CHALLENGE
To understand operating type of 40+ years old of boiler and design.
To study and identify old boiler wiring rework and system safety.
To draw, install and rework new wiring for new burner complete with BMS integrated safety according to new regulation.
To run testing and commissioning the burner within lead time.
PROPOSAL
Old supplied package boiler has operated with lower combustion efficiency and lead to high energy consumption and effect production outcomes.
By introducing duo-block burner complete with burner management system (BMS) to enhance boiler & combustion efficiency to resolve client issues.
Based on TEM Combustion analysis and study done to client boiler, we identify that existing boiler performance was below than expected which cause the energy consumption higher and affect the production line.
The main reasons are the boiler combustion efficiency has getting low after 40 years operation.
Combustion Efficiency and Excess Air Optimizing boilers efficiency is important to minimize fuel consumption and unwanted excess to the environment. To ensure complete combustion of the fuel used combustion chambers are supplied with excess air. Excess air increases the amount of oxygen to the combustion and the combustion of fuel, when fuel and oxygen from the air are in perfect balance - the combustion is said to be stoichiometric. The combustion efficiency increases with increased excess air - until the heat loss in the excess air is larger than the heat provided by more efficient combustion.
Excess air to achieve highest possible efficiency for some common fuels:
5 - 10% for natural gas
5 - 20% for fuel oil
15 - 60% for coal
Carbon dioxide - CO2 - is a combustion product and the content of CO2 in a flue gas is an important indication of the combustion efficiency.
Optimal content of carbon dioxide - CO2 - after combustion is approximately 10% for natural gas and approximately 13% for lighter oils. Normal combustion efficiency for natural gas at different combinations of excess air and flue gas temperatures are indicated below:
Net stack temperature" is temperature difference between flue gas temperature inside the chimney and room temperature outside the burner.
According to the data from Combustion Analysis by TCB teams the operational data for combustion for excess air 35% and CO2 25% respectively.
Therefore, technical presentation and discussion has been made and we manage to convince our client to change their burner system to Ecoflam duo-block complete with BMS in order to reduce energy consumption and enhance boiler performance.
Old boiler system wiring has been inspected by local wiring expert. Client could not provide us the old wiring drawing which made our investigation more complex.
By proposing a burner management system to enhance whole boiler operation, we recommend our customer to terminate old wiring and replace with new wiring design and provide new drawing for customer references in future.
OUTCOME
After having time to do study, analysis and inspection. TCB teams manage to find out the root cause and do excellence proposal to client.
Therefore, further technical discussion and proposal to the management and customer decided to use Ecoflam Duo-Block BLU 6000.1 TS
Current boiler operation system performance operates with 85-90% efficiency.
TCB team first advance BMS implementation in Malaysia