Optimizing Boilers Using Innovative Boiler Tube Imaging System

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

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

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

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

7

Where is it Being Used?

1. Lower Slope
2. Furnace/Burner Section
3. Superheat/Pendant Section








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 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)

18

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

Optimizing Boilers Using Innovative Boiler Tube Imaging System

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