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 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