EffiMax 500 for Manual Fired Boilers

Efficiency of Manual Fired Boilers
Our experience over the years has shown that-
  • The manual fired boilers generally operate at very low efficiency.
  • Since these are manually fired the operating practice is more or less fixed.

Thus a complete system which monitors various parameters and gives the user with timely indication through relevant pop-ups and alerts can significantly improve the boiler efficiency and operating practice.

EffiMax-500 system is programmed with proprietary software to continuously analyze data on the real time basis. It keeps the user informed about the best operating practices to be followed during boiler operation by suitable pop-ups and alerts. Host of other features like data logging of boiler parameters , trend analysis and remote monitoring through SCADA software ensure that you keep constant track of your boiler performance.

Effimax for Boiler efficiency and safetyDifferent Pop-ups generated by EffiMax 500-

  • Feed fuel
  • Close the door
  • Open damper
  • Close damper
  • Clean the tubes
  • Reduce feed
  • Stir/poke the fuel bed
  • Check condensate recovery
  • Avoid sudden loading
  • Excess steam demand
  • Possible back fire
  • Improve water quality
  • Drain mobrey
  • Mobrey not drained
  • Clean the TDS sensor
Inefficient Operation of Manual Fired Boilers Impact of EffiMax - 500
Why do Manual Fired Boilers Operate at Lower Efficiencies?

It is generally observed that the manual fired boilers operate at a very low efficiency, generally between 50% to 65% against the ideal rated efficiency of 78%.


Fuel feeding practices:

  • Low fuel feeding frequency
  • Stoker mostly overfeeds fuel as per his convenience & Grate space
  •  Irrespective of plant load, the boiler is usually fuelled fully. This results in high unburnts and stack losses
  • Fuel bed is generally uneven
  • Infrequent poking

Combution air practices:

  • Manual damper adjustments are based on expertise and vigilance of the boiler operator
  • After manual adjustments, damper settings are kept fixed irrespective of current operating conditions
  • Furnace Draft not measured and monitored

Blowdown practices

  • Blowdown is provided manually
  • Manual blowdown means too little/too high blowdown is provided than required.Too little blowdown  allows for build-up of high TDS levels resulting in foaming, moisture carryover in
  • steam and scaling on water side tube
  • High blowdown leads to wastage of fuel and Water Treatment Chemicals.

Boiler maintenance practices

  • Boiler tubes are cleaned periodically without looking at stack and steam temperatures
  • Mobrey is drained periodically but missed sometimes

Monitoring of parameters:

  • No monitoring of critical boiler parameters like draft pressure, blowdown TDS, blowdown flow, steam flow,
  • steam temperature, feedwater temperature, stack temperature