Download pdf - Optimizing Boilers Using Innovative Boiler Tube Imaging System

54th Annual ISA Power Industry Division Symposium 6-8 June 2011, Charlotte, North Carolina

1 1

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

2

• 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


Power Boiler Tube Imaging

3


What is BoilerSpection?

A new imaging system that provides coal-fired power boiler operators continuous information about slag deposits and clinker formations.

4


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)

5


Clear insight into internal condition of coal-fired boiler

• Recording of Sootblower Operation

• Recording of Sootblower blasting slag from superheat

pendant

6

MillerUnit2Cam5Complete.avi




SuperheatSection.avi






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

7

• ~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:


1. Lower Slope

2. Furnace/Burner Section

3. Superheat/Pendant Section

Where is it Being Used?


System Scope

9


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


Camera and Cooled Borescope Lens


Automated Retraction System

12


Mounting and Aiming Camera

Straight Aiming Up Aiming Down


Installation Details


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.

15


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


Broadcasting Results to Plant Network and Archiving for Historical Analysis

17


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

18

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)


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


Q & A

20