BOILER STEAM CAPACITY ENHANCEMENT CHECKLIST

When steam demand increases, Most of the companies think about capacity enhancement of existing Boilers OR Fuel conversion. OEM & Experts suggested a lot of proposals with high cost involvement for Boiler modification for only 10 to 15 % increment in boiler steam capacity against the rated boiler capacity.

Normally the boiler is designed with 10 to 15% minimum margin on pressure parts and auxiliaries including BFP, Few OEM already providing guarantees for 110% MCR operation for 30 minutes in an 8 hour shift. It means Boiler should be capable to operate in extreme overload capacity upto 110% MCR condition also with additional minimum 5 to 10% safe design margin.

We suggest reviewing the received proposal with existing Boiler technical details & auxiliaries before starting the process of steam capacity enhancement.

Generally beyond 10 to 15 % increment limit, steam capacity enhancement is not feasible / possible due to major parts and equipment replacement, OEM & Expert shall not suggest you do this.

Look at attachment for Comparison of BOILER CAPACITY ENHANCEMENT & OVER LOAD BOILER OPERATION TECHNICAL INPUT details required for capacity enhancement and overload operation and indicating safe operation within allowable parameters.

The Trip Level i.e. Low-Low Water Level (LLWL) and High-High Water Level (HHWL) is usually depend on steam drum diameter and by the highest point at which downcomers are entering in the steam drum / top of steam drum cyclone.

Few other changes in boiler you may receive like pipe line size increment, increment in heating surface area, fuel feeders replacement, air & gas duct size increment, modification in steam drum internals, refractory application on water walls.

For more Details, Please read   attachment  

M/s Unite Energy Corporation LLP, Ghaziabad, U.P., India is keen to provide the Boiler Spares, Sales & Services, Retrofit & Site Repairs of Boiler & Auxiliaries, Performance Evaluation, Shop & Site Fabrication, Erection & Commissioning, Design Modification & Feasibility Study, Consultancy & troubleshooting support to mitigate the irregularities in the plant, minimize breakdown & downtime and improvise design & system performance to improve the overall plant's health and performance.