Field Trial Testing of Boiler Fuel Additives

GENERATION BUSINESS LINE

Annexure-2

PROCEDURE FOR

FIELD TRIAL TESTING OF BOILER FUEL ADDITIVES

FOR QUAFICATION OF SUPPLIERS/MANUFACTURERS/PRODUCTS

Scope and Application:

1.1To pre-qualify various brands of Boiler Fuel Additives and their manufacturers/suppliers for application in Boilers of SEC Power Plants burning Heavy Fuel Oil. Dosing of the most suitable and appropriate Fuel Additive is intended to protect the Heat Transfer surfaces from the corrosive and fouling effects of the impurities present in the Heavy Fuel Oil by maintaining the pH of ashes produced at the Electrostatic Precipitator (EP) outlet to ~ 3.5 at Air Heater Outlet and Silo without any impact on the other operational parameters of the Boiler.

1.2To evaluate the performance of Fuel Additive in reducing Stack Emissions and increasing combustion efficiency.

1.3To determenie the effect of Fuel Additive on High & Low Tempreture Corrosion, Rate of Fouling, Emissions (SO3, SO2, NOx, Particulate) and Acid Dew Point.

1.4To determine the optimum Dosage Rate.

1.5To investigate any adverse effects of the Fuel Additive on the Boiler performance, such as efficiency, Fouling of Burners, Boiler tubes and plugging of the Air Heaters.

Method Summary:

Supply of adequate quantitie(s) of potential Fuel Additive(s).
Study of the present Fuel forwarding system and Fuel Additive dosing facility for preparing arrangement drawings for Trial run set up clearly identifying the equipment / instruments and temporary connections to the existing system.
To make necessary arrangements including all measuring instruments and conduct in situ Field Trial Test on the selected Boiler.
Analysis of Test results and comparison of performance in repect of:

 Maintaining the pH of Fly Ash ~ 3.5.

Free Acidity less than 1.0 % wt as H2SO4.

Improvement in Boiler performance by efficient combustion.

Reduction of fouling in the flue gas path components.

Minimization of emission pollutants.

Reduction of particulate emission

Comments:

Supplier should submit references about their experience giving list of utilities where their recommended brands of Fuel Additives are being used and Trial Test carried out by them prior to the selection of the Fuel Additive. This should include all details such as capacity / type of Boilers, date of commissioning, Fuel characteristics, benefits accrued etc.
It is understood that the expenses for Trial runs in connection with pre-qualification of Fuel Additive e.g instruments, arrangment of test at site, analysis of results etc. should be totaly borne by the Fuel Additive supplier. The agreed cost of Fuel Additive shall be paid on quarterly basis if the test conducted yieldsuccessful results during each quarter. However, if the supplier has got alternative options/scheme, the same may be submitted for SEC evaluation and consideration.
All tests and associated works shall be carried out by supplier without causing any damages to the equipment and perssonel of SEC and shall not anyway affect the normal operation of the plant.
The intent of whole exercise is only to pre-qualify Fuel Additive type/brand and their suppliers. It does not any way confer rights on the Fuel Additive supplier for the award of purchase order which shall be necessarily based on the merits of the respective offers received.
The offers complete in all details as elaborated herein shall be submitted in the concerned office.

TECHNICAL INPUTS:

Our Boilers are designed to burn Crude Oil or Heavy Fuel Oil. The specificationn of Arabian Light Crude and Heavy Fuel Oil, A-962 are attached.
The chemical and physical properties of the Fuel (Heavy Fuel Oil) being used currently. All the Trial runs should be designed to suit for the requirement of the Fuel being used.
The Boilers are equipped with Fuel Additive dosing facilites. However, supplier shall arrange his own experts for samples analysis and carrying out the tests in a reliable manner.
To the extent possible SEC shall provide the available laboratory facility. However, supplier shall arrange his own experts for samples analysis and carrying out the tests in a reliable manner.
The supplier should contact SEC for obtaining any design and operational details of the Boiler which they feel deem necessary for the selection of the Fuel Additives for FTT.

PROCEDURE:

Supplier should identify, techno-economically, from his product range the most suitable Fuel Additive for achieving the specified objectives.
The criteria for arriving at optimized Fuel Additive dosage rate, based on the Fuel constituents such as Vanadium, Sulphur, Sodium, Potassium etc., should be very clearly given together with procedures of calculation dosing rate and the theory underlying behind it.
Trial runs should be designed to suit the Heavy Fuel Oil currently in use.
All the measuring instruments shall be calibrated for achieving necessary accuracy of measurements. All details of instruments, procedures of calibration, actual methods of measurement at site, measurement frequency together with applicable standards shall also be provided to SEC.
The duration of FTT are specified on page 7/11 of this Manual.
It is foreseen that on use of the selected Fuel Additive for the 1st quarter, indications regarding its favorable effects get reflected; failing which test shall be terminated. In case if the Trial runs prove to be successful with the dozing of the Fuel Additive used in the first attempt, then the tests shall continue with the same Fuel Additive till annual inspection.
During Trial Testing, all the critical operating parameters shall be controlled by Auto Mode of operation.

METHODOLOGY:

During the Field Trial Testing, the following parameters shall be monitored by the Fuel Additive Supplier / Manufacturer as per format attached.

Gas Analysis:

O2, CO2 & CO: By Orsat Analysis / Portable Combustion Analyzer.

NOx: USEPA Method # 7/ Portable Combustion Analyzer.

SO2, SO3: USEPA Method # 6/ Portable Combustion Analyzer.

Moisture: By Gravimetric method by absorbing known volume of the Gas by anhydrous Calcium Sulphate

 Particulate: Actual Quantities Measurement by using ISOKINETIC sampling.

Opacity:

Ash Analysis:

Unburned Carbon

pH @ 5 minutes and 60 minutes.

Weight, bulk density and moisture content

Magnesium (soluble and insoluble), Vanadium and unburned carbon

 Free Acidity (Total Acidity, Mineral Acidity)

Fuel Analysis: Shall be carried out by the Power plant and Fuel Additive supplier / manufacturer for all the parameters as specified.
Acid Dew Point and Rate of Acid Build Up (RBU) by using Land Instrument.
Boiler Operation Data:(Daily or per shift basis shall be provided by the Power Plant).

Steam and Fuel Flow Rates

Temperature of Flue Gases at inlet to the Air Heaters

Air Heater ∆P

Boiler Efficiency

Heat Rate

Soot Blowing Frequency

Emission Level

Particulate Emission

Corrosion Monitoring:Corrosion coupons OR corrosion online analyzers in two locations (a) Down Stream Air Heaters (b) Up Stream Air Heaters shall be installed to investigate the effect of Fuel Additive on corrosion reduction.

Oxygen and Excess Air upstream and downstream of APH.

Norms of Evaluation:

The following norms of Boiler Operating parameters shall be used to evaluate the performance of Fuel Additive on quarterly basis.

SH and RH steam temperature should be within 538  5 °C.
SH spray water to be as per design values for Normal operation at Auto mode.
RH spray water to be Nil.
Exhaust Gas temperature at APH outlet is expected to be 150 – 160 °C. However the temperature of exhaust gas temperature shall be maintained at 10 °C above the Acid Dew Point temperature at stack. This is to protect the Boiler Cold End surfaces against Acid Dew Point impact.
To confirm the operation parameters as listed above, SEC shall provide 1st week data as typical reference of the concerned Unit.
Ash pH at APHs outlet and silo shall be ~ 3.5 @ 5 minutes.
Ash pH @ 60 minutes shall also be checked. Its value shall be 0.2 – 1.0 higher than the pH value @ 5 minutes of the same sample.
Free Mineral and Total Acidity shall be < 1.0 % as H2SO4.
Burner tilt shall be within the Boiler tuning limits.
GRF opening shall be within Boiler tuning limits.
Operation of the Unit under Trial Testing should be on AUTO mode of operation.
Boiler Inspection:

Boiler inspection (Furnace, Steam Generation Tubes, SH, RH, Economizer, APH, Flue Gas Ducts, etc.) prior to start and after completion the Trial Test shall be carried out jointly for comparison and to evaluate the performance of the Fuel Additive.
Photographs shall also be taken on both the occasions.
Deposit samples shall be collected form all critical areas such as Furnace, SH, RH, Economizer, APHs, Ducts etc.
Deposits samples collected during inspection shall be analyzed by the supplier/manufacturer at their cost and the results shall be incorporated in the final report to be submitted to SEC.

8. EVALUATION:

The criteria to be used to evaluate the performance of Fuel Additive shall be based on the findings determined on quarterly basis.
Systematic evaluations of results of various analyses and other findings of each quarter shall be made and compared with the baseline data as specified herein.
All critical parameters i.e. SH and RH spray, GRF opening/closing, Burner Tilt, Delta P across the APHs, Exhaust Gas Temperature shall remain within the normal operating range at Auto mode of operation.
During each quarter, the base line data and normal operating limits of the various parameters should be consistently maintained.
Findings of Boiler internal inspections in comparison to initial inspection.

9. Liability of Supplier / Manufacturer:

Suppliers/Manufacturer shall be liable to bear damage expenses caused to equipment/ machinery/ property, personal injury or severe physical or environmental damage arising out of the non-conformance of the supplied material or due to inappropriate action of the Supplier/Manufacturer site Engineer.

10. Duration of Field Trial Testing:

Boiler Fuel Additives: Starting from cleaned / washed condition till Annual Inspection / ~10 -12 Months Operation / As decided by the COMPANY.

11. Mode of Operation During FTT:During FTT, the Units under operation shall be operated most possible from 75% - Base Load/MCR.

12. Responsibilities OF SUPPLIE/MANUFACTURER:

12.1During FTT, all the services required (Fuel Additive Dosing pumps, Dosage

Management) shall be the responsibility of Supplier/Manufacturer.

12.2All arrangements/expenditures, what so ever, shall be arranged/borne by the Supplier/Manufacturer.

12.3 Samples of Fuel, Fuel Additive, Deposits shall be collected and analyzed by Fuel Additive Supplier/Manufacturer at their cost and Analysis shall be witnessed by SEC, if required.

13. Liability of Supplier / Manufacturer:

14. Progress Reports:

Product(s) performance report of Field Trial Testing shall be submitted to SEC on Monthly/Quarterly basis prior the submission of invoice for the material consumed during this period.

15. Mode of Payment of Material used during Field Trial Testing:

Payment of the quantity of (offered/proposed) product(s) to be used during Field Trial Testing shall be made after completion of successful and satisfactory FTT.

If any nonconformance is observed by SEC representative on the procedure followed; SEC would withhold the payment unless and until justified proved within a time frame of 10 days on the nonconformance date.

16. Termination of Field Trial Testing:

In case the performance of the product and services required during the Field Trial Testing at any stage is/are observed unsatisfactory; SEC reserves the right to terminate the Testing program with/without any prior notice to the party.

Payment of material consumed during the quarter in which the Field Trial Testing was terminated shall not be paid by SEC.

17. Technical Issues not covered in this PROCEDURE:

Suppliers are advised to contact SEC in the event of any technical issues which in their opinion may not have been covered with full details in this procedure, before submitting the proposal.

18. Schedule of Field Trial Testing:

Schedule of "Field Trial Testing" of various products shall be followed as specified, subject to the availability of Units and SEC policy.

19. Merit of Prequalification / Field Trial Testing:

Request of Suppliers/Manufacturer for the product qualification shall be considered on merit basis from the day of the submittal.

In case the "Preliminary Evaluation" report is not satisfactory, the next Supplier/Manufacturer shall be given opportunity to proceed.

The Supplier/Manufacturer already prequalified by SEC and offering "Free of Cost" supply of Fuel Additive may be considered on priority basis to meet the urgency.

20. Procurement of Material required for Field Trial Testing:

If the preliminary information regarding the product offered for qualification and the results of the samples of the same product are satisfactory, the respective Power Plant shall initiate the process of procurement for the quantity adequate for Field Trial Testing recommended by the Suppliers/Manufacturer.

Procurement of recommended quantity of proposed Fuel Additive shall be made on competitive rates basis as per the standard practice of procurement of SEC.

In case, the Supplier/Manufacture offers "Free of Cost" supply of their product to be tested, the required quantity shall be supplied to the site as per the procedure of SEC.

21. Mode of Communication:

No verbal answer, clarifications or promises from any of the COMPANY employees can be considered eligible during prequalification.

Incomplete results or in appropriate format of reporting by the Suppliers/Manufacturer shall not be considered / entertained by SEC.

22.Deviation / Non-Conformity:

Deviation/non-conformity from the terms and conditions as specified in this Manual at any stage after the product is prequalified, if any, is noticed by SEC then the supplier/manufacturer shall be intimated regarding the failure to fulfill the requirements. In case the supplier fails to rectify the short comings then SEC-WOA reserves the right to:

With draw the prequalification declared for that product by SEC.

With hold the process of procurements.

Cancel the order placed by SEC.

23. DATA COMPARISION AND VALIDATION:

As per item-9.2, Supplier/Manufacturer technical experts shall also be responsible to collect all the data as per attached "DATA SHEET" in coordination with respective Power Plant for the Unit running in parallel with other qualified Fuel Additive.

24. Final Reports:

Supplier/Manufacturershall submit Final FTT report within "One Month" after the completion of the FTT, which includes all the Weekly, Monthly, Quarterly Reports, Analysis of Fuel, Fuel Additive, Deposits etc. and Operational and Chemical Analysis Data, Inspection Reports with Photographs, All correspondence during Field Trial Testing and detailed procedure of recommended dosage regime and safety measures to be followed in future by SEC.

25. RECOMMENDATION:

On the basis of the successful and satisfactory performance of Field Trial Test, the respective Supplier/Manufacturer/Product shall be declared "Qualified" and shall be included in the list of SEC.

The Qualified Brand(s) of Boiler Fuel Additive(s) shall be considered during procurement on "Techno-economical" and competitive "Treatment cost" basis.

In case of change of Supplier/Manufacturer/Product already qualified by SEC, prior approval and concurrence from SEC shall be obtained by the Supplier/Manufacturer as per the instruction specified in the "Qualification Package". Otherwise their offer during the process of procurement shall not be considered.

26. ATTACHMENTS:

Chemical Analysis / Measurements sheet
Operation Data Log Sheet.
Soot Blower Operating Frequency.
Undertaking on Conflict of Interest.
Undertaking / Declaration / Agreement.
Bid Bond.
HeavyFuel Oil, A-962 Typical Specification
Arabian Light Crude Fuel Typical Specification.
Fuel Additive Analysis Format for Boiler operating on Heavy Fuel Oil.

27. ACRONYMS:

SEC: saudi electricity company

FTT: Field Trial Testing

HFO: heavy fuel oil

lac: Light Arabian Crude

d: diesel

CHEMICAL ANALYSIS / MEASUREMENTS SHEET

Attachment-I

Unit No.: _____

Sheet No.: ______

Analysis / Measurements / Item / Units / Baseline
Data / During Testing 1st Quarter
Weeks
1 / 2 / 3 / 4 / 5 / 6 / 7 / 8 / 9 / 10 / 11 / 12
FUEL ANALYSIS
(Quarterly) / All Physical & Chemical Parameters as per Specification Format
FUEL ADDITIVE ANALYSIS
(Quarterly) / All Physical & Chemical Parameters as per Specification Formats
ASH
(Weekly) / PH @ 5 minutes / --
PH @ 60 minutes / --
Free Acidity as H2SO4 / % wt
ASH
(Quarterly) / Unburned Carbon / % wt
Iron (Fe) / PPM
Vanadium (V) / PPM
Magnesium (Mg) / PPM
Calcium (Ca) / PPM
Aluminum (Al) / PPM
Nickel (Ni) / PPM
Silicon (Si) / PPM
Sulfate (as SO4) / PPM
Particle Size Distribution
Ash Fusion Temp. / °C
Mg / V Ratio
FLUE GAS ANALYSIS
(Weekly) / Oxygen (O2) (L) / % V
Oxygen (O2) (R) / % V
Carbon Dioxide (L) / % V
Carbon Dioxide (R) / % V
Carbon Mono Oxide (L) / % V
Carbon Mono Oxide (R) / % V
NOx / PPM
SO2 / SO3 / PPM
Acid Dew Point / °C
Rate of Acid Build Up
QTY. OF ASH PRODUCED / Truck / Day / Nos.
SOOT BLOWING / Frequency / Per Shift
BURNER NOZZLE CLEANING / Frequency / Per Shift
HIGH PRESSURE FILTER CLEANING / Frequency / Per Shift
∆ P / Frequency / Per Shift
AMBIENT AIR TEMPERATURE / Frequency / Per Shift
HEAT RATE / Btu/kWh, kJ/kWh

OPERATION DATA LOG SHEET

Attachment-II

Date: ______Sheet No.: ______

ITEM / UNITS / Limits / MHI
Tuning Data / Baseline
Data / Remarks
Unit NO. / No.
Load / MW

FEED WATER & STEAM:

FLOW
Steam Flow / T/H
SH Spray Flow / T/H
RH Steam Flow / T/H
RH Spray Flow / T/H
PRESSURE
Eco Inlet / Kg/cm²
Drum / Kg/cm²
Boiler Outlet / Kg/cm²
TEMPERATURE
Eco Inlet / °C
Eco Out (L) / °C
Eco Out (R) / °C
DeSH Inlet (L) / °C
DeSH Inlet (R) / °C
DeSH Outlet (L) / °C
DeSH Outlet (R) / °C
3RY SH Out (L) / °C
3RY SH Out (R) / °C
RH Inlet (L) / °C
RH Inlet (R) / °C
RH Outlet (L) / °C
RH Outlet (R) / °C

FUEL OIL

Flow A/B / %
Fuel Flow / T/H
Burner Pressure / Kg/cm²
Atom Steam Pressure / Kg/cm²
Supply Temperature / °C

AIR

Flow / M3/H
Temperature / °C
A-FDF Outlet / °C
B-FDF Outlet / °C
A-AH Inlet / °C
B-AH Inlet / °C
A-AH Outlet / °C
B-AH Outlet / °C

PRESSURE