inlet to the fan
each must be measured
– The number of test points should be the
larger of the following:
• 24 points
• Not less than one point for every 2ft2
– If testing an ID fan gas samples must be
measured
– A Fecheimer probe is typically required

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Fan Performance Test
– Plotted performance data on fan curve
– FD Fan performed below system load line on all 3 load points

FD Fan Performance Curve

90
Horse Power
2500
80

70 45% 15%
60% 30% 2000
Fan Total Pressure (inwg)

60

Brake Horse Power

50 75%
1500
Static Pressure
40
90% System Load
1000
30 Curve

20
500
10
75%
60%
90% 45%
0 0
0 50,000 100,000 150,000 200,000 250,000 300,000 30%
350,000 15% 400,000
Volume (cfm)

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Forward/Reverse Velocity Probe Measurement

Digital Thermometer
10” Incline Manometer Digital Manometer or U-Tube

Forward & Reverse velocity probe

Duct

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Sample Grid Considerations

• Test grid should be reasonably spaced with 1 point per 0.6 – 0.8 square meters (or 7-9
per Sq. Ft.)
• More test points do not substitute for insufficient number of test ports.

Test Grid Layout for Rectangular Duct Test Grid Layout for Circular Duct

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Calculation for “K” Factor
!"@A%&D%(F*@++I%%%-"+.A%(@/M+12%FP4F%(P./56@"6%T@A1A%U9:.%;@MM./."A@5+

&=<D<<<

&<<D<<<

>=<D<<<

C+12%a%&<<bC
" "
$#=# =# ><<D<<< C+12%a%A<<bC

(! )(!") ! ! !" C+12%a%B<<bC

C+12%a%=<<bC
C+12%a%F<<bC
=<D<<<

$#=#" (! )(!")
C+12%a%@<<bC

<
<?&= <?=< <?@= >?<< >?&= >?=< >?@= &?<< &?&= &?=< &?@= A?<< A?&= A?=< A?@= B?<<
W – Mass Flow (lbm/hr)
K – K Factor for flow device
d – density (lbm/ft3)
ΔP – Differential pressure across the transducer for the flow device

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Primary Airflow Logic
Example w/ Temperature Compensation

Primary air venturi temperature

AI Analog input, °F AI

Primary air venturi Primary air venturi

air temperature °F Differential pressure in
X (°F) Y(lb/ft3)
200 0.06718 “wc value is 0 to 6.5
Density function 250 0.06245
F(X) 300 0.05834
generator 350 0.05156
400 0.05156
Density Square root
Sqrt(X)
function block

Square root
Sqrt(X)
function block
Range is 0 to 2.55

Multiplication function block

X X #,##

Primary air venturi K x Sqrt(venturi PAA venturi K factor (klbs/hr)

airflow (k lbs/hr) differential pressure)

Multiplication function block

W (mass flow) = " "#" !$"#"!
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 Air Foil Construction (Typical)
Isolation Valve for Low Pressure Line
Pressure Transmitter
Instrument Valve for Low Pressure Line
Isolation Valve for Low Pressure Line a.) installed for blow down provisions with compressed air
b.) installed for local test connection
Instrument Valve for High Pressure Line
a.) installed for blow down provisions with
compressed air
b.) installed for local test connection
High Pressure Line Low Pressure Line
Impact holes
(located on end of airfoil)
Flow
Instrument Valve for
High Pressure Line

Instrument Valve for

Low Pressure Line Static Pressure holes
(located on top & bottom of airfoil)
½” S.S. tubing is recommended for sensing lines.
Horizontal runs should be sloped at a minimum of 10%
upward towards transmitter to avoid condensation buildup.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Pitot Tube Construction (Typical)
Pressure Transmitter
Isolation Valve for High Pressure Line
Isolation Valve for Instrument Valve for High Pressure Line
Low Pressure Line a.) installed for blow down provisions with compressed air
b.) installed for local test connection
½” S.S. tubing is recommended for sensing
lines. Horizontal runs should be sloped at a
minimum of 10% upward towards transmitter
Instrument Valve for Low Pressure Line
to avoid condensation buildup.
a.) installed for blow down provisions with
compressed air Low Pressure Line
b.) installed for local test connection
High Pressure Line
Instrument Valve for
Instrument Valve for Low Pressure Line
High Pressure Line

Static Pressure holes

(located 180° from
Impact holes Impact holes on low
(on high pressure line) pressure line)

w
Flo

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Venturi Construction
Pressure Transmitter
Isolation Valve for High Pressure Line

Instrument Valve for High Pressure Line Isolation Valve for Low Pressure Line
a.) installed for blow down provisions
w/ compressed air Instrument Valve for Low Pressure Line
b.) installed for local test connection a.) installed for blow down provisions with
compressed air
Instrument Valve for HP Line b.) installed for local test connection
High Pressure Line
Low Pressure Line

½” S.S. tubing is recommended for sensing

lines. Horizontal runs should be sloped at a
minimum of 10% upward towards transmitter
to avoid condensation buildup.

Flow
Instrument Valve for Low
Pressure Line

Thermocouple (Type “K” recommended)

Test Ports with 1 ½” high

quality ball valves Venturi

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 A proper mill load line ensures
proper and optimal mill airflow and coal flow relationship
A proper load line requires:

• Accurate measurement and control of mill airflow (PA) within ±3%.

• Accurate measurement and control of coal flow better than ±5%.
23
22
21
20
19
P.A. FLOW (kg/s)

18
17
LCV
16
15
During these test all values should be on the Normal
14 PAF MIN
blue (LCV) line.
13 Measured
12
11
10
10 15 20 25 30 35
FEEDER SPEED (RPM)

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Typical HVT Traverse Planes

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Visual Indications of Non-Optimum
Combustion Performance

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Typical HVT probe used to measure FEGT

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Typical HVT probe radiation shields
!"#$%C'CE)*#H#*#%#,!

!"#$%C'CE)*#H#*#%#,!

!"#$%C'CE)*#H#*#%#,!

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Gas Temperature Pyrometers
Must be used & accuracy verified by HVT Probe

HVT Probe
FEGT Test Port
Monitor

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Furnace Exit HVT Test Procedure
A Furnace High Velocity Thermocouple Traverse (HVT) performs the
following:

1. Quantifies furnace exit gas temp. (FEGT)

2. Ascertains furnace temperature profile
3. Quantifies furnace oxygen level
4. Ascertains furnace oxygen profile

!"#$"%&'(%"F*+",-F./F01%'2FP4P5
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 Flue Gas Profiling

Oxygen
Temperature

CO
NOX

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Using a Multi-Point Flue Gas Sampling Grid
(Examples)

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Boiler Air In-Leakage Paths

Air that leaks into the gas stream reduces

the temperature of the gas. The lower
gas temperature decreases the efficiency
of any heat transfer element i.e.
penthouse, boiler bank, economizer, air
heater and is a thermal efficiency penalty.

PTC-4 does not take into boiler air in-leakage.

Thus, this is “Stealth” leakage. In addition to the
thermal penalty, artificially high oxygen readings can
have serious performance impacts on combustion.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Optimizing Boiler Performance

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Understanding System Draft Loss (Balanced Draft Unit)

-4 “w.c.
-.5 “w.c.

- 6“w.c.

-20“w.c.
-.5“w.c.

-1-2”w.c.
-10 “w.c. -15“w.c.
-22- 25“w.c.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Boiler and Airheater Performance and Efficiency

• Minimum Measurements required for Static Pressure

Airheater and combustion Performance 1, 2, 3, 4
evaluation Velocity Head
o Temp in and out both air sides 2, 3, 4
o O2 before and after gas side Oxygen
o Air and gas flows before and after air Concentration
heater 3, 4
Temperature
• Velocity heads should be measured
1, 2, 3, 4
• Measured Performance Variables
o Air Heater Leakage
o Corrected Gas Outlet Temperature
o X-Ratio
o Efficiency

Testing Locations

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Measuring Air Heater Performance
Air In-Leakage calculation:

# %)#L0 " # %)1O

*+I-I.+)&'( = ! !"
%"$! " # %)#L0
Corrected gas outlet temperature:

480C9C:0 ! . (A%C' ! (3%C'A!"# A" (T64A! 3+I-A)G + 564 ! 3%C'A!"# ))

3%C'A!"#A.L--01#0O = + 3%C'A!"#
. (A%C'
Heat transfer efficiency:

L >CM1O ! (.M1OC;<9 " .M1O?C=6 )! M1OCI#''CEFGH

8"#9C.O#6'4"OC344151"65T =
L >C-#' ! (.-#'C=6 " .-#'C;<9CLGOO"59": )! -#'CI#''CEFGHC!"''C!"#A#%!

Fan efficiency:
/<H49=>/*S ! ;,M,%C."-'778-'9: 45C5S
"H4'-.>HE78?@,%HE = 12P1 !"
/ME.#AA%C%'ECF.! *H,H-.#AA%C%'ECF
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 Corrected to “No Leakage” Temperature & X-Ratio

ITA0;..4<#4=A9:-#A%C'AL48)4.C#".4 =
(I-.AT4C#4.A34C5C64A! 0 )EAI-. ! (L%C'EA!"# " [Link] ))
+ L%C'EA!"#
1OO ! 0 )EA%C'
Air Heater Leakage (%)
CpAir = Specific Heat of Air (BTU/lb °F)
TGas, Out = Temperature of Gas Leaving Air Heater (°F)
TAir, In = Temperature of Air Entering Air Heater (°F)
CpGas = Specific Heat of Gas (BTU/lb °F)

T6I-'#!" ! T6I-'#()G#34R#L0INIO0#HI-B-.
AX#: 8 9IGBR =
TAB&'#()G 8 TAB&'#!"

TGas, In = Temperature of Gas Entering Air Heater (°F)

TGas, Out (No Leakage Basis) = Air Heater Gas Outlet Temperature Corrected for No Leakage (°F)
TAir, Out = Temperature of Air Leaving Air Heater (°F)
TAir, In = Temperature of Air Entering Air Heater (°F)

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Air In-leakage impact on Fan Horsepower

Power Consumption vs Volumetric Flow

100
Power Consumption (%)

80

60

40

20

0
0 20 40 60 80 100
Volumetric Flow (%)

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Draft Loss Measurement

-4 “w.c.
-.5 “w.c.
- 6“w.c.

-20“w.c.

-.5“w.c.

-1-2”w.c.
-10 “w.c. -15“w.c.
-22- 25“w.c.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Fly Ash Sampler

Stainless Steel Perforated

Cylinder for Filter Paper to
Stainless Steel
Collect Flyash Sample
Flyash
Canister
Sampling Tip

Extension Pipe

Gas Flow Stainless Steel Flyash

Filter Canister

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 (3) Part Fly Ash Sieve/LOI Analysis

Place 50 grams of ash on the 200

MESH for sieve analysis
Determine LOI residue on 200
200 MESH mesh screen and within the pan
SIEVE to analyze the coarse and fine
(COARSE particle ash to compare with
ASH) overall combustion and boiler
performance. If the +200 mesh as
is great than 10% of the ash and
high in LOI, this suggests a
problem with mill performance. If
the fine particle ash is high in LOI
BOTTOM
for a given coal, this indicates a
PAN (FINE deficiency of Oxygen in the boiler
ASH) (and/or a region of the furnace).

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Burner Line and Burner Bucket Inspection Items
that Influence Burner Line Air and Fuel Balance
Traverse points on both the dirty air and clean air probe are marked on an equal area grid in accordance with the
ASME Performance Test Code for traversing circular ducts. This ASME standard, for pipes with 12" or larger
diameters, is illustrated by the figure below.
L0NO3 L0NO3
L4N43 L4N43

4RNE3 4RNE3
4ENE3 4ENE3
ESN73 ESN73

'LNL3 'LNL3

! "#A%&
'E) #G+,-G.%G
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 Burner Line and Burner Bucket Inspection Items
that Influence Burner Line Air and Fuel Balance
Coal line test taps required for dirty air and clean air traverses are shown by the illustration
below. Dirty air probes, require 1¼" full-ported ball valves. A minimum of two ports at 90°
apart will be required. An increased number of test ports are sometimes required when test
taps are close to elbows or other flow disturbances.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Test Methods for Ascertaining Fineness
The Isokinetic coal sampler is recommended for collection of coal
samples for determination of fineness.
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Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Test Methods for Ascertaining Fineness
Proper test connections must be installed for accurate coal fineness,
fuel balance and airflow data.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Test Methods for Ascertaining Fineness
The dirty air probe is used in conjunction with the Isokinetic coal sampler to
measure burner line airflow and to determine the sampling rate.

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Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Clean Air velocities to ensure system resistances are
equal are measured with a Pitot tube

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Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Importance of Primary Air Flow Calibration by
Local Traverse
Optimum pulverizer primary air (PA) flow, being of paramount importance in achieving optimum
unit performance, requires periodic testing to ensure optimum PA flow is maintained. Whatever
type of flow measurement element is utilized, measurement accuracy should be within ±3% of
actual flow measured by local traverse by competent test personnel using the appropriate
measurement equipment.

Regardless of measurement element type, elements should be calibrated by local traverse on a

regular basis (usually annually as a minimum). If air flow indicated by a measurement element
is not within ±3% of actual measurement, the element should be modified or replaced as
necessary to achieve desired accuracy. Primary air flow elements should always be calibrated
on a “hot” basis.

This requires air flow traverses to verify element accuracy being performed with the pulverizer
in service at operating temperature in close proximity with the measurement element. We have
found that calibration with the pulverizer out of service can be inaccurate due to flow profile
differences caused by hot and tempering air damper position.

Prior to calibration of the element, it is strongly recommended that all sensing lines from the
device to the differential transmitter be blown free of dust/ash accumulation and pressurized to
check for leaks. In addition, during calibration, an oil-filled manometer should be connected
locally across the transmitter in order to verify its accuracy.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Burner Line and Burner Bucket Inspection Items that
Influence Burner Line Air and Fuel Balance
Periodic dirty air tests will also identify burner line airflow imbalances. If excessive dirty air imbalances are observed, a
clean air test to investigate whether or not dissimilar burner line resistance is causing airflow imbalances should be
completed. Dirty air imbalances larger than ±5% deviation from the mean burner line velocity air is considered
excessive. Clean air imbalances larger than ±2% deviation from the mean burner line velocity are considered excessive.
However, clean air imbalances of ±5% rarely cause concern.

Dirty air balance refers to the measurement of burner line airflow and velocity while the pulverizer is operating and a
mixture of coal and air is passing through the burner lines. A special probe is required to measure airflow under these
conditions. The sketch below illustrates a dirty air probe that can measure airflow in a dust-laden environment.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 A clean air test should consist of two crews working simultaneously on the same pulverizer, starting at opposite corners
of the boiler and each crew performing a complete clean air test. This will facilitate collection of two independent sets
of data.

Collected test data should be reduced immediately following completion of the test. Reduction of clean air data will
consist of calculation of velocity, mass flow and deviation from the mean velocity for each individual fuel line. The
reduced data from each separate team will be compared. Percent deviation between the results of the two separate
sets of data should be no more than ±1%. If ±1% repeatability is not obtained, the test is considered invalid and should
be repeated. This is required to ensure repeatability, accuracy and validity of the test conditions. If repeatability is not
achieved, one or more of the following factors may be the cause:

• Human error
• Leaking and/or plugged Pitot tube, sensing lines or manometer
• Fluctuations in pulverizer air flow or temperature

To review, clean air traverses are required to accomplish the following:

• Establish similar system resistance for each coal line on a balanced air flow basis. The intended purpose of burner
line orifices is to establish similar system resistance. In essence, a clean air tests confirms that burner line orifices
are accomplishing their intended purpose.

• Provide a correlation between fuel line “dirty air” and clean air velocities.

• Clean air balancing is an integral part of fuel line air to fuel ratio balancing which incorporates air, as well as
fuel balancing.

• To ensure the minimum fuel line velocity is maintained after optimization of primary air flow to improve
flame stability at lower loads and reduce fuel line stoppages.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Test Methods for Ascertaining Fineness
Pulverizer testing may be of little concern to maintenance personnel. However, it is a critical part of
identifying pulverizer capacity and fineness problems. It is the only means to determine the
effectiveness of pulverizer maintenance. It is also important in diagnosing pulverizer problems that are
caused by operational or control variables rather than mechanical ones. Variables such as inaccurate
primary airflow indication or pulverizer outlet temperature can cause significant degradation in
pulverizer performance.

Coal fineness is ascertained by collecting a representative coal sample from each burner line and
shaking the sample through a series of sieves. Coal fineness samples should be collected from all
fuel lines of a specific pulverizer. The pulverizer fineness is considered the weighted average of all
fineness samples collected. No single pipe coal fineness should vary more than 5% passing 200
Mesh from the weighted average. An ASTM or ASME type coal sampler can be used to accurately
ascertain coal fineness. We recommend utilization of an Isokinetic sampler because much additional
information is provided that is useful in evaluating pulverizer performance. Collecting a coal sample
for fineness analysis with an isokinetic sampler rather than an ASME type sampler also provides other
critical information including:

• Pulverizer pipe-to-pipe fuel balance

• Fuel line air to fuel ratios
• Fuel line velocities
• Pipe-to-pipe dirty air balance

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Test Methods for Ascertaining Fineness

The quantity of coal passing each sieve

is used to determine coal particle sizing.
Sieves utilized are ASTM 50, 100, 140
and 200 Mesh.

The numeric designation on ASTM

sieves specifies the number of openings
in screen or mesh per linear inch. For
example, a 200 Mesh sieve would have
200 openings per linear inch. Boiler
manufacturers (OEM) have typically
specified coal fineness to be no less
than 70% passing 200 Mesh with 99%
passing 50 Mesh. Coal fineness levels
of 75% passing 200 Mesh and 99.5%
passing 50 Mesh are required to result
in acceptable boiler performance and
flyash Loss on Ignition with a Low NOx Arrangement of Sieves
firing configuration. for determining fineness
by Sieving

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Importance of Fineness
Improved fuel balance with higher fineness levels was briefly discussed in previous sections. Higher
fineness levels always promote more even distribution of fuel between a pulverizer’s separate burner
lines. Better distribution promotes better combustion, inherently lower NOx emissions and lower flyash
L.O.I. or carbon content. The graph below illustrates actual test data on a pulverizer with varied
fineness. Numerous tests were conducted at various feed rates. As feed rate decreased, fineness
improved. Note that better than ±10% fuel balance is not achieved until better than 70% passing 200
Mesh is achieved.

When >10% fuel imbalance is observed, burner lines with higher fuel flows typically have less
desirable fineness. Burner lines that have less fuel typically have better coal fineness. When this
occurs the adverse effects on combustion are compounded. Burners having more fuel make
effective mixing of combustion air with the coal-air mixture difficult. The adverse effects are
compounded because burners having more coal will likely be of lower fineness making it even more
difficult to achieve complete combustion in the burner belt zone.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Importance of Primary Air Flow Calibration by
Local Traverse
Optimum pulverizer primary air (PA) flow, being of paramount importance in achieving optimum
unit performance, requires periodic testing to ensure optimum PA flow is maintained. Whatever
type of flow measurement element is utilized, measurement accuracy should be within ±3% of
actual flow measured by local traverse by competent test personnel using the appropriate
measurement equipment.

Regardless of measurement element type, elements should be calibrated by local traverse on a

regular basis (usually annually as a minimum). If air flow indicated by a measurement element
is not within ±3% of actual measurement, the element should be modified or replaced as
necessary to achieve desired accuracy. Primary air flow elements should always be calibrated
on a “hot” basis.

This requires air flow traverses to verify element accuracy being performed with the pulverizer
in service at operating temperature in close proximity with the measurement element. We have
found that calibration with the pulverizer out of service can be inaccurate due to flow profile
differences caused by hot and tempering air damper position.

Prior to calibration of the element, it is strongly recommended that all sensing lines from the
device to the differential transmitter be blown free of dust/ash accumulation and pressurized to
check for leaks. In addition, during calibration, an oil-filled manometer should be connected
locally across the transmitter in order to verify its accuracy.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Both coal flow and primary airflow must be measured
accurately to properly regulate pulverizer airflow
Stock Load Cell
Gravametric
Feeders

Flow Nozzle
or Venturi
Capable of
±3% Accuracy

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Fires and Explosions
The presence of combustible materials in the pulverizer is usually the largest contributor to pulverizer fires. In most
cases, pulverizer fires begin in the under bowl area of the pulverizer that is a very hot environment with an
abundance of air. Accumulations of debris or coal anywhere in the pulverizer will increase the chance of a mill fire.
The pyrite removal chute should be inspected often to ensure rejected material is removed from the under bowl
area. Stoppage of pyrite chute flow can cause debris and-or coal to back-up into the primary air ducting.

Symptoms of a mill fire include the following:

• Rapid increases in pulverizer outlet temperature above set-point

• A pungent sulfurous odor of smoldering coal
• Peeling paint on the pulverizer or burner lines
• Discharge of sparks or burning embers from the pyrite chute
• Pulverizer housing or burner lines are glowing red

Mill fires require immediate attention to prevent damage to the pulverizer and more damaging mill “puffs”.
Explosions in a pulverized coal system are normally called “puffs”. A mill puff is an explosion in the mill system
caused by an explosive combination of coal, air and temperature. Mill puffs most often originate in the under bowl
area and can cause very destructive damage to the primary air ducting. Mill puffs are most common under the
following conditions:

• Pulverizer start-up and shut-down

• Interruptions in raw coal feed caused by factors such as raw coal hang-ups and broken feeder belts
• Possibility of a mill puff or explosion is always inherently higher when under bowl fires or spillage
are persistent

Mill puffs or explosions can be very dangerous resulting in serious damage to the pulverizer system or injury to
personnel. When conditions that promote mill puffs are evident, personnel should promptly make corrective actions
and avoid the immediate area around the pulverizers.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Mechanical Variables that Affect Spillage – NEED TO
REWRITE FOR 10E Mills
Maintaining proper mechanical tolerances is essential to acceptable grinding efficiency on a
pulverizer. Inefficient grinding reduces "once through" grinding and increases coal circulation between
the classifier and grinding zone. Increased circulation between the classifier and grinding zone
increases the quantity of coal retained in the pulverizer grinding zone. This increases the amount of
the coal that air flow through the vane wheel must lift, thus making it more difficult to prevent coal from
spilling through the vane wheel annulus. If grinding is poor, the air stream passing through the vane
wheel or pulverizer throat will be sufficient to prevent coal from falling through the throat to be
rejected.

Coal fineness is the best indicator of pulverizer performance. Good pulverizer fineness is rarely
achieved if grinding efficiency is less than adequate. Inadequacies of a pulverizer’s internal
components are diagnosed using fineness data. If all mechanical tolerances are proper within the
pulverizer, fineness should be >75% passing 200 Mesh and <0.5% remaining on 50 Mesh. Under no
circumstance is it desirable to allow less than 70% passing 200 Mesh or >1% remaining on 50 Mesh.

Coal accumulations under the bowl are in a hot, air rich environment and create a potential for
explosion during feeder "hang-ups”, pulverizer trips or shut-down. The chance of explosions or "puffs"
with under bowl fires and accumulations is increased by inaccurate primary air flow measurement.
Pyrite plows or scrapers are installed to remove material that falls through the vane wheel.
Maintaining these scrapers and ensuring clearance with the floor of the under bowl area is minimal will
remove prevent coal or other debris from accumulating under the bowl.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Fires and Explosions
Fundamental precautionary methods to reduce the chance of a pulverizer “puff” is to
ensure the following:
l Pulverizer airflow is adequate to facilitate stable transport of coal without
settling in the burner line (>3,500 Fpm) but not excessively high to provide an
abundant source of air for combustion in the presence of an ignition source.
Ignition sources could be smoldering coal in the classifier, pulverizer or raw
coal in the high temperature under bowl area.

l All efforts must be taken to prevent coal from accumulating or settling in any
of the pulverizer components. Dry coal that is allowed to remain in the
pulverizer system can spontaneously ignite.

l Raw coal to the pulverizer must be uninterrupted and controllable. Precise

feeder control and minimize stoppages above and below the feeder.

l Hot smoldering or burner raw fuel anywhere in the pulverizer system is

considered serious. Raw coal that is allowed to “spill” into the under bowl (air
inlet) section and is allowed to accumulate will be exposed to high
temperature [usually 500°F (260°C)or higher] and will eventually smolder and
begin to burn. It is imperative that raw coal spillage into the under bowl area
be prevented. When raw coal spillage is observed, immediate action should
be taken.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Excessive Raw Coal Spillage

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Only trace amounts of coal should be discharged from
the pulverizer

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 What Causes Spillage?
Pulverizer spillage describes the condition when raw or partially pulverized coal passing over the edge
of the bowl falls through the vane wheel or pulverizer throat to be rejected through the pyrite chute. No
miniscule amounts of coal should be discharged through the pyrite chute. As its name implies, the
pyrite chute is for discharging pyrites and tramp iron. The term “pyrites” refers to a compound typically
contained in coal deposits that is a combination of Iron and Sulfur (FeS2). It is also commonly called
“fools gold” because it can be shiny and similar in appearance to gold.

With respect to coal pulverizers, the term pyrites usually refers to any material rejected from the
pulverizer including the compound pyrite as well as “tramp” metal, rocks, clay and other debris.

Small pieces of tramp iron are also discharged through the pyrite chute. Tramp iron refers to pieces of
metal that enter the pulverizer that were contained in the raw coal. Typical tramp iron includes railroad
spikes, bolts, nuts, tools, scrap steel and other metallic debris. Tramp iron may have come from the
mine or entered the raw coal during transport or at the plant. All efforts are usually made to minimize
the amount of tramp metal that enter the pulverizer. Metal can not be pulverized and will place undue
stresses on the pulverizers bearings, main shaft, journals and bull ring. Larger pieces of tramp metal
have been known to dislodge or break bull ring segments, clamping rings and vane wheel segments
resulting in significant damage to the pulverizer.

Even though several variables can cause or exacerbate spillage, the root cause of coal spillage is
that the air passing through the vane wheel annulus does not have enough energy to maintain
suspension of the coal particles. Under normal conditions, air velocity across the vane wheel annulus
must be in the range of 7,000 Fpm to 7,500 Fpm to maintain suspension of raw coal between ¼” to
1” in size.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 ADD PHOTOS OF ACTUAL COAL SPILLAGE AND PHOTOGRAPHS OF
UNDER YOKE AREA

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 Purpose of Inverted Cone
The annular opening of the inverted cone is a critical tolerance. Annular opening between the classifier cone and
inverted cone must be uniform within 1/4”. Determining optimum clearance is often an iterative process as many
parameters associated with coal characteristics and pulverizer mechanical tolerances cause variation in the quantity
of rejected coal flowing back to the grinding zone. The purpose of the inverted cone is to prevent partially pulverized
coal from passing through the classifier cone chute directly to the pulverizer outlet without passing through the
classifier. This flow can be established without the inverted cone resistance due to air pressure being higher on the
grinding zone side than that inside of the classifier cone. This is usually only an issue at lower coal flows. At higher
coal flows, the inventory of coal in the classifier cone normally prevents flow.

Proper clearance is required to ensure the free flow of rejects back to the grinding zone without poor coarse particle
fineness or pulverizer surging. When classifier blades are throttled, the volume of rejected coal will be increased. If 50
Mesh fineness is less than optimum or pulverizer surging is observed, increase the clearance between the classifier
cone and inverted cone. Surging is the cyclic increase and decrease of pulverizer motor current, discharge pressures
or bowl differential. Sometimes surges can be severe enough to result in motor current spikes that are high enough to
trip the pulverizer.

Classifier overloading is when the annulus between the inverted cone or the classifier reject spout is too small to allow
free flow of rejected coal back to the grinding zone. When the free flow of rejects back to the grinding zone is
restricted, the classifier cone fills with coal and coarse rejected coal is swept into the pulverizer outlet.

The gap between the feed pipe and classifier cone below the inverted cone can also prevent free flow of rejects if it is
too small. The annular area between the feed pipe and classifier cone must be larger than the inverted cone-classifier
cone annulus.

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Inspection of Inverted Cone
Surging of pulverizer motor current is caused by the cyclic retention and release of coal from
the inverted cone annulus. This is caused when non-uniform or marginal clearance allows
coal to bridge between the inverted cone and classifier cone. If the cone is not yet fully
overloaded, a cycle will develop where the coal bridges between the inverted cone and
classifier cone, breaks loose and then bridges again. Each time the bridged coal releases, it
slugs the pulverizer with fuel causing pulverizer motor current to spike. This effect is
illustrated by illustration below.

Classifier blades more tightly

closed to reject more coal to
Reduced Primary air lower classifier cone
velocities entrain fewer
large coal particles
Classifier cone loads up and
eventually slugs the mill with
fuel

Clearance should be uniform around

circumference and at proper annular
clearance which is determined by
pulverizer size and coal quality

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance
 The ESP Performance Relationship

The electrostatic precipitators performance may also be affected,

with increased exit gas temperature and increased carbon in ash
(not to mention higher velocities due to air in-leakage).

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance

 Inadequate Soot Blowing Steam
Temperature, a common problem

!""#$B&"'()$*+##(),
Steam Supply Pressure (600 PSI) = Yields Saturation at 486 Deg F. is about 26 Deg. F below
saturation. Soot blowing medium +50 Deg. F superheat or about 536 Deg. F to prevent further
tube erosion & failures/forced outages from condensate in the soot blowing system

Wednesday, August 4, 2011 CLP Coal-Fired Boiler Testing & Performance