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Heater
25 October 2009
MITSUBISHI HEAVY INDUSTRIES, LTD.
NAGASAKI SHIPYARD & MACHINARY WORKS
Basic of Boiler
PAGE 2
Part.1
Basic of Boiler
PAGE 3
Agenda
1st topic 2nd topic Company Introduction General Explanation of Ljungstrom Regenerative Air Heater Heating element Page 5
Page 8
3rd topic
Page 13
4th topic
Sealing System
Page 18
5th topic
Page 21
Basic of Boiler
PAGE 4
Agenda
1st topic 2nd topic Company Introduction General Explanation of Ljungstrom Regenerative Air Heater Heating element Page 5
Page 8
3rd topic
Page 13
4th topic
Sealing System
Page 18
5th topic
Page 21
Basic of Boiler
PAGE 5
Basic of Boiler
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Company Introduction
ALSTOM Ljungstrom Group
APER APER GmbH GmbH Div. Div. Air Air Preheater Preheater Europe Europe Alstom Alstom KK KK EER EER Asia Asia Air Air Preheater Preheater Company Company North North America America
Bammental, Germany Shanghai, China Osaka, Japan (NK) (CNEER) Kobe, Japan Concordia, KS Shanghai, China (CNASAEER) Wellsville, NY (Headquarters)
Basic of Boiler
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Agenda
1st topic 2nd topic Company Introduction General Explanation of Ljungstrom Regenerative Air Heater Heating element Page 5
Page 8
3rd topic
Page 13
4th topic
Sealing System
Page 18
5th topic
Page 21
Basic of Boiler
PAGE 8
AH
EP STACK
SAH
FDF
Basic of Boiler
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Cold Side
Cold Side
Air
Gas
Basic of Boiler
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Basic of Boiler
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General Explanation of Ljungstrom Air Heater Explanation of Ljungstrom Air Heater type
Ex.
26 -VI- 1325
Element Total Height (mm) Flow Type: V, VI=Vertical shaft, H=Horizontal shaft
Basic of Boiler
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Agenda
1st topic 2nd topic Company Introduction General Explanation of Ljungstrom Regenerative Air Heater Heating element Page 5
Page 8
3rd topic
Page 13
4th topic
Sealing System
Page 18
5th topic
Page 21
Basic of Boiler
PAGE 13
Heating Element
Explanation of where the HE are installed
NF DUNTM
Basic of Boiler
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Heating Element
Heating Element Spec. of AH for Shuqaiq-2
Layer Depth (mm) Type Thickness (mm) Material
Hot
1025
DUN
0.6
Mild steel
Cold
300
NF
1.2
CRLS*
Basic of Boiler
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Heating Element
Element performance characteristic tendency
Pressure drop
DUNTM DU
NF
Thermal efficiency
Basic of Boiler
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Plant name
Blue Waters Unit 1&2 Carlos Manuel De Cespedes Unit No. 4 Cairo West Unit 7&8 Shin Onoda Unit1&2 Mizue Unit1 IPP Aichi Unit3 Mizushima Unit3 Chiba Plant CBL B15 Hitachi-naka Unit1 Tanjung Bin, Johor Jimah Tula Power Plant Unit5 Mindanao Seraya P.S. Unit1~3 Lin-Yuang EVN O MON
Capacity
226MW 158 MW 350MW 500MW 185MW --450T/H 250t/h 1000MW 700MWx3 700MWx2 300MW 210MW 250MWx3 --300MW
Fuel
Coal Oil N.Gas&Oil Coal VR&Gas VR Oil Oil & Gas Coal Coal Coal Oil Coal Oil Oil Crude Oil
AH type
30.5-VI-1625 (RT) 24-VIRX-2200 28.5-VIX-2225 30.5-VI-2525(RT) 26.5-VI-1800 28-VIX-1025 23.5-VIR-1350 23-HRX-1250 33.5-VI-2450(RT) 32.5-VI-1900 (RT) 32.5-VI-1900 (RT) 27.5-VIX-1800 27.5-VI-1700(RT) 26-VIX-1950 27-VIX-2150 28-VIX-2400
Basic of Boiler
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Agenda
1st topic 2nd topic Company Introduction General Explanation of Ljungstrom Regenerative Air Heater Heating element Page 5
Page 8
3rd topic
Page 13
4th topic
Sealing System
Page 18
5th topic
Page 21
Basic of Boiler
PAGE 18
Sealing System
Explanation of Leakage
GAS
- Direct leakage W=CA(2g P) SEAL C : Flow coefficient A : Total areas of seal gap (m2) AXIAL 2) g : Gravitational acceleration (m/sSEAL : Specific weight of gas (kg/m3) P: Pressure difference between two flows - Entrained leakage
W= VRPH V : Volume of rotor plenum (m3) RPH: Rotor revolutions per hour
BY-PASS
ENTRAINED LEAKAGE
Axia l seal Axial Leakage plat e RADIAL SEAL SECTOR PLATE
AIR
COLD SIDE
Basic of Boiler
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Sealing System
Rotor Seals (Typical)
POST SEAL (HOT)
BY-PASS SEAL ANGLE BY-PASS SEAL (HOT) T BAR AXIAL SEAL T BAR BY-PASS SEAL (COLD) HOUSING
Basic of Boiler
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Agenda
1st topic 2nd topic Company Introduction General Explanation of Ljungstrom Regenerative Air Heater Heating element Page 5
Page 8
3rd topic
Page 13
4th topic
Sealing System
Page 18
5th topic
Page 21
Basic of Boiler
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Soot Blower
Basic of Boiler
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Basic of Boiler
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Bearing
(Self-aligning roller bearing)
Bearing
(Thrust self-aligning roller bearing)
Basic of Boiler
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Basic of Boiler
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Steam
Type : Half Retractable Type Steam condition (Cold side) Blowing Press. 11.8barg Consumption 1.7ton/hr Electric power : 0.1kw
MHI BUSINESS CONFIDENTIAL
Basic of Boiler
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Detecting sensor : Thermocouple Installation position of Thermocouple : Gas outlet duct : 4 pcs.
Basic of Boiler
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Type : Stationary Multi Nozzle Type (at gas inlet & gas outlet duct) Water Condition Blowing Press. : 4.9barg Consumption : 96ton/hr/each side
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The fire extinguishing device consist of 1 stationary multi nozzle pipe located in the gas inlet duct. The device is used in conjunction with the water washing device. The device is design to emit large amount of water onto a concentrated area of the heating element surface. Type : Stationary Multi Nozzle Type (at gas inlet) Water Condition Blowing Press. : 4.9barg Consumption : 192ton/hr
Basic of Boiler
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Part.2
Basic of Boiler
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Agenda
1st Operation 1-1. Pre start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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Agenda
2nd Maintenance 2-1. Daily inspections 2-2. Periodical Inspections 2-3. Water washing 3rd Safety precautions
Basic of Boiler
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Agenda
1st Operation 1-1. Pre start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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Basic of Boiler
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Basic of Boiler
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Agenda
1st Operation 1-1. Pre Start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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Hot-run adjustment
MHI BUSINESS CONFIDENTIAL
Basic of Boiler
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Agenda
1st Operation 1-1. Pre Start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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1-3.Hot-run adjustment
Instructions
Basic of Boiler
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Agenda
1st Operation 1-1. Pre Start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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1-4.Start-up
Instructions
The following operation sequence should be used to place the air heater into service. Start the air heater's main drive motor before the forced and induced daft fans are started. The rotor must be rotating before emitting hot flue gas through the air heater. B. When firing the boiler on oil, start cold end soot blowing to the air heater continuously during start-up using an auxiliary blowing medium until stable boiler conditions are achieved and the normal soot blowing medium is available. C. Energize the guide bearings oil circulation units. The pump motors will start upon oil temperature rise. D. Start the air heater's auxiliary equipment control system. E. After normal soot blowing medium is available, activate the air heater soot blower A.
Basic of Boiler
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Agenda
1st Operation 1-1. Pre Start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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1-5.Shutting down
Instructions
The following sequence should be used to remove the air heater from service. A. B. C. D. E. Activate the soot blower to remove any deposits which may have accumulated on the heating element surface. Keep the FD & ID fans running during the cleaning operation so that the air heater temperature will decrease more rapidly. Deactivate the air heater soot blowers. De-energize the air heater's auxiliary equipment control system. Keep the rotor turning and the fans operating until the gas inlet temperature at the heater inlet drops below 150C. This will evenly distribute the effects of thermal distortion, over the entire rotor structure. Shut down the FD & ID fans. De-energize the rotor drive unit of the air heater. Close the manual valve to stop compressed air to the auxiliary air drive motor. Deactivate the guide bearing oil circulation units.
F. G. H. I.
Basic of Boiler
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Agenda
1st Operation 1-1. Pre Start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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Trip!!
Instructions ! CAUTION
If operation mode is selected to manual mode, aux. air motor does not start automatically. Operation mode of aux. electric motor should select to AUTO at normal condition.
MHI BUSINESS CONFIDENTIAL
Basic of Boiler
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NOTE: The air heater structure will not experience permanent damage as long as the temperature of the gas entering the air heater does not exceed 480. However, if the rotor cannot be restarted immediately (within approx.15 min), damage to some of the seals and/or sealing plates is likely to occur due to non-uniform thermal expansion of the rotor.
Gas side
Air side
Basic of Boiler
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Agenda
1st Operation 1-1. Pre Start-up checks 1-2. Cold-run inspection 1-3. Hot-run adjustment 1-4. Start-up instructions 1-5. Shutting down instructions 1-6. Rotor stoppage due to motor failure 1-7. Operation procedure of soot blower
Basic of Boiler
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(Standard operation frequency) : once every 8 hours for the cold side, in principle
Basic of Boiler
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Close the drain valve after having discharged the drain of steam
Basic of Boiler
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ENSURE THAT MOISTURE IS NOT ALLOWED TO ENTER THE AIR HEATER THROUGH THE SOOTBLOWING STEAM. WET STEAM USED FOR SOOT BLOWING CAN CAUSE DAMAGE TO THE ROTOR SEALS AND HEATING ELEMENTS.
Basic of Boiler
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Agenda
2nd Maintenance 2-1. Daily inspections 2-2. Periodical Inspections 2-3. Water washing 3rd Safety precautions
Basic of Boiler
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2-1.Daily Inspections
Draft loss and temperature Check and record the draft loss both side and temperature Lubricant oil circulation unit Check the oil pressure and cooling water. Rotor guide&support bearing Check the rotating sound, oil level, gas leak.
Soot blower Check the blowing pressure and leak. Rotor Visual Check the elements and seals condition from observation port. Rotor drive unit Check the temp., vibration, current, oil level.
Basic of Boiler
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Agenda
2nd Maintenance 2-1. Daily inspections 2-2. Periodical Inspections 2-3. Water washing 3rd Safety precautions
Basic of Boiler
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- Repair. - Replacement
Basic of Boiler
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Components parts Rotor drive unit - Speed reducer,Elec. motor Aux motor,Pinion gear Rotor seal - Post seal, Radial seal, Bypass seal, Axial seal, Static seal,Sector plate Soot blower - Speed reducer, Carriage, Feed tube, Lance tube, Wall box, Flanges Stationary water washing Fire extinguishing device - Nozzle,Tube Others - Manholes, doors Observation port
Contents of inspection 1.Overhaul 2.Visual check 3.Measuring 1.Hammering 2.Measuring the thickness 3.Measuring the seal clearance 4.Measuring the degree of parallelism 1.Visual check 2.Overhaul 3.Measuring
- Repair. - Replacement
- Repair. - Replacement
1.Visual check
- Repair. - Replacement
Basic of Boiler
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Agenda
2nd Maintenance 2-1. Daily inspections 2-2. Periodical Inspections 2-3. Water washing 3rd Safety precautions
Basic of Boiler
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Water washing
Water washing
2-3.Water washing
Initial value
Operation
Out of service
Instructions
When pressure drop across the Air heater keeps increasing despite continued use of the soot blower properly, it is a sign that the deposits have coagulated and stick fast to the heating element surface. In general, we recommend that when the pressure drop exceeds the initial value x 1.5times, water washing shall be carried with the Air heater during out of service.
Basic of Boiler
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Finish
8-12hr
- Measuring the pH value of drain water. - Check the supply water pressure. - Check the piping for drain out. - Check the conditions of washing.
Basic of Boiler
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Finish
pH value pH
Washing water Drain water -> pH value decreases due to sulfuric acid
b) Observe the heating elements over entire area to check deposit being removed. If deposits still remain, continue washing. 1) Close water valves 2) Open dampers in the inlet and outlet ducts 3) Remove the illumination light 4) Close drain lines 5) Dry up heating elements(It is desirable to dry by operating the fans) 6) Stop rotor rotation
Complete
MHI BUSINESS CONFIDENTIAL
Basic of Boiler
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DANGER: WASHING OF THE AIR HEATER HEATING ELEMENT SHOULD ONLY BE CARRIED OUT WHEN THE AIR HEATER IS OUT OF SERVICE AND THE GAS SIDE TEMPERATURE IS COOL ENOUGH TO ALLOW MAINTENANCE PERSONNEL ENTRY TO THE AIR HEATER AND ADJACENT DUCTS. HOWEVER, IN NO CASE SHOULD WATER BE EMITTED ONTO THE ROTOR UNTIL THE METAL TEMPERATURE OF THE GAS INLET HEATING ELEMENT IS BELOW 150C. CAUTION: BEFORE AND DURING WATER-WASHING, INSPECT HOPPER DRAINS TO INSURE THAT THE DRAINS ARE NOT PLUGGED. TREMENDOUS QUANTITIES OF WATER MUST EXIT THE DRAINS OR THE CONNECTING DUCTS CAN BECOME FLOODED CAUTION: INSUFFICIENT WATER WASHING HAS ADVERSE EFFECTS TO THE HEATING ELEMENT AND INCOMPLETE DRYING WILL CAUSE RAPID PROGRESSION OF CORROSION AND ACCUMULATION OF DEPOSITS ON THE HEATIMNG ELEMENTS WHEN RETURNING TO SERVICE.
Basic of Boiler
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Agenda
2nd Maintenance 2-1. Daily inspections 2-2. Periodical Inspections 2-3. Water washing 3rd Safety precautions
Basic of Boiler
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! IMPORTANT
For detail operation and maintenance instructions, please refer to:
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CAUTION: WHENEVER WELDING IS DONE ON THE ROTOR POST OR ROTOR ASSEMBLY, THE ROTOR POST (MAIN SHAFT) MUST BE CONNECTED TO AN EARTH GROUND.FAILURE TO PROVIDE A PROPER GROUND MAY RESULT IN DAMAGE TO THE AIR HEATER BEARINGS.
DANGER: NEVER APPROACH OR TOUCH ANY ROTATING PARTS (SHAFTS, COUPLINGS, ETC.) DURING OPERATION. LOOSE CLOTHING CAUGHT IN THESE ROTATING PARTS MAY RESULT IN SEVERE INJURY AND/OR DEATH.
CAUTION: OPERATING THE AIR HEATER WITH GAS INLET TEMPERATURES IN EXCESS TO THE MAXIMUM DESIGN TEMPERATURES CAUSE THE ROTOR SEALS TO CONTACT THE AIR HEATER STRUCTURE AND RESULT IN PREMATURE WEAR OR POSSIBLE PERMANENT DAMAGE TO THE SEALING SYSTEM.
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