Optimizing Boilers Using Innovative Boiler Tube Imaging System
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Transcript of Optimizing Boilers Using Innovative Boiler Tube Imaging System
54th Annual ISA Power Industry Division Symposium 6-8 June 2011, Charlotte, North Carolina
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Lenny Shaver LumaSense Technologies, Inc.
Innovative Boiler Tube Imaging System Used to Optimize Boilers
54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Digital, Radiometric Infrared System Enables Automation and Analysis
• Capture Lost Boiler Capacity by reducing unnecessary cleaning
• Increase Efficiency with
better management of slag
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• Lower Maintenance Costs by optimizing washes and reducing damage caused by large clinkers
• Manage Fuel-Switching Strategies by accurately measuring slag and uniformity as fuel changes
54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Power Boiler Tube Imaging
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
What is BoilerSpection?
A new imaging system that provides coal-fired power boiler operators continuous information about slag deposits and clinker formations.
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
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)
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Clear insight into internal condition of coal-fired boiler
• Recording of Sootblower Operation
• Recording of Sootblower blasting slag from superheat
pendant
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
How does it work? Fundamentals of Infrared (IR) measurements in Boilers
• ~3.9µm – Combustion flames are most transparent, used to “see through flames” for boiler tube measurements
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• ~4.5µm – CO2 in gas is opaque at this wavelength and this is used for FEGT and other gas temperature measurements
Unique Properties in mid-IR:
54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
1. Lower Slope
2. Furnace/Burner Section
3. Superheat/Pendant Section
Where is it Being Used?
54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
System Scope
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
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
Camera and Cooled Borescope Lens
54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Automated Retraction System
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Mounting and Aiming Camera
Straight Aiming Up Aiming Down
54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Installation Details
54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
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.
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Digital Information is the Key to Automation
Fully “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 formation
Data 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
Broadcasting Results to Plant Network and Archiving for Historical Analysis
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54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
Case Study in Savings
6-Month Comparison
Before Camera
After Camera
6-Month Reduction in Cleanings
Estimated 6-Month Savings
Annualized Estimated Cost Savings
# of De-slags 25 12 13 $633,705 ~$1,250,000
# of Online Washes 4 0 4 $446,000 ~$900,000
Total ~$2,150,000
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Plant 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
Benefits of 24/7 Infrared Imaging Increasing 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
Q & A
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