4 MW Plant Observation
S.No Observation
1. Furnace bed temp is low ( 600 to 700oC)
*unburnt GCV = 3235 Kcal
2 Excess air percentage is higher than the
normal.
Based on DCS report.
Actual air flow = 85 TPH( Main & Super)
It is equivalent to 61% of Excess air and 8%
of O2 in flue gas.
Actual O2 in flue gas = 10%
It is equivalent to 15 ton of air ingress in
both boilers
In Sivaganga, excess air percentage is 15 to
20%
3 Draft system to be strengthened
4 Furnace draft is almost positive and the
same is manually controlled by adjusting ID
rpm.
5 Spent wash analysis
6 Super heater boiler – there is almost no
heat transfer in SH 1 and SH2
7 Coal Coating.
We may consider coal coating for an hour on daily basis. It will help to increase the boiler-
running days.
During the coal coating, flue gas velocity and coal ash generation will be increased.
Increased velocity of flue gas with suspended Coal ash, which is coarse in nature, will scour
the flue gas path and remove slop ash deposition on flue gas path.
Area to be Focused
To achieve – above 800
 Slop distribution to be increased
 Slop line pressure to be reduced to
reduce the slop flow velocity
 If required, Refractory castable
coating to be given on LHS,RHS and
rear side of the water wall panel
 SA air distribution to be controlled
 Flue gas flow meter to be fixed in
both ID duct for measuring flue gas
and air ingress
 Duct leakages to be addressed
 If required, flue gas to be recycled
to maintain flue gas velocity.
 Draft transmitter were installed.
They have to be calibrated
 From the draft, we can measure DP
of Each zone. It will help us to
identify chocking of flue gas path in
earlier.
 Furnace Draft should be -3mmwc
and the same will be controlled by
DCS
 Drag chain exposed to the heat will
be avoided and it will increase the
life of drag chain.
 In house lab, we can analyse
moisture percentage, total solids ,
Ash and GCV
 Ultimate analysis of slop and coal is
required to fine tuning of excess air
and to identify Acid due point temp.
 flue gas path to be checked
 SH1 and SH2 coil scaling and
chocking to be checked
 Thermocouples to be checked