Air Heaters

Tanjung Jati B Training
AIR HEATERS
OPERATIONS
AIR HEATERS
Boiler Precipitator
FGD Absorber
2 x 660MW (net)
P.T. Central Java Power
Tanjung Jati B Units 1 & 2
Tri-Sector Air Heater
Function
Two (2) 50% capacity Ljungstrom Tri-Sector Air Heaters
transfer heat from the flue gas leaving the boiler to the
incoming cold primary and secondary air.
Secondary Air System
FD Fan
FD Fan
SCAH
SCAH
Tri-Sector
Air Heater
Tri-Sector
Air Heater
N
Sections
The Air Heater is divided into three (3) sections
Flue Gas Side
Secondary Air Side (~4/5 of air side)
Primary Air Side (~1/5 of air side)
Orientation
AIR HEATER A AIR HEATER B
ROTATION ROTATION
GAS SIDE GAS SIDE
SECONDARY
AIR SIDE
SECONDARY
AIR SIDE
PRIMARY
AIR SIDE
Air Heater Components
Terms to remember
Rotor & Rotor Drive
Emergency Air (Rotor) Drive
Heating Elements or Baskets
Guide & Support Bearings
Oil Circulating Systems
Sector Plates & Seals
Thermocouple Temperature Monitoring Panel
Sootblower
Water Washing
Flow Paths
FLUE GAS IN
PRIMARY
AIR OUT
SECONDARY
AIR OUT
Heating Elements (Baskets)
Baskets , which contain a multitude of corrugated
steel plate, absorb the heat from the flue gas stream.
HOT END
LAYER
(42 )
HOT
INTERMEDIATE
LAYER
(12 )
COLD END
LAYER
(10 )
Heating Elements (Baskets)
CORRUGATED PLATE DESIGN
Rotor Drive
The Air Heater Rotor Drive consists of the following
major components
30 HP, 380 VAC Motor
Speed Reducer
Fluid Coupling
Pinion Gear & Hub
Rotor Drive
43.5 LITER
If the electric motor should lose power, an Emergency
Air Drive is used to insure the continuous operation of
the Air Heater.
SOLENOID VALVE
FAILS OPEN UPON
LOSS OF POWER
Bearings
The Air Heater has two (2) main bearings, one
Guide Bearing & one Support Gearing.
The Guide Bearing is located at the top portion
of the rotor assembly, while the Support Bearing
is near the bottom.
Bearings
GUIDE
BEARING
SUPPORT
BEARING
Guide Bearing
Due to the Guide Bearing being located in a hot
environment, an Integral Oil Circulating System is provided
to maintain oil viscosity and provide a bath of clean oil.
Cooling water is from the CCCW System.
The Integral Oil Circulating System has the
following components
Oil Pump
Dual Oil Filters
Oil Pressure Gauge
Differential Pressure Gauge with Switch
Oil-Water Heat Exchanger
Pressure Relief Valve (set @ 75 psig)
Thermometer Probe
Adjustable Temperature Controller (set @ 38
o
C)
Integral Oil Circulating System
(Guide Bearing)
(Guide Bearing)
OIL REQUIREMENT:
~43.5 LITERS
(Guide Bearing)
Due to the potential for oil to leak and get under
the casing and insulation, there is always a
potential for fires to start.
It is recommended that an operator periodically
check the oil system.
(FIRE Potential)
Support Bearing
The Support Bearing is equipped with an Oil Circulation
System. The bearing itself is submerged in an oil bath
requiring approximately 185.5 liters.
External Oil Circulation System
(Support Bearing)
Unlike the Integral Oil Circulating System for the
Guide Bearing, the Support Bearing has what is
called an External Oil Circulating System .
This system is similar but has no Oil-Water Heat
Exchanger.
The External Oil Circulating System has the
following components
Oil Pump
Micro-Klean Filter
Pressure Gauge
Thermometer
Pressure Relief Valve (set @ 50 psig)
Filter Differential Pressure Switch
(Support Bearing)
(Support Bearing)
The sealing systems are comprised of the follow
seals
Radial
Circumferential
Axial
Rotor
Our discussion will focus on the Radial Seals.
The hot and cold sides of the air heater have these
seals which run from the center of the air heater to
its outer circumference.
Radial Seals, along with Sector Plates minimize Air
Heater Leakage
Sector Plates & Radial Seals
RADIAL SEALS
(HOT END)
(Leakage)
Leakage occurs between the following Air and
Gas streams
Primary Air stream to the Flue Gas stream
Primary Air stream to the Secondary Air stream
Secondary Air stream to the Flue Gas stream
Flue Gas In
Flue Gas Out
Pri. Air
In
Sec Air
In
Pri. Air
Out
Sec. Air
Out
Leakage occurs because the pressure on
the air side is greater than the pressure on
the gas side. Also, Primary Air pressure is
greater than Secondary Air Pressure.
Leakage
Sector Plates are also located on both the Hot and
Cold End of the Air Heater. The Sector Plates are
essentially pie-shaped plates and are adjustable
on the Hot Side and stationary on the cold side.
Sector Plates are used to set the gap between the
Plate and the Radial Seals.
1 of 3 SECTOR PLATES
RADIAL SEAL
Sector Plates - Numbering
1 2
3
Top View of Air Heater B
(Mirror Image for Air Heater A )
GAS SIDE
PRIMARY
AIR SIDE
SECONDARY
AIR SIDE
The Hot Side Sector Plates, which are adjustable,
incorporate an automatic system which checks
and sets the gap between the plate and the Radial
Seals. A Rotor Position Sensor is utilized for this
task.
The Rotor Position Sensor Assembly and Sector Plate
Drive Assembly are located at the ends of the Sector
Plate.
The Sector Plate position can also be set manually.
Each Sector Plate, numbered 1 , 2 & 3 , has its
own Local Control Panel to perform this function.
CAUTION! An experienced operator or technician
should be the only one to adjust the Sector Plates
via the Local Panel, otherwise Radial Seal damage
can occur.
Sector Plates Drive Location
AIR HEATER A AIR HEATER B
ROTATION ROTATION
GAS SIDE GAS SIDE
SECONDARY
AIR SIDE
SECONDARY
AIR SIDE
PRIMARY
AIR SIDE
1 1 2 2
3 3
Sector Plate Local Panel
Thermocouple Temperature Monitoring Device
The Thermocouple Temperature Monitoring
Device (TTMD), is designed to measure the air
temperature leaving the Air Heater.
The TTMD will alarm if a thermocouple detects an
unexpectedly high local air outlet temperature.
A high outlet air temperature could be an indication
of a FIRE internal to the Air Heater.
Each Air Heater has one TTMD Panel.
The TTMD utilizes the following Thermocouples
One (1) for Air Inlet Temperature
One (1) for Gas Inlet Temperature
Fourteen (14) for Air Outlet Temperature
The 14 Thermocouples are located internally along
the radius of the rotor with a spacing of approximately
one foot (305 mm) and as close as possible to
the heat transfer surface (baskets).
All Thermocouple readings are routed to the TTMD
Panel for evaluation or comparison .
The TTMD panel will send an alarm signal to the DCS
and alarm locally as well.
T
/
C

#
1

t
h
r
u

#
1
4
CUTAWAY OF
ROTOR SECTION
THERMOCOUPLES
LOCATED IN THE
AIR OUTLET STREAM
TTMD Panel Alarm Potential Fire
When the TTMD Panel has a High Temperature
Alarm, immediate attention should be given to
it by an operator and I&C technician.
First, push the alarm acknowledge button and
see if the alarm clears or resets.
If not, check to see if the Thermocouple is functioning
properly, for example, the thermocouple has not
failed (infinite resistance).
At first evidence of a fire from temperature indication
or otherwise, inspection of the Air Heater should be
made.
If the temperature continues to rise or if a fire is
visible, the fans should be shut down and water should
be admitted to the Air Heater in sufficient quantities
to quench the fire.
If it is possible to isolate the area of the fire, then stop
the Air Heater so that the water can be directed at
the fire.
On the other hand, if the fire is burning in several areas,
continue to rotate the Rotor as long as it will turn.
Note: If the fire has progressed to the metal Heating
Elements, temperatures could range from 1093
o
C to
2204
o
C.
DO NOT CONSERVE ON WATER!!
GET AS MUCH WATER AS POSSIBLE ON THE FIRE!!
Out of Service Water Washing
Over time, Air Heater air and gas pressure differential
may increase. Air heater inspection and water washing
may be necessary.
A Water Wash system with wash nozzles is provided
to serve this task.
Flue Gas In
Flue Gas Out
Pri. Air
In
Sec Air
In
Pri. Air
Out
Sec. Air
Out
Pressure Difference
Across Elements
P
in
- P
out
Pressure Difference
Across Elements
P
in
- P
out
Out of Service Water Washing
(Pressure Drop)
Sootblower
The extendable lance sootblower is used to
minimize the buildup of combustion byproducts
on the Air Heaters heat transfer elements.
It also minimizes No. 2 fuel and fuel ash deposition
during relatively cold start-up conditions.
Typical Sootblower Arrangement
Plugged Heating Elements
Sootblower
Since there is no auxiliary boiler, and if both units
are cold , compressed air is used. Service Air
Compressors provide this air.
Steam which is generally more economical, should
be used when auxiliary steam is available.
Sootblower
During boiler start-up, the Air Heater Sootblower
should be operated on a continuous basis. This
is due to the greater potential for the accumulation
of No. 2 Oil combustion byproducts and oil itself.
Once the Boiler is up and operating, the sootblower
is used periodically (typically once per shift).
Start-Up & Shutdown
The Air Heater is started prior to firing the
Boiler and the sootblower is operated on a
continuous basis.
During normal operation, periodically check
the operation of the Air Heater and be sure
the Emergency Air Drive air isolation valve
is open.
Start-Up & Shutdown
During normal operation, check for unusual
noises. A periodic or repetitive noise can be
a sign of excessive rubbing between the Radial
Seals and the Sector Plate(s).
When shutting down the Boiler, the sootblower
should be operated continuously prior to
extinguishing the fires.
Loss of Air Heater during Unit Operation
Most often, the reason for an Air Heater to
stop during Unit Operation is due to electrical
overload of the Main Drive Motor.
This is generally due to excessive rubbing
between the Radial Seals and the Hot End
Sector Plates.
If this should occur, the Emergency Air Motor
Drive will not be able to rotate the Air Heater
as well.
Provisions should be made to reduce Unit Load
as quickly as possible so that the Air Heater can
be isolated from the incoming Flue Gas, if this
should become necessary.
At the time of Air Heater Rotor Stoppage, the
Operator should immediately go to the Air Heater
and Retract all three (3) Sector Plates by way
of the Local Control Panel.
Once this is done, try to restart the Air Heater
Drive Motor.
If the Main Drive Motor is successfully restarted,
continue to operate the Air Heater with the Sector
Plates in the retracted position.
Once the Unit is stable at the reduced Unit Load,
the Sector Plates can be extended by automatic
control.
If the Main Drive Motor will not restart, and
when Unit Load permits, close all Isolation
Dampers to isolate the Air Heater.
The main reason for retracting the Sector Plates
as soon as possible is to avoid damage of the
Radial Seals.
All Operators should thoroughly familiar with
the Air Heater operating instructions found in
the Operations & Maintenance Manual.
High Leakage
Increases fan power requirements
Possible load curtailment
Reduced thermal performance
Negative effects on precipitators and scrubbers
High Pressure Drop
Increases fan power requirements
Low Thermal Performance
High gas outlet temperature
Low air outlet temperature
Lowers unit efficiency
Increases leakage
Performance
Build up and blockage of heating surface flow paths by ash and
corrosion products
Effects
Increases pressure drop
Increases leakage
Reduces thermal performance and effects boiler operation
Shortens element life
Limits unit capacity
Control
Sootblowing
Water washing
Cold end temperature control
Performance
Surface Plugging
Ineffective sootblowing
Low cold end metal temperature
Incomplete water washing
Ash carryover
High Leakage
Deteriorated seals
Incorrect seal adjustment
Improper operations
Rotor or sector plate problems
Performance
OPERATIONS
AIR HEATERS
(END)

Air Heaters

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