Boiler Performance Test Procedure

Performance Test Procedure
WPCPL 4135MW POWER PLANT

PROJECT
Boiler Performance
Test Procedure
PROJECT : WPCPL 4135MW POWER PLANT PROJECT
WPCPL 4x135MW
OWNER :
WARDHA POWER COMPANY PVT LTD HYDERABAD INDIA

WARDHA
CONSULTANT : DEVELOPMENT CONSULTANTS PVT. LTD.,MUMBAI

DCPL
CONTRACTOR SICHUAN ELECTRIC POWER DESIGN & CONSULTING CO.,LTD
PROJECT CONTROL No.: SCCTI-W1-TP-G01

Rev. No. 1
COMMISSIONING THE COMMISSIONING AND TEST INSTITUTE OF SICHUAN
ELECTRIC POWER INDUSTRY
Project
Document No.
WPCPL 4135MW
SCCTI-W1-TP-B01
Rev. 1
Generation Project
System
Pg.2of 16
Boiler Performance Test Procedure
WPCPL 4135MW POWER PLANT PROJECT
Boiler Performance
Test Procedure
Revision
Date
/09/04/2009
Description
Released by (date/signature)
Compiled:
WangJianhua
Checked:
ChenMo
Approved:
LeiLi
Released:
SEDC
Table of Contents
1. Overview of Boiler Equipment.......................................................................3
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WPCPL 4135MW
Document No.
SCCTI-W1-TP-B01
Rev. 1
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System
Pg.3of 16
2. Items of Boiler Performance Test..................................................................6

3. Test Standard and Technical Basis................................................................6
4. Guaranteed Test Value and Conditions.........................................................6
5. Preconditions for Performance Acceptance Test.........................................10
6. Calculation Method of Boiler Performance Acceptance Test......................12
7. Test Measuring Points, Instruments and Measuring Method......................14
8. Summary of Performance Acceptance Test Items......................................16
Project
Document No.
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Rev. 1
SCCTI-W1-TP-B01
Generation Project
System
Pg.4of 16
1. Overview of Boiler Equipment

1.1 Equipment introduction
Type NO.: DG440/14.29-10
Type: super-high pressure, once reheat, single furnace, natural
circulation and coal fired.
1.2 Boiler design technical specification
Refer to table 1 for boiler design technical specification
Table 1 Boiler Design Technical Specification (BMCR operating condition)
Item
main steam flow (t/h)
superheat steam pressure (MPa. g)
superheat steam temperature (C)
reheat steam flow(t/h)
reheat steam pressure (MPa. G)
reheat steam temperature (C)
feedwater temperature (C)
Guaranteed thermal efficiency of boiler (HHV) (%)
Data
440
14.29
540
358.7
2.46
540
247
86
1.3 coal properties

Refer to Table 2 for coal properties
Table 2Coal Properties
No.
Description
Symbol
Unit
1
2
3
4
5
6
7
8
9
10
11
Fixed carbon
Carbon as received basis
Hydrogen as received basis
Oxygen as received basis
Nitrogen as received basis
Sulphur as received basis
Total water
Ash as received basis
Water of air dried basis
Volatile of dry ash-free basis
High heating value as
received basis
FC
Car
Har
Oar
Nar
Sar
Mt
Aar
Mad
Vdaf
GCV
%
%
%
%
%
%
%
%
%
%
kCal/
kg
Design
Coal
37.51
49.61
2.80
8.50
1.10
0.50
11.49
26.00
Worst
Coal
30.00
41.85
2.75
3.30
0.50
0.60
15.00
36.00
Best
Coal
42.00
53.90
3.00
11.50
1.20
0.30
9.10
21.00
39.99
4600
38.78
4200
39.91
4900
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Document No.
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2.Technical Procedure
2.1 Items of Boiler Performance Acceptance Test
2.1.1 Boiler maximum continuous rating
2.1.2 Boiler efficiency (HHV, include piping loss)
2.1.3 Coal conveying capacity
2.1.4 Unburned carbon in bottom ash and fly ash
2.1.5 Fly ash evacuation rate/hr from ESP other ash hoppers of the boiler
2.1.6 Coal consumption based on GCV OF 4600kCal/kg
2.2 Test Standard and Technical Basis
2.2.1 Steam generating unit performance test code ASME PTC 4.1 -1998
2.2.2 Air heater performance test code ASME PTC 4.3-1991
2.3 Test purpose
The purpose of the acceptance tests is to prove the boiler performance
guarantee value in the delivery contract, and to check if the boiler operating
characteristic can reach the design requirement.
2.4 Measuring points, instruments and measuring method
2.4.1 Test Sampling
2.4.1.1 Coal sampling
Two representative samples of raw coal shall be taken at the coal
feeder. Sampling shall be made at an interval of 30 minutes, with each
sample having a weight of 5-6k. The coal sample shall be put into an
enclosed container in time. After test, the coal samples taken during test
period shall be mixed in manner of equal proportion and divided into three
parts by means of quartering, with each part having a weight of 5kg. One part
shall be delivered to the Owner for proximate analysis, one part to the
commissioning sub-contractor for proximate analysis, ultimate analysis and
HHV measurement, and one part to the Owner for spare purpose. The
analysis data of the commissioning sub-contractor will be accepted as the
final analysis data for the test.
Analysis contents of coal as fired:
1) ultimate analysis (Car, Har, Oar, Nar, Sar, Mar, Aar)
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2) proximate analysis (Var, Mar, FCar, Aar, HHV)

2.4.1.2 Fly ash sampling
Fly ash shall be sampled at No. 1 and No. 2 electric fields below the
electrostatic precipitator. Sampling shall be made at an interval of 30 minutes,
with each sample having a weight of 5-6kg. After test, ash samples taken from
No. 1 and No. 2 electric fields shall be mixed in a proportion specified in test
agreement, and divided into three parts by means of quartering.One part shall
be delivered to Owner for unburnt carbon analysis, one part to the
commissioning sub-contractor for unburnt carbon analysis, and the third part
to the Owner for spare purpose. The analysis data of the commissioning subcontractor will be accepted as the final analysis data for the test.
2.4.1.3 Bottom ash sampling
Bottom ash shall be sampled at slag separator outlet. sampling shall be
made at an interval of 30 minutes; after test, ash sample taken shall be mixed
in equal proportion, and divided into three parts by means of quartering; one
part shall be delivered to owner for unburnt carbon analysis by its chemical
workshop; one part to commissioning sub-contractor for unburnt carbon
analysis; one part to Owner for keeping as spare, the analysis data of
commissioning sub-contractor will be accepted as the final analysis data for
the test.
2.4.2 Field Analysis
2.4.2.1 Flue gas analysis
In the inlet/outlet flue duct of both A and B sides of air preheater, a flue
gas sampling pipe shall be installed according to grid method. Number of
measuring points at inlet flue at A and B sides are 4 (holes) 3 (points) ; there
are 24 points in total at both sides; Number of measuring points at outlet flue
at A and B sides are 5 (holes) 2 (points) ; there are 20 points in total at both
sides; During test, flue gas sampled at various points, after mixing, shall enter
into flue gas analyzer MODEL3080 manufactured by Beijing SDL, for the
purpose of analysis of O2, CO and CO2 content analysis. Measuring shall be
made once at an interval of 5 minutes.
2.4.2.2 Flue gas temperature
In the inlet/outlet flue duct of both A and B sides of air preheater, flue
gas temperature measuring point is provided; K type thermocouple shall be
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Document No.
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SCCTI-W1-TP-B01
Rev. 1
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installed to measure flue gas temperature according to grid method. Number

of measuring points at airheater inlet both A and B sides are 4 (holes) 3
(points) ; there are 24 points in total at both sides; Number of measuring
points at airheater outlet both A and B sides are 5 (holes) 2 (points) ; there
are 20 points in total at both sides;
2.4.2.3 Climate information
Air humidity and atmospheric pressure shall be measured once
through wet and dry bulb thermometer and barometer at an interval of 20
minutes.
2.4.3 Main test and measuring instruments
Refer to table 3 for main test and measuring instruments.
Table 3 Test and Measuring Instruments
Instrument
Name
Model and
Specificatio
n
MODEL3080
Manufacture
Measuring
Range
Accuracy
Class
Inspection
Beijing SDL
Instrument
Company,
China
O2: 0%
20.9%
CO2: 0%
20%
CO: 0%
0.1%
Full range
national
institute of
measurement
and testing
technology
Flue gas
analysis preprocessor
MODEL3080
NiCr-NiSi
thermocouple
K-type, class
I
Beijing SDL
Instrument
Company,
China
Sichuan
Instrument
Company,
China
0400
0.5 C
national
institute of
measurement
and testing
technology
Multi-component
infrared
analyzer
1.0%
2.5 Preconditions for Performance Acceptance Test

2.5.1 Fuel
The characteristics for test fuel shall be close to design fuel . Variation
range of coal quality shall be as follows (absolute value):
Mar: 0.15% for Mar of fuel <5%
0.25% for Mar of fuel >5%
Car 1.25%
Har 0.15%
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Nar 0.09%
HHV 70Btu/lb
2.5.2 Conditions and stabilization time of performance acceptance test
Before starting the test formally, the boiler must be in stable operation
under test load. Especially when carrying out the test and measuring the
boiler efficiency under rated operating conditions, the period for stable boiler
operation shall not be lower than four hours.
During test and when boiler is under stable operating conditions,
parameter variation shall be within following range:
Main steam volume:
Main steam temperature:
Main steam pressure
3% (relative value)
10 (absolute value)
3% (relative value)
Before starting test, the sootblowing system, if necessary, shall be

enabled during stable boiler operation.
2.5.3 Boiler thermal efficiency test
2.5.3.1 Test duration shall be 4h;
2.5.3.2 In order to maintain cleanliness of the boiler and the air preheater,
sootblowing shall be carried out prior to the test;
2.5.3.3 Boiler thermal efficiency shall be measured and calculated through
indirect heat balance;
2.5.3.4 During test, keep boiler under stable combustion;
2.5.3.5 Flue gas analysis and temperature measurement at air preheater
inlet/outlet shall be carried out through grid method;
2.5.3.6 Boiler steam rate will be determined from the main steam flow. Main
steam temperature and pressure, reheat steam temperature and
pressure are all rated values; steam purity is qualified.
2.5.3.7 Boiler surface radiation and convection loss L shall not be measured
and can be got from PTC 4.1 curve;
2.5.3.8 Boiler sootblowing shall be completed before test. During test,
sootblowing and blowdown shall not be carried out;
2.5.3.9Before formal test, preliminary test shall be carried out;
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2.5.3.10 All preliminary tests shall be carried out according to formal test
procedures; after preliminary test, test conditions shall be studied
immediately. After study, in case consensus is reached among various
participants, preliminary test can also be deemed as formal test.
2.6 Guaranteed Test Value and Conditions
2.6.1 Boiler efficiency
2.6.1.1 Guaranteed value
Guaranteed value for boiler efficiency ( according to HHV, including pipe
loss) shall be: 86%.
2.6.1.2 Conditions of guaranteed value
(1) Airpreheater inlet temperature: 32, relative humidity 65%,
atmospheric pressure 983.6 hPa, boiler blowdown 0%.
(2) Design fuel , pulverized coal fineness is qualified.
(3) Rated feedwater temperature.
(4) Superheat steam temperature and pressure are rated values;
reheat steam inlet/outlet temperature and pressure are rated values.
(5)
rated load (test condition: BECR) ;
(6) Boiler thermal efficiency shall be calculated based on ASME PTC4.1

standard;
(7) Pipe efficiency is design value (99%).
2.6.2 Boiler maximum continuous rating
Guaranteed value of boiler maximum continuous rating(BMCR) shall
be: 440t/h
(1) Airpreheater inlet temperature: 32, relative humidity 65%,
atmospheric pressure 983.6 hPa , boiler blowdown 0%.
(2) Design fuel , pulverized coal fineness is qualified.
(3) Rated feedwater temperature.
(4) Superheat steam temperature and pressure are rated values;
reheat steam inlet/outlet temperature and pressure are rated values.
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Guaranteed value of coal conveying capacity shall be: 750t/h
Operation of boiler is normal, operation of coal conveying system is
normal
2.6.4 Fly ash evacuation rate/hr from ESP other ash hoppers of the boiler
Guaranteed value of evacuation rate :
Bottom ash evacuation rate: 2.88t/h
Fly ash evacuation rate: 15.76t/h
(1) Design fuel for combustion
(2) BMCR operating conditions
2.6.5 Unburned carbon in fly ash and bottom ash
Guaranteed value of unburned carbon in fly ash and bottom ash:
Unburned carbon content in bottom ash: 5.8
Unburned carbon content in fly ash: 3.0
(1) Design fuel
(2 Pulverized coal fineness is qulified
2.6.6 Main steam temperature and pressure at the outlet of superheater
Guaranteed value of main steam temperature at the out of superheater:
540
Guaranteed value of main steam pressure at the outlet of superheater:
14.29MPa
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(1) Design fuel

(2) Design excess air coefficient
(3) Overtemperature is not allowed at various places of superheater
and reheater
2.6.7 Reheat steam temperature and pressure at the outlet of reheater
Guaranteed value of reheat steam temperature at the outlet of reheater:
540
Guaranteed value of reheat steam pressure at the outlet of reheater:
2.43MPa
(1) Design fuel
(2) Design excess air coefficient
(3) Overtemperature is not allowed at various places of superheater and
reheater
2.6.8 Coal consumption based on GCV OF 4600kCal/kg
Guaranteed coal consumption: 69t/h
(1) Design fuel for combustion
(2) HHV shall be 4600 kcal/kg
(3) Test condition: TMCR
2.7 Calculation Method of Boiler Performance Acceptance Test
Boiler efficiency shall be calculated in indirect heat balance method
and according to HHV :
=100-(LmA+L'G+Lmf+LH+Lucd+Lco+L+Lum)
= p
Where:
: Boiler efficiency (including pipe loss), %
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: Boiler efficiency, %
p: Pipe efficiency, % (take the design value as 99%)
LmA: Thermal loss due to water in air, %

L'G: Thermal loss of dry flue gas, %
Lmf: Thermal loss due to water in fuel, %
LH: Thermal loss due to water generated from hydrogen
combustion, %
Lucd: Thermal loss due to unburned carbon, %
Lco: Thermal loss due to CO, %
L: Thermal loss due to surface radiation and convection, %
Lum: Unmeasured thermal loss, % taken as 0.2%
Boiler surface radiation and convection loss L shall not be measured
and can be obtained from ASMEPTC 4.1 curve; wind speed shall not be
amended.
Unmeasured loss Lum shall not be measured; total unmeasured loss
shall be equal to 0.2%.
For bottom ash/fly ash ratio, the design value shall be applied: 10/90.
Boiler efficiency measured and calculated shall be corrected to
conditions on which guaranteed value is based, through following method:
The correction to the outlet flue gas temperature variation resulted from
inlet air temperature variation shall be considered.
The following parameters, in case of deviation to rated values, shall be
revised according to correction curve given in attachment:
Feedwater temperature
Volatile matter (taken from fuel's fixed carbon & volatile matter ratio)
Fuel ash
Fuel sulphur
Fuel water
Fuel hydrogen
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Gross calorific value of fuel

For boiler thermal efficiency under rated load, the mean value of two
tests shall prevail; in case the deviation for two tests is 0.5%, mean
arithmetical value for two tests shall be taken as final value. In case measured
efficiency error for both tests are larger than specified value, third test is
required; in this case, two efficiency values within range of allowable error
shall be taken, and then their mean arithmetical value shall be taken as final
efficiency value.
2.8 Summary of Performance Acceptance Test Items
2.8.1 BECR Test (first)
Load: BECR
Duration: 4 hours
Inspection items:
Boiler efficiency
Main steam temperature and pressure at the outlet of superheater
Reheat steam temperature and pressure at the outlet of reheater
Unburned carbon in fly ash and bottom ash
Fuel consumption
2.8.2 BECR Test (second)
Load: BECR
Duration: 4 hours
Inspection items:
Boiler efficiency
Main steam temperature and pressure at the outlet of superheater
Reheat steam temperature and pressure at the outlet of reheater
Unburned carbon in fly ash and bottom ash
Fuel consumption
2.8.3 Boiler Maximum Continuous Rating test (BMCR)
Load: BMCR
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Duration: 2 hours
Inspection items:
Main steam flow
Main steam pressure
Main steam temperature
Inspection items:
Coal conveying capacity
2.8.5 Evacuation rate test of fly ash and bottom ash
Inspection items:
Fly ash evacuation rate
Bottom ash evacution rate
3. Organization and Personnel Arrangement

3.1 Organizations for the test
The general director for the test shall be the personnel dispatched by the
general contractor .
3.2 Organization & Responsibilities for the Performance Test
3.2.1 The General Contractor shall be responsible for the organizational
management and coordination through the whole process of the unit
preformance test under the leadership of trial operation command.
3.2.2 The Construction Sub-contractor shall be responsible for the installation
of the measuring points and equipments for the performance test.
3.2.3 The Commissioning sub-contractor shall be responsible for the
compiling of performance test measures, and shall hand over all the
performance test reports within the specified time limit .
3.2.4 The Operation Sub-contractor shall be responsible for normal
production and defect removal, submitting the test application to the
Power Grid, organizing the operation personnel and laboratory test
personnel to adjust the operation conditions and to do laboratory test
(coal, water, oil, etc.) together with the Test Unit, as well as
coordination for the performance test.
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4. Safety Measures
4.1 During the test duration, the unit shall be running stably with the load
required by the test. The running operation shall be adjusted by the
operators as per the test plan.
4.2 The test personnel shall demobilize from the site if any sign of accident is
found or any accident occurs during the test, and the personnel on duty
shall deal with such case as per the accident handling procedure. The
test personel shall be contacted promptly if any abnormal condition is
found during the test. The test shall be stopped if any event which may
cause injury or fault of equipment occurs, and the test can only be
continued after it is confirmed that the abnormal condition has been
eliminated.
Attachment 1 List and Description of Measuring Points for

Boiler Performance Acceptance Test
No.
1
Type
Flue gas
temperature
2
3
Air
temperature
Name
air preheater
inlet
temperature
air preheater
outlet
temperature
Inlet primary air
temperature of
air preheater
Qty
24
Description
Measuring holes at air preheater
inlet according to grid method
20
Measuring holes at air preheater

outlet according to grid method
Using DCS data
16
Project
WPCPL 4135MW
Document No.
SCCTI-W1-TP-B01
Rev. 1
Generation Project
System
4
5
Flue gas
sample
6
7
Raw coal
8
9
Pulverized
coal
Fly ash
10
Bottom ash
11
Ambient
conditions
12
13
14
Pg.16of 16
Others
Inlet secondary
air temperature
of air preheater
Air preheater
inlet sample
Air preheater
outlet sample
Raw coal
sample
Pulverized coal
sample
Fly ash sample
2
24
20
Same measuring holes as that for air

preheater inlet temperature
Same measuring holes as that for air
preheater outlet temperature
Open hole at each coal feeder
Install pulverized coal sampler at
each primary air pipe
Arrange sampling pipe at
electrostatic precipitator
Bottom ash
sample
Ambient
temperature
Atmospheric
pressure
Air humidity
Main operating
parameter
Using DCS data
at slag separator outlet

glass thermometer
barometer
As per
actual
conditions
adopting wet and dry bulb

thermometer
Adopting DCS record values

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Performance Test Procedure

WPCPL 4135MW POWER PLANT

WARDHA POWER COMPANY PVT LTD HYDERABAD INDIA

CONSULTANT : DEVELOPMENT CONSULTANTS PVT. LTD.,MUMBAI

PROJECT CONTROL No.: SCCTI-W1-TP-G01