Optimizing Boilers Using Innovative Boiler Tube Imaging System

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This presentation was delivered at the 54th Annual ISA POWID Symposium by Lenny Shaver. It explores how using digital, radiometric infrared inspection for boilers recaptures lost capacity, increases efficiency, lowers maintenance costs and manages fuel-switching strategies.

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Optimizing Boilers Using Innovative Boiler Tube Imaging System

  1. 1. Innovative Boiler Tube Imaging System Used to Optimize Boilers Lenny Shaver LumaSense Technologies, Inc.54th Annual ISA Power Industry Division Symposium6-8 June 2011, Charlotte, North Carolina 1
  2. 2. Digital, Radiometric InfraredSystem Enables Automation and Analysis• Capture Lost Boiler • Lower Maintenance Costs Capacity by reducing by optimizing washes and unnecessary cleaning reducing damage caused by large clinkers• Increase Efficiency with • Manage Fuel-Switching better management of slag Strategies by accurately measuring slag and uniformity as fuel changes 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 2
  3. 3. Power Boiler Tube Imaging54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 3
  4. 4. What is BoilerSpection?A new imaging system thatprovides coal-fired powerboiler operators continuousinformation about slagdeposits and clinkerformations. 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 4
  5. 5. What is New and Innovative?• Ever increasing pressures on plant operator’s to improve efficiency and uptime while reducing maintenance costs.• Innovative Infrared (IR) imaging system provides clearer images and reliable data 24/7• Digital data and software enables automation, alarms, and historical trending / analysis• Continuous information allows operators to manage changing conditions (e.g., fuel or maintenance) 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 5
  6. 6. Clear insight into internal condition ofcoal-fired boiler• Recording of Sootblower Operation• Recording of Sootblower blasting slag from superheat pendant 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 6
  7. 7. How does it work? Fundamentals ofInfrared (IR) measurements in Boilers Unique Properties in mid-IR:• ~3.9µm – Combustion flames are most transparent, used to “see through flames” for boiler tube measurements• ~4.5µm – CO2 in gas is opaque at this wavelength and this is used for FEGT and other gas temperature measurements 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 7
  8. 8. Where is it Being Used? 1. Lower Slope 2. Furnace/Burner Section 3. Superheat/Pendant Section    54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
  9. 9. System Scope54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 9
  10. 10. BoilerSpection Components • Radiometric Thermal Imaging Camera • Heavy-duty enclosure with integrated cooling • Automated Retraction System • Networking devices for connecting cameras to Control Room • Computer server and software that is capable of controlling multiple camera systems and reporting that data directly to the plant DCS or control system • Additional software tools for analysis and data broadcasting (HTML based) • Everything designed for and proven in harsh power plant environment 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
  11. 11. Camera and Cooled Borescope Lens 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
  12. 12. Automated Retraction System 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 12
  13. 13. Mounting and Aiming Camera Straight Aiming Up Aiming Down 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
  14. 14. Installation Details 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
  15. 15. What are the Results? Significant reduction in de-slags Significant reduction of online boiler cleanings • Save the service cost of performing the wash, but with each on-line wash the boiler’s output is typically reduced to less than half. By better managing slag on a daily basis the on-line washes have been deferred dramatically allowing an overall increase in average MW produced on boiler. Insight into combustion uniformity • Monitor uniformity both within a unit and from boiler to boiler. The IR imaging system has allowed operators to immediately identify problems with burners or maintenance and address them sooner than otherwise. 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 15
  16. 16. Digital Information is the Key to AutomationFully “Radiometric” Images • Areas can be defined in software to trip alarms for automation of sootblowers or water cannons • Thresholds can be established to set minimum acceptable levels of clinker formationData is completely digital • Images can be displayed via html page throughout the plant and system wide • Alarms and continuous temperature monitoring can be fed directly into the plant control system via OPC 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
  17. 17. Broadcasting Results to Plant Networkand Archiving for Historical Analysis 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 17
  18. 18. Case Study in Savings6-Month Before After 6-Month Reduction Estimated Annualized EstimatedComparison Camera Camera in Cleanings 6-Month Savings Cost Savings# of De-slags 25 12 13 $633,705 ~$1,250,000# of Online Washes 4 0 4 $446,000 ~$900,000 Total ~$2,150,000Plant Parameters:• 720 MW Units• Units brought down to minimum load (300 MW) for cleaning• Assumed $65 per MW hour for cost calculations• Load lost during online washes is 400 MW• Load lost during de-slags is 150 MW (done during off-peak hours) 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 18
  19. 19. Benefits of 24/7 Infrared ImagingIncreasing Efficiency and Reducing Wear• Reduce the number and frequency of washes thereby increasing uptime and maximum efficiency of the boiler• Prevent Boiler tube erosion through excessive cleaning• Identify clinkers and eliminate them prior to extensive growth• Help to identify what is causing the formation of deposits within the boiler (historical- changes in fuel, feed rates, moisture, etc.)• Provide operators with a clear picture of what is going on in the boiler 24/7• Eliminate the need for operators to manually inspect critical areas, reducing manpower & increasing safety 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
  20. 20. Q&A54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 20

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