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


Power Boiler Tube Imaging

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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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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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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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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

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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:


1. Lower Slope

2. Furnace/Burner Section

3. Superheat/Pendant Section

Where is it Being Used?


System Scope

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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

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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.

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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

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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)


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

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Optimizing Boilers Using Innovative Boiler Tube Imaging System