Optimizing Boilers Using Innovative Boiler Tube Imaging System
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The document discusses an innovative boiler tube imaging system developed by Lumasense Technologies that optimizes coal-fired power boilers by providing continuous infrared imaging to monitor slag deposits and clinker formations. This system enhances maintenance efficiency, reduces costs, and increases boiler efficiency through automation and real-time data analysis. A case study highlights significant financial savings in cleaning costs and increased operational capacity due to better management of slag and combustion uniformity.
Optimizing Boilers Using Innovative Boiler Tube Imaging System
- 1. Innovative Boiler Tube Imaging System Used to Optimize Boilers Lenny Shaver LumaSense Technologies, Inc. 54th Annual ISA Power Industry Division Symposium 6-8 June 2011, Charlotte, North Carolina 1
- 2. Digital, Radiometric Infrared System 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. Power Boiler Tube Imaging 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 3
- 4. What is BoilerSpection? A new imaging system that provides coal-fired power boiler operators continuous information about slag deposits and clinker formations. 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 4
- 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. Clear insight into internal condition of coal-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. How does it work? Fundamentals of Infrared (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. 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. System Scope 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 9
- 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. Camera and Cooled Borescope Lens 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
- 12. Automated Retraction System 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 12
- 13. Mounting and Aiming Camera Straight Aiming Up Aiming Down 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
- 14. Installation Details 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina
- 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. 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
- 17. Broadcasting Results to Plant Network and Archiving for Historical Analysis 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 17
- 18. Case Study in Savings 6-Month Before After 6-Month Reduction Estimated Annualized Estimated Comparison 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 ~$2,150,000 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 18
- 19. 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
- 20. Q&A 54th Annual ISA POWID Symposium, 6-8 June 2011, Charlotte, North Carolina 20