AIR HEATER PERFORMANCE

GAS OUTLET
TEMPERATURE
LOWER THAN
OPTIMUM
LEADS TO COLD
END CORROSION
LOSS OF HEAT
TRANSFER
ELEMENTS

GAS OUTLET
TEMPERATURE
HIGHER THAN
OPTIMUM
MORE DRY GAS LOSS
RISE OF 220C ABOVE
OPTIMUM REDUCE
BOILER EFFICIENCY
BY 1%
20C RISE ABOVE
OPTIMUM RESULTS
LOSS OF 600Kcal HEAT
IN 1 TONNE OF F.G.

FACTORS AFFECTING A.H. GAS

OUTLET TEMPERATURE

LOWER THAN HIGHER THAN OPTIMUM

QTY. OF AIR PASSING THROUGH
OPTIMUM
A.H.

LIGHTING AND
FIRING COLD
BOILER
USE SCAPH

AIR LEAKAGE

TEMPERING AIR
SETTING INFILTRATION
BYPASS DAMPERS PASSING

TEMP.OF GAS ENTERING A.H

SEALS CONDITON
DIFF. PR. BETWEEN
AIR AND F.G

DEPOSITS ON BOILER HEAT TRANSFER

AREAS
DELAYED/SY.COMBUSTION
FEED WATER TEMP

FOULED / CORRODED ELEMENTS

DEFECTIVE BAFFLES
QTY.OFGAS PASSING THROUGH A.H

AIR HEATER PERFORMANCE TESTS

REQUIREMENTS
CHECKING ACTUAL PERFORMANCE
AGAINST MANUFACTURERS GUARANTEE
COMPARISON WITH A STANDARD OF
OPERATION
COMPARING PERFORMANCE WHEN FIRING
DIFFERENT FUELS
DETERMINING THE EFFECTS OF CHANGES
TO EQUIPMENT
DETERMINING CORRECTIONS TO A.H.
EXITGAS TEMP. CAUSED BY VARIATIONS IN
INLET TEMP. IN AN EFFICIENCY TEST OF A
BOILER

AIR HEATER PERFORMANCE

TESTS
PERFORMANCE ITEMS DETERMINED

GAS SIDE EFFICIENCY

AIR LEAKAGE
X-RATIO
GAS AND AIR TEMPERATURE
CORRECTIONS
GAS AND AIRPRESSURE LOSS

DATA REQUIRED FOR A.H.

PERFORMANCE TESTS

TEMP.OF AIR ENTERING

TEMP.OF AIR LEAVING
TEMP.OF GAS ENTERING
TEMP.OF GAS LEAVING
QTY. OF AIR ENTERING
QTY. OF HEATED AIR LEAVING
AIR SIDE INLET AND OUTLET STATIC PRESSURE
AIR SIDE INLET AND OUTLET VELOCITY PRESSURE
GAS SIDE INLET AND OUTLET STATIC PRESSURE
GAS SIDE INLET AND OUTLET VELOCITY PRESSURE
GAS ANALYSIS OF F.G.ENTERING AND LEAVING A.H
HUMIDITY OF INLET AIR

DATA REQUIRED FOR A.H.

PERFORMANCE TESTS

QTY. OF GAS ENTERING A.H.

QTY. OF GAS LEAVING A.H.
QTY. OF FUEL MEASURED OR COMPUTED
ULTIMATE ANALYSIS OF COAL
QTY. OF ATOMISING STEAM IF BURNING OIL

AIR HEATER CALCULATIONS

GAS SIDE EFFICIENCY
G

{(tG14-tG15(NL))/(tG14-tA8)}*100

WHERE tG14
- MEASURED GAS TEMP. ENTERING A.H.
tA8
- MEASURED AIR TEMP. ENTERING A.H
tG15(NL) - CALCULATED GAS TEMP LEAVING
A.H. CORRECTED FOR NO AIR
LEAKAGE

HEAT BALANCE FOR LEAKING AIR IN

AIR HEATER
HEAT GAINED BY LEAKING AIR=HEAT LOST BY F.G

HEAT GAINED BY LEAKING AIR=HEAT REQUIRED TO

RISE TEMP. OF
LEAKING AIR (t A8)
TO GAS OUTLET
TEMP.( tG15)
=A (L)*CpA*(tG15- tA8)
WHERE A (L) - % AIR LEAKING
C pA - Sp.HEAT OF AIR

HEAT BALANCE FOR LEAKING AIR IN

AIR HEATER

HEAT LOST BY F.G

=HEAT LOST TO BRING

DOWN THE GAS TEMP.
FROM IF THERE IS NO
LEAK (tG15(NL)) TO
ACTUAL GAS TEMP. ( tG15)

=100*CpG*( tG15(NL) - tG15 )

WHERE CpG - Sp.HEAT OF F.G.

100*C *( t
- tG15 )
pG
G15(NL)
tG15(NL)

A (L)*CpA*(tG15- tA8)

= [{A (L)*CpA*(tG15- tA8)}/ 100*CPg ] + tG15

AIR HEATER LEAKAGE

A(L)

=[WET AIR LEAKAGE/WET GAS ENTERING A.H]*100

=[{WG15-WG14}/WG14]*100

BY EMPRICAL APPROXIMATION
A(L)

=90*{%CO2 ENTERING A.H.-%CO2 LEAVING A.H.}/

%CO2 LEAVING A.H.

EFFECT OF VARIOUS
PARAMETERS ON A.H. GAS SIDE
EFFICIENCY
AIR INLET TEMP.IN ALL CASES 300C
CASE

GAS
INLET
TEMP.
0
C

GAS
OUTLET
TEMP.
0
C

LEAKAGE
%

EFFICIENCY
%

IDEAL

400

140

13

66.5

400

155

13

62.2

400

140

20

64.6

400

155

20

59.7

430

165

20

59.8

EFFECT OF COMPONENT ON DRY GAS

LOSS / EFFICIENCY
Gcv

Gross calorific value

of fuel

C
S
U

Carbon in fuel
Sulphur in fuel
Unburnt carbon/kg
fuel
CO2 Carbon di oxide in
flue gas
Wd Dry gas wt. Per kg
of fuel
Sp.ht Specific heat
Tg

Gas temperature
leaving boiler
Ta
Ambient
temperature
DT
Tg-Ta
L1
Dry gas loss
Change in loss for
1% CO2
100C

Kcal/kg

3689.10 3689.10

3689.10

%
%
Kg

36.92
0.28
0.0066

36.92
0.28
0.0066

36.92
0.28
0.0066

13

12

13

Kgmol/kg

0.2331

0.2525

0.2331

Kcal/kgmol 7.31
/0c
0
C
155

7.31

7.31

155

165

35

35

35

120
5.54

120
6.00

130
6.00

C
%
%

-0.46
-0.46

EFFECTS OF TRAMP AIR

TO BOILER
NOT CONTRIBUTING TO
COMBUSTION
OFTEN IT IS COLD
INCREASE GAS VELOCITY
THROUGH E.S.P
BYPASSING A.H. INCREASED GAS
OUTLET TEMPERATURE

SOURCES OF AIR INGRESS

ASH HOPPER SEALS

ASH HOPPER DOOR LEFT OPEN
DEFECTIVE EXPANSION JOINTS
DUCT OPENINGS UNCOVERED
BOILER ROOF SEALS DEFECTIVE
ATTEMPERATING AIR DAMPERS
PASSING
A.H.AIR BYPASSING DAMPERS PASSING
SUCTION MILLING PLANT
WORN SHAFT SEAL ON EXHAUSTERS

X RATIO
HEAT CAPACITY OF AIR PASSING THROUGH A.H.
X RATIO = -------------------------------------------------------------------------HEAT CAPACITY OF GAS PASSING THROUGH A.H.

WA9*CpA*(tA9 - tA8)

WG14*CpG*(tG14 - tG15(NL))

WA9*CpA
(tG14 - tG15(NL))
X RATIO = ------------- = -----------------WG14*CpG
(tA9 - tA8)

CpA / CpG = 0.95

INDICATION OF AIR BY PASSING A.H

EFFECT OF BYPASSING AIR ON F.G. TEMP.
LEAVING A.H

EFFECT OF AIR BYPASSING AH ON X RATIO AND GAS TEMP.

Qg

Gas quantity entering

A.H.
Qa Air quantity leaving A.H.
Xr X ratio Qa*95/Qg
Tgi Gas temp. entering A.H.
Tai Air temp. entering A.H.
Tao Air temp. leaving A.H.
Tgo Gas temp. leaving A.H.
without leakage
Tgi-[ Xr*( Tao- Tai )]
VARIATION
Aef A.H.Efficiency

T/hr
T/hr

700

700

700

C
0
C
0
C
0
C

500
475
525
0.68
0.64
0.71
330
330
330
35
35
35
310
311
309
143.39 152.08 134.78

8.69
60

63

- 8.62
66

CALCULATING AIR INGRESS %

Qg Gas quantity at A.H.inlet
Qaf Air quantity based on excess
air at A.H.inlet
Xr A.H.Xratio
Qa Air quantity leaving A.H.
Xr*Qg/0.95
Qat Tempering air quantity from
mill heat balance
Qi Air ingress quantity
Qaf-Qat-Qa
% Air ingress

T/hr 700
T/hr 650
0.7
T/hr 515.79
T/hr 100
T/hr 34.21
5.26