PROBLEMS FACED & ACTION TAKEN EROSION Problem :

High pressure air mixes with ash and leaks to low pressure side leads to erosion of static seals, radial seals etc.

Action Taken :
Reverse rotation of APH ( Gas to SA to PA ) Additional layer of by-pass seal near sector plate. Kao-wool packing carried out at the inboard sector plates, static seals and ASP TO SP seal. Seal thickness increased (1.6 mm to 2.5 mm) Seal tabs introduced in Axial & Radial seals.

PROBLEMS FACED & ACTION TAKEN

Problem : High Leakage of Air to Gas path Action Taken :

1. Double sealing arrangement introduced in Khaperkheda, Simhadri & Talcher projects etc. 2. PG tests conducted in various R&M projects and results found encouraging. 2. Before PG tests, APHs are attended for seal adjustments, issued Technical Directive regarding Leakage & necessary operations.

PROBLEMS FACED & ACTION TAKEN

FIRE During start up with oil firing, improper combustion may result in the accumulation of condensed oil vapours and un burnt carbon on Air preheater surfaces by carry over from furnace. PREVENTIVE Soot blower should be in operation. Fire sensing device ( Thermocouples ) to be commissioned. Oil carry over detector to be commissioned and monitored during oil firing. Heat rate of firing should be controlled.

PROBLEMS FACED & ACTION TAKEN

BEARING FAILURES Oil contamination Starvation of oil Mis-alignment Lack of maintenance Higher operating oil temperature Foreign materials in bearing

Action Taken : Technical directive issued.

PROBLEMS FACED & ACTION TAKEN

PROBLEMS IN DRIVE UNIT ASSY ;

Over running clutch failure

Over heating Sealed bearings No oil circulation

Action Taken :
New design evolved eliminating Overrunning clutches in main and stand by electric drives.

Vibration of drive unit

Misalignment. Failure of bearings in motor, gear box etc

PROBLEMS FACED & ACTION TAKEN

CLEANING DEVICE ASSY : Drive unit failure

Chandrapur unit-7 SAPH failed due to closure of soot blower drain valve. - The drain valve to be kept crack open - Technical directive issued. Nozzle erosion - Parking position to be at inboard end.

PROBLEMS FACED & ACTION TAKEN

FIRE SENSING DEVICE ASSY :

Failure of Thermocouples: Design changed to individual thermocouples. Failure of scanners: Local Temperature scanners eliminated and directly connected to DDCMIS for better operation from Khaperkheda project onwards.

OPERATION PROBLEMS HIGHER PRESSURE DROP ACROSS APH 1. Choking of heating elements 2. Higher flows 3. Eroded/damaged heating elements obstructs flow path. 4. Improper steam parameters and eroded nozzles and steam pipes. 5. Low cold end average temperature.

OPERATION PROBLEMS

HIGH GAS LEAVING TEMPERATURES

1. More gas flow with high inlet temperature temp. 2. Less air flow and high inlet temp. 3. Choking of SCAPH less air flow 4. Choking of heating elements 5. Erosion & corrosion of heating elements

OPERATION PROBLEMS
CHOKING OF HEATING ELEMENTS : 1. Improper evacuation of economiser hopper. 2. Corrosion of heating elements 3. Boiler slagging 4. Improper drying of heating elements after water washing. 5. Excess air operation. 6. Leak in SCAPH and water washing & deluge line, soot blower passing etc. 7. Frequent water washing of heating elements and improper drying. 8. Proper exit gas temperature with respect to % of sulphur in fuel.

OPERATION PROBLEMS
CORROSION OF COLD END HEATING ELEMENTS: 1. 2. 3. 4. 5. 6. 7. High sulphur content in fuel Low cold end average temperature Low load operation for long periods Improper firing procedure Boiler slagging Excess air Leak in SCAPH and water washing & deluge line, soot blower passing etc 8. Frequent water washing of elements and improper drying.

TROUBLE SHOOTING

Sl.

FAULT

PROBABLE CAUSES

REMEDY

01

Excessive leak between gas and air side

Damaged / worn out seals. - Due to high gas inlet temp. Less air flow. Warped rotor due to excessive expansion.

Inspect all seals and adjust or replace if necessary.

02.

Excessive from rotor

noise

Reduce boiler load or admit more cold air.

Foreign rotor.

object

in

Stop rotor and visually inspect it

Replace Bearings.

Bad bearings

03.

Rotor does not turn

Defective drive unit

Ensure power is available to drive unit Check pinion gear and pin rack. Inspect rotor and remove any foreign object. Lubricate drive unit components Adjust drive unit to proper clearances.

Foreign object in rotor 04 Drive overheats unit Inadequate lubrication in drive unit. Pinion gear and pin rack meshing too hard due to expansion Hard rubbing seals Bad bearings in gear reducer.

Adjust seals *
Change the bearings.

* Slight overheating due to hard rubbing seals may be relieved when the Air preheater reaches normal running temperature or after the seals have worn in properly.

05

Noisy Bearings

Inadequate lubrication

Check that oil is flowing through Flow indicator and check oil line, if necessary Check that adequate water flow is going into oil cooler Replace oil with proper type of oil. Insulate properly.

06

Oil temperature too high

Insufficient cooling

Improper oil viscosity being used. Absorption of radiation heat due to improper insulation. 07. Circulating foamy oil Air leak into the oil system

Check for an air leak on the suction side of the oil system.

08. 09.

Low oil level Soot blower not functioning

Leak in oil system Power failure

Locate and arrest the leak. Check electrical connection. Check the speed reducer moveable parts for binding.

Swivel header travel incorrect. Incorrect pressure 10. Excessive pressure drop through gas & air sides steam

Adjust travel of nozzle pipe. Ensure adequate steam supply is available. Check DA head valve.

Badly fouled heating elements. - due to improper combustion. Excessive plugging.

Thinned down and damaged elements

Operate soot blower and check soot blower steam for proper pr. and temperature. Investigate & remeditate the cause. If soot blower is not effective, heater can be isolated and water washed off load (in worst case), remove the basket and clean them outside. Rectify and replace the element baskets.

11.

Variation (periodic kick) in the main drive ammeter current

Excessive rubbing of some seals.

Faulty bearings

Locate faulty seals and replace.

Rectify or replace the bearings.

12.

Abnormal increase in the temperature

Starting up of fire inside the Air preheater

Immediately isolate air heater and check for fire and admit large quantity of water. CO2 foam, steam should not be used.

13.

Increase in gas outlet temp. and steady fall of air outlet temp.

Air preheater stalled.

Isolate Air pre heater and check for troubles in the drive system.

Heating elements plugged

Clean heating elements.

14.

Excessive pressure build up by Lub oil pump.

Oil filter chocked

Clean or replace the cartridge.

IMPROVEMENTS REQUIRED - INSTALLATION

1. 2. 3. 4. 5. 6. 7. Storage of APH components. Maintenance of stored components. Support bearing - oil contamination. Improper locking of shim type sector plate adjusters. Welding of drive panel before final alignment Insulation of primary centre section sector plate adjusters. Ensure free movement of hot end sector plates after static seal welding to avoid guide bearing failures. 8. Check the main drive motor alignment with gear box and correct if necessary before trial operation.

IMPROVEMENTS REQUIRED - COMMISSIONING

Before light up: Commission Cleaning device assy, oil carry over probe, fire sensing device, RSA & wash pipe assy. Maintain gas outlet tempr is same in both APHs (with in 10 C ) If one APH is used out of two, the other APH should be kept in rotation or should be blanked properly to avoid fire. Ash accumulation over guide bearing assy, soot blower assy & LOPs must be avoided. Ensure clean dry air to Air motor without moisture. Keep the air motor in working condition by operating 5 minutes in a day.

IMPROVEMENTS REQUIRED - COMMISSIONING

1.

Lub oil pumps should not be started when the lub oil temperature is less than 40 c to avoid pump oil seal failure. Water washing is to be done during shutdown when the gas inlet temperature is 100 c. Do not water wash APH just before light up since proper drying is not possible which may lead to more unburnt deposition which in turn cause APH fire.

1.

IMPORTANT INSTRUCTIONS - PRECAUTIONS

1. Always ensure proper storage and handling of components 2. Airpreheater can be fast erected if a proper sequence of erection followed. 3. Extra care taken during erection will ensure trouble free operation. 4. Refer to Airpreheater Engineering / BHEL / Ranipet for any doubts / deviations in the drgs / Erection manuals. 5. Ensure all erection welding is done by a qualified welder. 6. Check all components for defects, damages and dimensional deviations before erection and correct them. 7. Tonnage and quality of erection should go hand in hand. 8. Inspect all weld joints for defects and rectify them to avoid leakage of air and seepage of water. 9. Overlooking of minor details of drawings will lead to major rework. 10. Never erect a damaged component 11. Ensure proper earthing to rotor while doing any welding in rotor.

IMPORTANT INSTRUCTIONS - DO'S

1. 2. 3. Plan in advance the sequence of erection. Keep the necessary tools and tackles ready before start of erection. Contact the Airpreheater engineering / BAP / Ranipet if any deviation or rectification is to be made. 4. Apply rust preventive oil to protect components from rusting due to long storage and bad weather. 5. Store the heating elements covered with tarpaulin and ensure cover sheets even after installation into the rotor. 6. Maintain the required accuracy in erection, which leads for a satisfactory operation. 7. Tighten bolts to the required torque. 8. Fill the bearings with specified oil or equivalent even during erection. 9. Rotate the Airpreheater in the correct direction of rotation. 10. Keep a record of the readings in the check sheets which shall be despatched for the reference of Airpreheater Engineering / BAP / Ranipet. 11. Seal weld outside and inside for rotor housing panels, connecting plates (hot and cold) to housing panels, connecting plates (hot and cold) to air and gas ducts.

IMPORTANT INSTRUCTIONS - DON'TS

1. 2. 3. 4. 5. Do not mix up items belonging to different Airpreheaters. Do not use shop lugs for lifting components / assemblies. Do not support rotor on hot end connecting plate while lifting. Do not carry out the bearing assemblies in open, dusty atmosphere. Do not spoil the seal leaf by standing on them, by any other external load or interference with foreign material or by wrong direction of rotation. Do not allow any foreign particle such as electrode bits, slag wool etc enter into heat transfer elements during erection. Do not carry out final welds before final alignments, checks etc. Do not spoil the seal straight edge during trail run. Do not start Airpreheater without filling with specified lubricants during erection check up. Do not operate air motor without filter lubricator during trial run.

6. 7. 8. 9. 10.

DAILY CHECK
Oil levels in : Support bearing, Guide bearing, Main drive gear reducer & Air line lubricator

For any unusual noise in : Rotor , Rotor main drive bearings, Drive motor, Main gear reducer, Cleaning device during operation & Oil circulation systems
For cleanliness near : Rotor drive unit, Rotor main bearings, Cleaning device & Oil circulation system Instruments for proper working : Bearing lube oil thermometers, Bearing lube oil pressure gauges , Thermocouples if provided in bearings for alarm or remote indication. Air inlet and outlet, gas inlet and outlet temperature measuring instruments. Manometers for measuring pressure drop across air preheater for gas and air flows. The condition of cold end elements