Scribd Logo
Upload

Welcome to Scribd!

  • BOC Technical Webinar Series: Boiler Tune-Up and Maintenance

    Uploaded by

    Anonymous u0wETydF
    44 views33 pages
    matenimiento de calderos

    Original Title

    webinar boiler

    Copyright

    © © All Rights Reserved

    Available Formats

    PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    matenimiento de calderos

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    44 views33 pages

    BOC Technical Webinar Series: Boiler Tune-Up and Maintenance

    Uploaded by

    Anonymous u0wETydF
    matenimiento de calderos

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Flag for inappropriate content
    Download as pdf or txt
    of 33

    BOC Technical Webinar Series

    Boiler Tune-Up and Maintenance


    September 9th, 2009
    Welcome! We will begin momentarily.
    The webinar audio is provided via phone line.

    Dial: 888-346-3950 Passcode: 6479877#


    Today’s Sponsors
    BOC Webinar

    Boiler Tune-Up and Maintenance


    September 9th, 2009
    Instructor-Greg Jourdan
    Wenatchee Valley College

    © 2009 Courtesy Cleaver-Brooks Boilers


    3
    The Basics of Boiler Tune-Up
    and Maintenance
    Boilers are major energy users in many facilities. The
    combustion efficiency of a boiler will degrade over time
    necessitating a tune-up to restore efficiency of the unit.
    • Boilers can be either steam or hot water; tune-up
    procedures apply to both types.
    • A complete boiler Tune-Up measures the efficiency,
    corrects the problems, and measures efficiency regularly.
    • A Tune-Up improves combustion efficiency by reducing
    stack losses and improving combustion.
    • Regular Annual Maintenance includes inspecting,
    repairing as needed, cleaning, and adjusting the
    components of the boiler for optimum performance.
    © 2009
    4
    Benefits of Boiler Tune-Up
    And Annual Maintenance

    • Reduced energy consumption


    • Reduced requirement for expensive repairs
    • Improved efficiency will prolong boiler life
    • Financial savings
    $

    Photos courtesy of TSI,, ECMT Inc,


    © 2009 and Testo Test Tools
    Using a Flue Gas Analyzer
    Determine Boiler Efficiency
    • Test boiler combustion efficiency and perform
    required adjustments on a regular basis to
    ensure peak operating performance.
    • Optimum efficiencies range between 75 to
    80%, boiler efficiency can fall to 50% or less
    without proper maintenance and adjustment.
    • Done by trained maintenance staff or qualified
    contractors as a part of regular maintenance
    activities annually.
    • The combustion analyzer measures the:
    CO2, O2, CO, Exhaust temperature
    © 2009
    Boiler Excess Air
    Excess air is required to achieve complete combustion
    • Is required for optimum efficiency at a minimum.
    • Depends on boiler configuration, burner design,
    controls and fuel type.
    • Determined by reducing O2 until CO starts to
    appear.
    • 2 % excess O2 with zero CO is achievable with gas-
    fired boilers.
    • Controlling excess air is the most important tool for
    managing boiler efficiency and emissions.

    © 2009
    Example of Benefit of Reducing
    Excess Air from 11% to 2%

    A Boiler operating at:


    • O2 of 11% Excess Air
    • Temperature of stack is 300° F
    • Temperature of inlet combustion air is 85 ° F
    Reducing the O2 from 11% to 2% will improve
    efficiency from 80% to 84%

    © 2009
    Causes of Boiler
    Combustion Inefficiencies
    • Combustion efficiencies lower than 75% may
    be caused by:
    • Dirty fire side of the heat exchanger - an
    indicator of poorly adjusted burners.
    • Dirty water/steam/air side of the heat
    exchanger - often an indication of poor
    water treatment.
    • Inadequate combustion air (air shortage
    problems occur most often with natural
    draft boilers) - excessive combustion air.

    © 2009
    9
    Other Steps to Improve
    Boiler Efficiency

    • Increase combustion air temperature


    • Consider air pre-heater

    • Draw air from a high point in the boiler

    room
    • Clean Boiler Tubes as needed to improve
    heat transfer capacity of boiler
    • Maintain Water Treatment to keep water side
    of boiler free of scale buildup

    © 2009
    10
    Potential Savings % by Increasing
    Combustion Efficiency
    Enter left side column and find your existing efficiency.
    Go across the top and find you new efficiency.
    The percentage in the middle is your new fuel savings.

    © 2009
    11
    Example of Percent of
    Potential Savings
    Existing efficiency is 72%; new efficiency is 85%.
    By increasing your efficiency, you will save 18.06%

    © 2009
    12
    Benefits of Boiler
    Tune-Ups
    On average, Un-tuned boilers may have combustion
    efficiencies of 60% or lower. As the exhaust
    temperature increases, the combustion efficiency
    decreases, as more heat is lost in the flue gases.
    A well-tuned boiler can dramatically lower the fuel cost
    of operating a boiler or industrial process heater.
    Example-At an average of 60 cents/therm, a 10,000-lb/hr
    boiler with an average annual capacity factor of 50%
    would save about $26,000 per year in fuel costs with a
    10% increase in combustion efficiency. Even a 1%
    increase in efficiency would save about $2,600 per year.

    © 2009
    13
    Cost of Boiler Testing
    The cost of testing and the implementation of
    typical remedial measures can range as follows:
    Efficiency testing - $60 to $500
    Chemical boiler cleaning - $800 to $1,500 to ….*.
    Water treatment/year - $1,500 to $3,500 to ….. *
    Burner adjustment - $200 to $500
    Enlarge air intakes - $500 to $1,000
    * Note-Boiler plant size dictates actual cleaning,
    chemicals, and water treatment costs.

    © 2009
    14
    Major Energy Saving
    Opportunities

    • As a ‘Rule of Thumb,’ boiler efficiency can be


    increased by 1% for each 15% reduction in excess
    air or 40 degree reduction in stack temperature.
    • The clean operation of a boiler makes all the
    difference.
    • Just 1/16th layer of soot on the fire side of the boiler
    tube can cost 10% to 20% of the fuel efficiency,
    increasing fuel costs by 10% to 20%.
    • The same percent loss can also happen if scale on
    the water side of boiler tube is 2 human hairs thick.

    © 2009
    15
    Portable Analyzers vs. Automatic
    Stationary Trim Systems
    Portable Flue Gas Analyzers
    The flue gas can be measured by inexpensive
    gas-absorbing test kits. More expensive (ranging
    in cost from $500 to $10,000) hand-held,
    computer-based analyzers display percent
    oxygen, stack gas temperature, and boiler
    efficiency. They are a recommended investment
    for any boiler system with annual fuel costs
    exceeding $50,000.

    Photos courtesy of TSI,, ECMT Inc,


    and Testo Test Tools
    © 2009
    16
    Portable Analyzers vs. Automatic
    Stationary Trim Systems
    Automatic Oxygen Control or O2 Trim Systems
    When fuel composition is highly variable or where steam flows are
    highly variable, an online oxygen analyzer should be considered.
    The oxygen “trim” system provides feedback to the burner
    controls to automatically minimize excess combustion air and
    optimize the air-to-fuel ratio.

    © 2009 Photos courtesy of Cleaver-Brooks


    17
    Boiler Maintenance
    Recommendations

    Check water level


    at try cock valves.

    Annually clean and


    check the low water
    float safety controls.
    Check pop off relief valves
    as recommended by
    Check pressure
    manufacturer.
    controls.

    © 2009 Photos courtesy of Greg Jourdan


    Boiler Tube Inspections
    • If the fire side of the heat exchanger is dirty, but
    the fuel/air mixture is correct, check for excessive
    boiler room dust.
    • Remedy; clean the floor more often and paint
    the boiler room floor to reduce dust levels.
    • If the water side of a boiler has scale buildup,
    water treatment may be inadequate.
    • If the water side of a boiler appears to have
    corrosion
    • Remedy, maintain proper water treatment
    levels as per water chemical expert
    recommendations.
    © 2009
    Annual Maintenance

    Clean fireside
    surfaces

    • Brush & vacuum


    tubes
    • Clean tube sheets &
    refractory
    • Amount of soot
    indicates how well
    burner is performing

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Repair refractory

    • Cracks 1/8” and


    under will close up
    when heated
    • Look for loose
    sections

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Check hydraulic
    valves

    • Bubble test for


    valve seat
    tightness check
    • Actuators open &
    close properly

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Remove and
    Recondition safety
    valves

    • Inspect piping for


    loose hangers
    putting weight on
    valves

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Recondition Boiler
    feed pumps

    • Wear rings
    • Seals
    • Packing
    • Bearings
    • Recondition shaft
    and/or impellers

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Check condensate
    receivers

    • Flush out
    • Check any lining for
    failure
    • Clean pump
    strainers

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Check chemical feed


    system

    • Clean out tank


    • Recondition pump
    • Inspect & clean out
    piping to injection
    points

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Tighten electrical
    terminals

    • Power off!!
    • All panels, all
    controls &
    components

    © 2009 Courtesy Cleaver-Brooks Boilers


    Annual Maintenance

    Check de-aerator or
    boiler feed system
    • Water spray head
    • Collector cone
    assembly & steam
    atomizing valve of
    spray types
    • Check any possible
    lining
    • Clean out pump
    strainers
    © 2009 Courtesy Cleaver-Brooks Boilers
    Annual Maintenance

    Check linkages

    • Lubricate
    • Tighten
    • Replace worn parts

    © 2009 Courtesy Cleaver-Brooks Boilers


    Working with Outside Contractors
    Offering Boiler Tune-up Services

    • Look for experienced contractors


    • Verify combustion analyzers are calibrated
    annually
    • Ask for combustion analyzer print-out report
    • Don’t just look for the cheapest
    contractor….look for quality!
    • Ask your GAS Utility if Boiler Tune-Ups are
    subsidized.

    © 2009
    30
    Boiler manufacturer resources
    and Tune-Up Info
    • Cleaver-Brooks
    • Burnham Commercial Boilers
    • Lochinvar Boilers
    • Hays Cleveland Oxygen Trim Controllers
    • Testo Combustion Analyzers
    • Bacharach Combustion Analyzers
    • TSI Test Tools
    © 2009
    31
    BOC Webinar

    Boiler Tune-Up and Maintenance


    September 9th, 2009
    Instructor-Greg Jourdan
    Wenatchee Valley College

    Thank –You
    Questions?

    © 2009
    32
    For more information
    BOC Information
    Phone: 206-292-4793 x2
    Web: www.theBOC.info
    Email: [email protected]

    You might also like