GEECO Enercon Pvt.

Limited
An ISO 9001, 14001, 50001 & OHS AS 18001 Certified Company

RAPH | ESP | CFD | FEA | FES | TESTING | TRAINING

ABOUT US

ROTARY AIR PREHEATER

ELECTROSTATIC PRECIPITATOR

COMPUTATIONAL FLUID DYNAMICS

FINITE ELEMENT ANALYSIS

FIELD ENGINEERING SERVICE

TESTING

TRAINING

RESEARCH AND DEVELOPMENT

ABOUT US
GEECO Enercon Pvt. Limited, a successful engineering organization had its inception in the year 1985 & ventured into Rotary Air
Preheater spares manufacturing. After proving our uniqueness & stand-alone capability in Air Preheaters & putting forth Energy
Conservation, we enhanced our notion towards Environmental Conservation with Electrostatic Precipitator System (ESP) solutions.
GEECO's various functional areas include 'Design, Engineering, Research & Development, Manufacturing, Supply, Erection,
Commissioning & Service Supervision'. Our Company operations are efficiently managed by established ERP systems.
Our Administrative, Design, Commercial & Marketing operations are supported by Head Office located at Tiruchirapalli, India &
other activities which include Production, Quality & Warehousing are being carried out at our wide spread factory spanning 20 acres
located at Thanjavur, India. GEECO's manufacturing facility is established in a total covered area of 1,54,000 Sq.ft.
With our global exposure & technical expertise, the consequences of global warming are being solved through APH & ESPs using
customized designs based on our customer requirements.

VISION
➔ To be a world class engineering organization that provides the best products & services

MISSION
We commit to be the most admired company by:
➔ Providing the products & services that exceed customer expectations
➔ Innovating & Deploying total business solutions
➔ Empowering our employees & creating an environment for them to perform at their highest potential
MANAGEMENT TEAM

Mr. V. Rajagopal - Chairman & Managing Director

A Post Graduate in Mechanical Engineering with vast experience in Air Preheater since starting with BHEL in
1975. He was first trained at Combustion Engineering, USA and later headed the Air Preheater Division at Alstom. He
has worked with most of the Air Preheater designs available around the globe and is actively involved in its selection,
design and field engineering. A multifaceted personality who develops strategical plans towards company growth.

Mr. C. Gunasekaran - Director

A versatile entrepreneur who holds an Manufacturing Industry for Boiler components since 1982 with “Indian
Boiler Regulation” certification and has huge experience in manufacturing components for Cement & Steel Plants. He
guides & monitors the overall work flow of GEECO with extra care on Financial activities and is instrumental in
making sound investment decisions. He monitors financial outcome against the Company's plans and budgets.

Mr. M. Amirthalingam - President

Since his graduation as Mechanical Engineer, joined Asia’s largest power plant manufacturer M/s. Bharath Heavy
Electrical Limited (BHEL), Trichy in 1970 and reached the General Manager level in his 44 years tenure. His areas of
expertise include Materials Management, Commercial, Marketing, Project Management & Manufacturing. He is
persistent towards attracting more customers and develops strategies for promoting GEECO's products.

Mr. V. R. Vijayaprakash - Technology Management Advisor

A Mechanical Engineering graduate with dual Masters from Germany, one in Management & other in
Computational Engineering. He has handled various customers around the globe during his tenure with Bombardier &
CD-adapco. Has been a tremendous contributor to GEECO's success by actively involving in Management, R&D,
Engineering & IT. He is also leading TEFUGEN Technologies Pvt. Ltd., which offers CFD / FEA / IT solutions.
ROTARY AIR PREHEATER
STRENGTH & CAPABILITIES
➔ Supply of Quality Spares for any make and size of Air Preheater up to 1000 MW
➔ Supply of New Air Preheaters
➔
Carrying out CFD / FE Analysis
➔
In-house Research & Development (R&D)
➔ Undertaking Assessment Studies
➔ Undertaking R&M Jobs
➔ Field Engineering Support
➔
Conducting Air Preheater Performance Test

SPARES SUPPLIED BY GEECO

Rotor Assembly / Heating Elements / Baskets / Seals / Housing / Connecting Plate / Sector Plates / Support Bearing / Guide
Bearing / Rotor Drive / Oil Circulation System / Cleaning device / Wash Pipe & Deluge Assembly / Fire Sensing Device / Rotor
Stoppage Alarm.
ENGINEERING CAPABILITIES
➔ Complete In-house design
➔ Development of a validated software program for selection of Air Preheaters
➔ Computerized performance prediction
➔ Analysis & Optimization of flow with the help of advanced CFD techniques
➔ Structural Design & Optimization by Finite Element Analysis

MANUFACTURING CAPABILITIES
➔ Manufacturing Capacity of 1600 MT per month
➔ Concurrently, 4 numbers of bigger size APH 36 VI can be manufactured
➔ Equipped with all the machines required for our In-house machining
ROTARY AIR PREHEATER
NEW AIR PREHEATER
Executed a contract to M/s. Bharat Aluminium Company Ltd., Power Plant – II for the replacement of existing Air Preheaters [size
24VIT] with the New Air Preheaters [2-numbers of size 25.5 VITM 1900 (2100)] including Design, Engineering, Manufacturing, Supply
& Site Supervision for one of their 135 MW unit, to their entire satisfaction. This APH is consistently running with desired parameters.
Contract was awarded and completed for the total supply of New Air Preheaters [Two Numbers of size 27 VIT - 2100] to M/s.
Ansaldo for their Nagai – I Power Plant.

GAS TO GAS HEATER

We have executed a "Major Order" from the leading power producer in India, TATA
Power, for the replacement of existing Gas to Gas Heaters to New Gas to Gas Heaters [1 -
number of size 27 VIM 84”] including Design, Engineering, Manufacturing, Supply & Site
Supervision for their 500 MW Trombay unit.

RENOVATION & MODERNIZATION - ADVANTAGES

➔ Reduced Leakage
➔ Increased Heat Transfer Area
➔ Reduced Differential Pressure across the APH
➔ Assured Highest possible efficiency
➔ Reduced Fuel Quantity
➔ Reduced fan current
➔ Increased Revenue
MAJOR SUCCESSFUL PROJECTS

Hindalco Industries Limited (Renukoot Executed a contract involving Design, Engineering, Manufacturing & Supply including Site
Power Division) Supervision during Erection & Commissioning for Air Preheater with increase in size.

Hindalco Industries Limited (Renusagar Executed a contract for 5 Boilers, involving Design, Engineering, Manufacturing, Supply &
Power Division) Site Supervision for Air Preheater.

Tuticorin Thermal Power Station Contract was executed involving Design & Supply of Complete Support Bearing Assembly
(210MW), TANGEDCO including Erection & Commissioning for Air Preheater.

Talcher Thermal Power Station Executed a contract through M/s. NASL, India, involving Design, Detailed Engineering,
(110MW), NTPC Ltd. Manufacturing & Supply of Air Preheater with Sector Angle Modification.

Tuticorin Thermal Power Station Three contracts for Unit 3, Unit 4 & Unit 5, Converting existing Air Preheater to Modular
(210MW), TANGEDCO Air Preheater with Double Sealing Arrangement was executed.

Mettur Thermal Power Station The existing Air Preheaters were replaced with higher sized Air Preheaters.
(210MW)

National Aluminium Co. Ltd. Replacement of existing Air Preheaters with higher size Air Preheaters to increase the heat
Damanjodi transfer area.

Bharat Petroleum Corporation Ltd. The existing Air Preheaters were replaced with higher sized Air Preheaters.
(Kochi Refinery)
ELECTROSTATIC PRECIPITATOR
ENGINEERING CAPABILITIES
➔ Sizing & Selection of ESP for any type of applications &
for a wide variety of fuels including fossil and biomass
➔ Design & Engineering for both Tumbling Hammer
Rapping Mechanism & Electro Magnetic Impulse Gravity
Impact (EMIGI) Rapping Design
➔ Compliance with stringent emission norms as low as
20mg/Nm3.
➔ Structural frame analysis using FEA
➔ Computational Fluid Dynamics model study

MANUFACTURING CAPABILITIES
➔ Manufacture of ESP Components within our shop floor
➔ International Quality Standards in manufacturing

SPARES SUPPLIED BY GEECO

All types of Emitting Electrodes & Collecting Electrodes / Rapping Shafts / Plain Bearing / Set Ring / Coupling / Firm & loose
type shock bars / Shock pads / Shock Bar guide front & rear / 'U' guide / Inner arm / Outer arm for collecting & Emitting systems / Pin
wheels / Grip couplings / Bush bearing / Gear motor / Rapping timer systems / Heaters for Hoppers, Shaft insulators & Support insulators
/ Thermostats / Ash level indicators / Rapper Coil for EMIGI / Hyplan Boot with SS Clamp / Inlet / Outlet GDs Screen / Screen Tubes /
Conical & Cylindrical support Insulators / Shaft Insulator, Pin Insulator & Bushing Insulator / TR set panel & Accessories / plunger /
Mech. Safety rods / Torque Wrench / Stretching tools / Purge air system.
PROCESS CAPABILITIES
GEECO being an IMS certified company, the following procedures are
adopted as a routine while manufacturing the components of ESP in shop floor and
during installation at sites.
➔ Product - specific Quality Control procedures
➔ Standard Welding & Painting procedures
➔ Standard Quality Plans
➔ Field Quality Control procedures
COMPUTATIONAL FLUID DYNAMICS
Duct System
With the remarkable progress achieved in the field of computer technology,
Computational Fluid Dynamics (CFD) would be a useful low-cost optimization tool for
internal flows through duct / pipe networks. Using CFD models, pressure, velocity &
temperature fields are visualized through the existing component for a particular operating
point. As a result of sudden geometry changes like sharp bends & abrupt expansion /
contraction in the existing geometry, problematic areas such as flow recirculation & non-
uniform velocity zones that contribute to the excessive pressure drop are identified.
Multiple optimization cycles are carried out in order to arrive at a final optimized design,
which has the minimum possible pressure drop for the duct system & uniform velocity
Initial Design
distribution. The Boundary Conditions are arrived by manually testing the flow onsite.
The Streamlines depict the flow inside the Electrostatic Precipitator & the Flue gas
outlet duct vividly showcases the reduction in wall pressure between the initial &
optimized designs.
Velocity Magnitude (m/s)
18

16

14

13

11

5 Optimized Design
4
Pressure (Pa)
2
-1900 -1860 -1820 -1780 -1740 -1700 -1660 -1620 -1580 -1540 -1500
0

Electrostatic Precipitator
 Transient Analysis of various Air Preheater Heating Element profiles was carried out in a test
environment to provide a detailed comparison of Temperature, Pressure, Velocity, Boundary Heat Transfer,
Turbulent Kinetic Energy & Nusselt Number. The results are used to select the most appropriate heating
element profile for the plant operating condition. CFD Analysis is also carried out to study the flow pattern &
establish a uniform flow upstream of the Air Preheater.
The velocity flow streamlines depict the flow behaviour & possible stagnation zones. These zones are
studied for their turbulence characteristics & efforts are taken to minimize flow losses.
Flow through
DU VAR1 PROFILE FNC PROFILE NF6 PROFILE DU VAR2 PROFILE CU PROFILE Air Preheater

Geometries of APH
Heating Elements.

Time Step : 0.2 secs

Unsteady Heat Transfer
Study of APH Heating
Elements.
Temperature Plot.

Time Step : 20 secs

Unsteady Heat Transfer
Study of APH Heating
Elements.
Temperature Plot.

Temperature (C)
30 94 158 222 286 350
FINITE ELEMENT ANALYSIS
Finite Element Analysis, an advanced computational program based on numerical methods for evaluation of structures & system is
used to accurately predict components' response when subjected to thermal & structural loads. It verifies design integrity & identifies
critical location on a component, thereby design improvements can be done before building the component.
FEA is being used extensively at GEECO during the Product Design & Development stage to ensure safe operation and longer life
of the products. It accurately predicts the induced stresses and the resulting deformation during operation of the component and thus paves
way for optimized product design. The picture given below illustrates the FEA process cycle deployed during the design of a typical
bearing housing at GEECO.

2 3
Geometry FEA
Discritization Solver
FEA
Process Cycle
3D CAD
Implementation
Geometry
& Production
1 4
FEA APPLICATIONS

Manufacturing Process Thermal Loading Structural Loading

GEECO uses FEA for various FEA is used for the prediction of stresses Structural loading stresses & deformations
manufacturing process optimization. One & distortions resulting from Thermal on APH & ESP components are predicted
such example is the cold rolling of heating loadings on APH & ESP components. using FEA. Housing, which holds the
elements simulation to optimize the Rotor deformations resulting from thermal weight of the rotor assembly including
process for ensuring best heating elements loads during the APH operation are baskets are simulated for deformation and
profile accuracy during manufacturing. simulated & based on the FEA report, stresses. This helps to ensure safe
The method is applied in modifications are done to the rotor design operation of the components at the Client
➔ Forming Process accordingly. Thermal loadings are also location. Structural analysis is also done
➔ Tool Wear & Tear checked for for
➔ Residual stress ➔ Center Section ➔ Bearing Housing
➔ Weld sequence & Clamping ➔ Rotor ➔ Center Section
➔ Supporting Joints ➔ Seals
➔ Trunnion

Stress (MPa)
0 25 50 75 90
FIELD ENGINEERING SERVICE
CAPABILITIES
➔ Dedicated & Technically competent Engineers
➔ Quick Troubleshooting
➔ Imparting knowledge to the Customer
➔ Fast Response & Customized solutions
➔ Identify even the smallest problem that may lead to performance loss
➔ Suggest performance improvements
➔ Maintain long-term customer relationship
➔ Increase the reliability of operation

SUPPLY / SERVICES RENDERED

➔ Smallest size 15 HSX (Ø 2600mm) to Biggest Size 35 VI (Ø 16400mm)
➔ Horizontal Type
➔ Vertical Type
➔ Rothemuhle Type
➔ From 30 MW to 1000 MW
➔ Any dry type & any capacity of ESP
EXPERT SITE SERVICE
➔ Field Engineering consultancy services for Boilers & Auxiliaries
➔ Site surveys
➔ Inspection & Plant Evaluation
➔ Preventive maintenance & maintenance advice
➔ Support during Annual Overhauling & Unplanned Shutdowns
➔ Performance improvement & combustion optimization
➔ Boiler Tube failure investigation
➔ Replacement & repair recommendations for pressure parts & auxiliaries during overhaul
➔ Recommendations & execution of R & M
➔ Boiler explosion analysis & remedial recommendations
➔ Troubleshooting of Boiler & Auxiliaries

0
TESTING
AIR IN LEAKAGE TEST
The air in leakage test is conducted to ensure that the erection weldments are sound & leak proof.
The purpose of the test is to proactively identify the leakage sources & to arrest them appropriately with
suitable welding, thereby reducing the possible leakages when ESP is in operation. This is done as a part
of erection activity before insulation work is taken up.GEECO possesses necessary expertise & has
advanced test instrumentation consisting of venturi meter with blower & U tube manometers to assess the
leakage constants of the precipitator casing & quantify the leakages.
GD TEST
As the ESP cross section area is huge & the gas velocity is reduced from 15 m/s to less than 1
m/s, the flue gas flow across the cross section should be uniform so as to achieve effective utilization of the
collecting area provided for collection of dust particles. GD test is mandatorily done in all precipitators as part
of precommissioning test. GD test is carried out conforming to domestic & ICAC standards by GEECO's
experienced team using equipments like vane type digital anemometer suitable for measuring velocities from
0.3 m/s to 40 m/s.
VALIDATION TEST
Pre-tests are conducted for all layouts connecting APH with ESP & ESP with ID Fan
systems to get required inputs for CFD optimizations. The purpose is to ensure uniform flow
distribution across the cross section in the medium through which fluid is allowed to flow. This
distribution also aids in reducing pressure drop across the equipment by which it operates at its
best efficiency. This is also further ascertained by conducting post-tests with pitot tubes,
micromanometers & vane type anemometers by doing grid measurements.
AIR LOAD TEST
In ESP, upon completion of all erection activities, air as a medium of load, the voltage is let through the emitting & collecting
electrode system gradually. This is to ascertain the healthiness of the particular field. The current is increased in steps of 50 mA till the
field receives the full power & the equipment (TR. Set) reaches its full load capacity. During the gradual increase of current &
corresponding voltage, there should not be any sparking. During air load test, if the voltages are nearer to the RMS voltage of full
capacity, then it can be concluded that the field is healthy. This procedure shall be repeated for other fields of the ESP.
PERFORMANCE TESTING
➔ GEECO is equipped with test equipments required for conducting full scale performance testing
conforming to Domestic Standard (IS11255) & International Standard (EPA Method 17)
➔ Involves velocity measurement & particulate sampling which is done at iso-kinetic conditions
➔ Possesses instruments such us Air-neutronics to assess the pressure drop across the System
➔ Possesses wattmeter for conducting power measurement
CAPABILITIES OF TESTING GROUP
Having experience of over three decades in Engineering, Manufacturing, Field support service, we are specialized in all types of
combustion including Oil, Gas, PF & bed firing systems. GEECO conducts Performance testing, Residual Life Assessment study, Tube
failure analysis during commissioning, execution of R&M & regular operation of Boiler & Auxiliaries.
Performance Guarantee testing is done as per performance test codes & standards of Boilers & Auxiliaries to prove the contractual
guarantee. Performance Evaluation testing of Boilers & Auxiliaries (APH, ESP & Pulverisers) is done to assess the present condition &
also to meet out the influences of different coal properties for further improvements.
Other testings include Air / Gas flow equalising test, Cold air velocity test for boiler, Clean / dirty air flow test for pulverisers.
TRAINING
TRAINING OFFERED TO
➔ Engineering & Management Professionals
➔ Power Plant O&M Engineers
➔ Newly recruited Power Plant Engineers
➔ Power Sector Consultants
➔ Technicians & Operators of Power Plant
➔ Students

AREAS OF TRAINING

Air Preheater
➔ Principle of Working
➔ Construction & Features
➔ Improvements
➔ Problems & Solutions
➔ Case Studies
➔ O&M Practices
Electrostatic Precipitator
➔ Principle of Working
➔ Construction & Features
➔ Developments
➔ Erection Methods
➔ O&M Practices

Computational Fluid Dynamics

➔ CFD – An overview
➔ Application of CFD in Power Plants
➔ Case Studies

Boiler Performance
➔ General Boiler Performance
➔ Combustion Optimization
RESEARCH AND DEVELOPMENT
CAPABILITIES
➔ Develop new Product & Technology to meet customer needs Y
Hot
➔ In-depth product / process knowledge & expertise End

➔ Optimize operating conditions to significantly improve

Performance & Thermal Efficiency
➔ Research to minimize leakage & enhance the life of seals
➔ Development of new element profiles for high heat recovery
& easy cleanability
➔ CFD, FEA & Numerical Modeling to understand & improve
product functioning

SA X
Cold End
PA
APH Simulator: Predicted Fluid
GAS Temperatures
as a function of APH Height
CORE ACTIVITIES
➔ Comparison & development of heating element profiles for efficient heat recovery, lower pressure drop & easy cleanability
➔ Development of Diagnostic tool to continuously monitor the health of APH
➔ Identification of suitable geometry & wear-resistant material for seals to minimize indirect leakage
➔ Optimization, Automation & Modification of cold rolling process of heating elements
➔ Criterion for Basket Replacement, fouling & cleanability of heating elements
➔ Installation of Guide Vanes at inlet & outlet ducts for uniform fluid flow through APH
➔ Development of APH Simulator to predict transient steady-state metal temperature
➔ Prediction of thermal deformation of rotor using FEA & numerical methods
➔ Surface Modification of Hot End Elements for Erosion Resistance
➔ Improvement of Soot Blowing Process

R & D - ADVANTAGES
➔ Deeper Insight
➔ Innovative Design
➔ Optimized Solution
➔ Cost Saving
➔ Better Reliability
➔ Continual Improvement

Head Office (India)
GEECO Enercon Pvt. Limited,
D/C 6, SIDCO Industrial Estate,
Thuvakudy,
Tiruchirapalli - 620 015.
Tamil Nadu, India.
Tel : +91 431 2501239
+91 431 2501312
E-mail : geeco@geeco.in
Fax : +91 431 2500705
DESIGN | ENGINEERING | RESEARCH & DEVELOPMENT | MANUFACTURING | TESTING | ERECTION | SERVICE
CONTACT DETAILS
Factory (India)
GEECO Enercon Pvt. Limited,
103, Muthandipatti (Post),
Pudupatti, Sengipatti (Via),
Thanjavur - 613 402.
Tamil Nadu, India.
www.geeco.in
Office (Malaysia)
GEECO Power Mech SDN BHD,
No.50-1 A, Pusat Perniagann Barat,
Jalan Raya Barat, 41100 Klang,
Selangor Darul Ehsan, Malaysia.
Tel : +603 33744306
E-mail : geeco.my@geeco.in