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Industrial Boiler Fingerprint

Boiler benchmarking establishes current performance level and a basis for evaluating and identifying improvement opportunities, recommendations for improvement, and associated estimated return on investment (ROI).

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Benefits & Features
Performance Indicators
Audit & Testing

Benefits

− Facilitates management decisions by focusing on high-impact opportunities for improvement
− Provides clear path to quickly close performance gaps
− Builds a solid foundation for continuous improvement based on data analysis

Features
− Access to ABB optimization experts
− Boiler Performance Benchmarking
− Detailed ROI-based improvement plan

The ABB Industrial Boiler Fingerprint diagnostic service compares existing controls to industry standards as well as actual operating data to expected capability. It generates both a performance benchmark and an actionable improvement plan. The Fingerprint includes the collection of data to identify efficiency improvement opportunities, including steps to reduce unplanned outages (trips), and to improve availability.

Boiler Performance Indicators

The Industrial Boiler Fingerprint includes comprehensive testing, measurement and analysis of four key performance indicators that are used to assess performance and improvement potential:

− Instrumentation
− Control System Performance
− Capacity
− Combustion Control and Efficiency

Boiler Audit and Testing

The Fingerprint uses a bottom-up approach to performance improvement. Data collected verifies that basic instrumentation is working as needed, for good operation and control. Configured signal conditioning options are also examined and verified.

Closed-loop control of fuel and air flow, draft, steam temperature, and drum level are examined under steady load conditions, and during load ramps. Disturbance rejection, setpoint tracking, actuator  mechanical issues and loop interaction are evaluated.

Where maximizing steam generation capability is desirable, the constraining condition is identified. Examination of process control system logic ensures that the improvement capacity is not artificially constrained by the process control system.

Combustion control logic is evaluated and existing process control system controls are compared to ABB standards.

Cross limiting is examined for effect on load rate of change. Proper use of scaling in the cross limits is verified. The integration of O2 trim with cross-limiting system is checked. Efficiency is accurately evaluated using the losses method.

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