Steam generator on-line efficiency monitor

A system for the automatic and continuous determination of the efficiency of a fossil fuel-fired vapor generator for utilization by an automatic load control (88) to control the distribution of the system load among a plurality of generators, wherein various heat losses from various combustion sources are separately determined, the individual losses summed (80) and subtracted (86) from 100 percent to obtain a measure of the vapor generator efficiency.

TECHNICAL FIELD 
This invention relates to a system for automatically and continuously 
monitoring the efficiency of a fossil fuel-fired steam generator for 
utilization by an automatic load control which controls the distribution 
of the system load among a plurality of generators. 
BACKGROUND ART 
Boiler efficiency calculation methods are useful for determining which 
operating methods will reduce the amount of fuel required. Because there 
are many variations in the combustion process and many control settings 
available to meet steam demands, some type of efficiency calculation is 
necessary. 
An on-line efficiency calculation is desirable due to the fact that the 
combustion process is highly variable with constant changes in load demand 
and gradual, long term changes in burner equipment efficiency and ambient 
atmospheric conditions. 
Fuel heating value can also vary for fuels such as bark, refuse, blast 
furnace gas, residue oils, waste sludge, or blends of coal. As a result, 
control settings, based on steady state calculations of boiler efficiency 
using average daily or weekly fuel/air and fuel heating values, may not 
result in the most economical operation of the boiler. 
For systems with multiple boilers, operating costs may be reduced thru the 
use of boiler management optimization and load allocation systems. Boiler 
management systems set the fuel firing to the various boilers to minimize 
fuel costs. Some reliable measurement of boiler efficiency is required 
with these systems to obtain maximum fuel savings. 
One technique for determining the efficiency of a fossil fuel-fired steam 
generator, as set forth in the ASME/ANSI Power Test Codes, is the 
so-called Heat Loss Method which is based on the calculation of heat 
losses per pound of fuel. The generator efficiency is then the difference 
between the higher heating value of the fuel minus the total of the 
calculated heat losses, expressed in percent, for given feedwater 
conditions. 
A complete efficiency test of a fossil fuel-fired steam generator as 
presently conducted requires many manhours of labor to record the required 
data at stipulated increments of time over an extended period of time and 
then to make the necessary calculations at each of several loads. 
Furthermore, to obtain meaningful results, during the period of time in 
which the tests are conducted, the generator must be held in a 
steady-state condition. For these reasons efficiency tests are usually 
conducted only when required to meet performance guarantees. 
Bonne et. al. (GF Pat. No. 2,016,707 A) recites a flue gas loss or 
combustion efficiency meter primarily for use in furnaces using natural 
gas. Compensation is not made for losses due to incomplete combustion, 
radiation, air leaks, blowdown, moisture in the air, and unburned carbon 
in the ash. The present invention compensates for all of these losses and 
results in a system capable of measuring the boiler efficiency of a 
furnace utilizing most fuels including coal, oil, natural gas, hydrogen, 
etc. 
With the foregoing in mind it is the principal objective of this invention 
to provide a system whereby the efficiency of a fossil fuel-fired steam 
generator is automatically and continuously monitored and is utilized by 
an automatic load control, such as described in U.S. Pat. No, 4,435,650, 
to control the distribution of the system load among a plurality of 
generators. This and further objectives of the invention will be apparent 
as the description proceeds in connection with the drawings in which:

DETAILED DESCRIPTION 
In the drawing conventional logic symbols have been used. It will be 
recognized that the components, or hardware, as it is sometimes called, 
which such symbols represent are commercially available and their 
operation well understood by those familiar with the art. Further, 
conventional logic symbols have been used to avoid specific identification 
of this invention with any particular type of components such as analog or 
digital, as this invention comprehends either one or a combination of such 
types. 
Referring now to the drawing, excess air in the flue gas is determined by 
means of an oxygen transducer 1, generating a signal transmitted to a 
function generator 2, the output signal from which is proportional to the 
total air supplied for combustion in percent by weight. 
There is a substantially constant relationship between oxygen content in 
the flue gas and total air regardless of the fuel being burned, 
particularly as in modern steam generators the excess air can be 
maintained at low values in the order of 20 percent or less. If required, 
however, the output signal from the function generator 2 may be adjusted 
to compensate for changes in the proportionality between oxygen content in 
the flue gas and total air occasioned by a change in fuel. 
A signal proportional to the pounds of air supplied for combustion per 
pound of fuel is obtained by multiplying, in a multiplying unit 8, the 
signal from the function generator 2, by a signal proportional to the 
theoretical air required in pounds per pound of fuel, generated in a 
manually adjustable unit 10. 
Oxygen analyzers of the so-called electrochemical type using a 
Zirconium-oxide sensor operate at approximately 1500.degree. F. At this 
temperature unburned combustibles, such as CO and H.sub.2 react with the 
oxygen present in the flue gas. As a result, the signal generated by the 
oxygen transducer 1 is proportional to the excess oxygen remaining in the 
flue gas based on complete combustion. If such an oxygen transducer is 
incorporated in the system, a correction to the output signal from the 
function generator 2 is made by dividing in half, by means of a divider 
unit 11 and a signal generator 15, the output signal from a function 
generator 13 responsive to the signal generated in a combustibles 
transducer 62. 
The output signal from divider unit 11 is then summed in a summing unit 17 
with a constant value signal generated in signal generator 19. The output 
signal from function generator 2 is then multipled in a multiplier unit 21 
producing an output signal proportional to the pounds of dry air in pounds 
per pound of fuel. If the oxygen transducer is of a type having an 
operating temperature below the temperature at which the unburned 
combustibles react with the oxygen present in the flue gas, such as the 
so-called catalytic combustion or paramagnetic types, then no such 
correction is required. 
The pounds of dry exit flue gas per pound of fuel is obtained by adding, in 
an adder unit 25, to the output signal from multiplier unit 8 a signal 
proportional to the weight of combustibles in a pound of fuel generated in 
a signal generator 27. 
Having thus obtained the pounds of dry air and pounds of dry flue gas per 
pound of fuel, the individual losses due to heat in the exit flue gas, 
moisture in the air supplied for combustion, sensible and latent heat in 
the H.sub.2 O in the fuel and combustibles in the flue gas (if any) are 
determined as follows: 
Heat Loss in Dry Flue Gas (BTU/lb. of Fuel) 
EQU L.sub.1 =(Pounds Dry Flue Gas/Pound of Fuel) (0.247) (T-t) (1) 
Where: 
L.sub.1 =Heat Loss in dry flue gas in BTU/lb. Fuel 
T=Flue Gas Temperature .degree.F. 
t=Ambient Temperature .degree.F. 
0.247=Sp. Ht. dry air BTU/(lb.-.degree.F.) at 14.7 PSIA 
It has been assumed that the specific heats of the dry flue gas is very 
nearly equal to the specific heat of dry air. 
A signal proportional to the difference in ambient and exit flue gas 
temperatures is generated in a difference unit 12 responsive to the output 
signal from an ambient temperature transducer 14 and a flue gas exit 
temperature transducer 16. The signal generated in difference unit 12 is 
then multiplied in a multiplying unit 18 by the output signal from a 
signal generator 20 proportional to the specific heat of the dry flue gas. 
To obtain a signal proportional to the heat loss in the exit dry flue gas 
per pound of fuel the output signal from multiplying unit 18 is multiplied 
in a multiplying unit 22 by the output signal from adder unit 25. The 
output signal from multiplying unit 22 forms one input to a loss summing 
unit 24. 
Sensible Heat Loss Due to Moisture in the Combustion Air & Fuel 
##EQU1## 
Where: L.sub.2 =Sensible heat loss due to moisture in air & fuel 
y=Moisture in combustion air lbs./lb. of combustion air 
Conveniently, L.sub.2 can be determined by first determining the total 
moisture in the combustion air and fuel, then determining the heat loss 
per pound of moisture, the product of the two determinations being the 
sensible heat loss L.sub.2. 
The amount of moisture in the combustion air is often taken as y =0.013 
pounds per pound of dry air, corresponding to conditions of 80.degree. F. 
ambient temperature and 60 percent relative humidity; or y can be 
calculated from measurements of ambient air temperature and relative 
humidity for varying weather conditions. 
When moisture is assumed to be 0.013 pounds per pound of dry air, a signal 
proportional thereto is generated in a signal generator 26, transmitted 
through a selector switch 28 to a multiplying unit 30 for multiplication 
by the output signal from multiplier unit 8 to produce a signal 
proportional to the pounds of moisture in the pounds of combustion air per 
pound of fuel. 
When moisture is calculated from measurements of ambient air temperature 
and relative humidity, a signal proportional to the vapor pressure of 
H.sub.2 O at ambient temperature is first generated by means of a function 
generator 32 responsive to the signal generated in ambient temperature 
transducer 14, which is multiplied in a multiplier unit 34 by a signal 
proportional to the relative humidity of the ambient air supplied for 
combustion, generated in a relative humidity transducer 36. The output 
signal from multiplier unit 34 is then modified in accordance with changes 
in atmospheric pressure by means of a signal generator 38 generating a 
signal corresponding to ambient pressure which is subtracted from the 
output signal (a) from multiplying unit 34 in a difference unit 40 
producing an output signal (b) by which the output signal (a) is divided 
in a divider unit 42. The output signal from the divider unit 42 is then 
multiplied, in a multiplier unit 44, by a signal corresponding to the 
ratio between the molecular weight of water vapor and air, generated in a 
signal generator 46, to produce a signal proportional to the pounds of 
water vapor per pound of air supplied for combustion. This signal may then 
be transmitted through selector switch 28 to multiplier unit 30 to produce 
the signal proportional to the pounds of moisture in the pounds of 
combustion air per pound of fuel. 
A signal proportional to the pounds of moisture in a pound of fuel is 
generated in a signal generator 47 and transmitted to a summing unit 48 
wherein it is added to the signal from multiplying unit 30 to produce an 
output signal proportional to the total moisture in the combustion air and 
fuel per pound of fuel. This output signal is then multiplied in a 
multiplier unit 50 by a signal proportional to the heat in BTU wasted in 
the flue gases per pound of moisture to produce a signal proportional to 
the total loss per pound of fuel which is transmitted to loss summing unit 
24. The heat wasted in the flue gases per pound of moisture is obtained by 
multiplying the signal from difference unit 12 in a multiplier unit 52 by 
a signal proportional to the specific heat of water vapor, usually taken 
as 0.475 BTU per pound per degree, generated in a signal generator 54. 
Heat Loss Due to Vaporization of Water in the Fuel 
EQU L.sub.3 =(lbs. water in fuel/lb. of fuel) (1049) (3) 
Where: 
L.sub.3 =Heat loss due to vaporization of water in the fuel 
1049=Latent heat of vaporization BTU/lb. of water 
The signal proportional to the moisture in the fuel, generated in signal 
generator 47 is multiplied, in a multiplier unit 58, by a signal 
proportional to the heat of vaporization (assumed to be 1049 BTU/lb. of 
water) generated in a second generator 59. The output signal from 
multiplier unit 58 is transmitted to a loss summing unit 60. 
Heat Loss Due to Unburned Combustibles in the Flue Gas 
EQU L.sub.4 =(% combustibles in the flue gas) (lbs. dry flue gas/lb. of fuel) 
(9,746) (4) 
Where: 
L.sub.4 =Loss due to Unburned Combustibles 
9746 =Heat of Combustion BTU/lb. CO to CO.sub.2 
While by good design and careful operation no unburned gaseous combustibles 
will be found in the flue gases, under certain conditions they may be 
unavoidable. The usual gaseous combustible is CO which, if present, 
materially reduces steam generator efficiency. This loss in BTU per pound 
of fuel is determined by means of the transducer 62 and function generator 
13 generating a signal proportional to the percent combustibles present in 
the flue gas which is multiplied, in multiplier unit 64 by the output 
signal from adder unit 25 to obtain a signal proportional to the pounds of 
CO per pound of fuel. The output signal from multiplier 64 is then 
multiplied, in a multiplier unit 66, by the output signal from a signal 
generator 68 proportional to the heat of combustion of CO to CO.sub.2 
which is 9,746 BTU per pound of CO. The signal from multiplier unit 66, 
proportional to the BTU loss per pound of fuel forms one input signal to 
loss summing unit 24. 
Heat Loss Due to Unburned Carbon in the Ash 
##EQU2## 
Where: L.sub.5 =loss in BTU/lb. of fuel due to carbon in the ash 
14,500-heat of combustion, carbon to carbon dioxide 
This calculation requires an analysis of the ash to determine the pounds of 
carbon in the ash per pound of ash. The loss in BTU per pound of fuel is 
then determined by means of equation (5). As shown in the drawing, a 
signal proportional to the loss is generated in a signal generator 70 
which is transmitted to loss summing unit 24. 
Heat Loss Due to Heat Radiation 
EQU L.sub.6 =(K)((Fractional Load).sup.-0.95) (6) 
Where: 
L.sub.6 =Radiation loss in percent of heat input 
K=A constant 
The heat loss due to radiation varies inversely in non-linear functional 
relationship to generator load as expressed in equation (6). As shown in 
the drawing, a signal proportional to the fractional boiler load is 
generated in a steam flow transducer 72 and a signal proportional to the 
non-linear functional relationship between fractional load and radiation 
loss is generated in function generator 74. 
Unaccounted for Losses 
EQU L.sub.7 =Unaccounted for losses in percent of heat input 
In addition to the loss due to heat radiation, there are certain other 
losses due, for example, to heat leaks and blow down. These losses are 
based on experiences reported in the literature and are expressed as 
percent losses and accordingly may be added to the signal output of 
function generator 74 by means of a summing unit 76. A signal generated in 
signal generator 78 inputs to summing unit 76 to produce an output signal 
proportional to the total of radiation and unaccounted for losses in 
percent which is transmitted to a summing unit 80. 
Determination of Vapor Generator Efficiency 
##EQU3## 
Where: L.sub.8 =Boiler efficiency in percent of heat input 
The losses summed in summing unit 60, expressed in BTU per pound of fuel, 
are converted to losses in percent by dividing the output signal from 
summing unit 60 in a divider unit 81, by a signal proportional to the 
higher heating value of the fuel generated in a signal generator 82, to 
produce a signal proportional to the losses summcd in summing unit 60 
expressed in percent. The output signal from divider unit 81 is then 
summed in summing unit 80 with the signal from summing unit 76 to obtain 
an output signal proportional to the total percent losses, which is 
converted to a signal proportional to boiler efficiency by subtracting the 
output signal, in a difference unit 86 from the signal having a constant 
value of 100, generated in a signal generator 84. The output signal from 
difference unit 86 is transmitted to an automatic load control, 
schematically illustrated at 88 such as described in U.S. Pat. No. 
4,435,650, to control the system load along a plurality of generators.