H-3 Power Point (Air Heater)

7/28/2019 H-3 Power Point (Air Heater)

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MITSUBISHI HEAVY INDUSTRIES, LTD.NAGASAKI SHIPYARD & MACHINARY WORKS

25 October 2009

SAUDI ARABIASHUQAIQ-2 IWPP PROJECT

COURSE- H-3

ITEM Boiler & auxiliaries

CONTENTS

Heater


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Basic of BoilerBasic of Boiler

Part.1

General

for

LjungstromAir Heater


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1st topic Company Introduction Page 5

2nd topic General Explanation of Ljungstrom Regenerative

Air HeaterPage 8

3rd topic Heating element Page 13

4th topic Sealing System Page 18

5th topic Auxiliary Equipment for SHUQAIQ Page 21

Agenda


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Air HeaterPage 8




Agenda


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Company Introduction

Company History of ALSTOM K.K.

1907 Founded as Gadelius Trading Co.1979 Merged into Flakt AB Sweden

1988 Merged into ABB Group

1999 Jointed with ALSTOM- formed

ABB ALSTOM Power2000 Transferred to ALSTOM Group

2007 100thAnniversary

Long Presence in JapanLong Presence in Japan


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Company Introduction

ALSTOM Ljungstrom Group

Air Preheater Company

North America

Air Preheater Company

North America

Alstom KK EER

Asia

Alstom KK EER

Asia

APER GmbH Div. Air

Preheater Europe

APER GmbH Div. Air

Preheater Europe

Bammental,

Germany

Kobe, Japan

Wellsville, NY

(Headquarters)Osaka, Japan (NK)

Vinhedo,

Brazil

Concordia, KS

Engineering

Facilities

Manufacturing

Facilities

Shanghai, China

(CNEER)

Shanghai, China

(CNASAEER)


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Air HeaterPage 8




Agenda


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AH

Boiler

FDF

EP

STACK

Function of LjungstromAir Heater

General Explanation of Ljungstrom

AirHeater

DeDe--SOxSOx

SystemSystem

SAH


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HotSide

Cold

Side

General Explanation of Ljungstrom

Air HeaterAir and Gas Flows

HotSide

Cold

Side

Air

AirGas

Gas


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General Explanation of LjungstromAir

Heater Construction of LjungstromAir Heater

Heating Element

Rotor Drive Unit

Guide Bearing

Housing Panel

Corner Duct

Pin Rack

Center Section

Soot Blower

Radial Seal

Bypass Seal

Axial Seal

RotorDiaphragm

Stay Plate


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Ex.

26 -VI- 1325

Element Total Height (mm)

Flow Type: V, VI=Vertical shaft, H=Horizontal shaft

AH Nominal Size: Related to Rotor Diameter

General Explanation of LjungstromAir

HeaterExplanation of LjungstromAir Heater type


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Air HeaterPage 8




Agenda


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Heating Element

Explanation of where the HE are installed

Heating

ElementDiaphragm

Stay Plate

DUNDUNTMTMNFNF


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CRLS*1.2NF300Cold

Mild steel0.6DUN1025Hot

MaterialThickness

(mm)

TypeDepth

(mm)

Layer

* CRLS : Corrosion Resistant Low-alloy

Steel

Heating ElementHeating Element Spec. of AH for Shuqaiq-2


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Pressure

Pressured

rop

d

rop

Thermal efficiencyThermal efficiency

NFNF

DUNDUNTMTM

DUDU

Heating Element

Element performance characteristic tendency


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28-VIX-2400Crude Oil300MWEVN O MONVietnam

27-VIX-2150Oil---Lin-YuangChinese Petrochemical co. (Taiwan)

26-VIX-1950Oil250MWx3Seraya P.S. Unit1~3Power Seraya Ltd. (Singapore)

27.5-VI-1700(RT)Coal210MWMindanaoState Power Development Corp.(Philippines)

27.5-VIX-1800Oil300MWTula Power Plant Unit5Comision Federal De Electricida

(Mexico)

32.5-VI-1900 (RT)Coal700MWx2JimahSKS Power RDN.BHD. (Malaysia)

32.5-VI-1900 (RT)Coal700MWx3Tanjung Bin, JohorSKS Power RDN.BHD. (Malaysia)

33.5-VI-2450(RT)Coal1000MWHitachi-naka Unit1Tokyo Electric Power Co., Ltd. (Japan)

23-HRX-1250Oil & Gas250t/hChiba Plant CBL B15Sumitomo Chemiccal Co. (Japan)

23.5-VIR-1350Oil450T/HMizushima Unit3Mitsubishi Chemical Co. (Japan)

28-VIX-1025VR---Aichi Unit3Idemitsu Kosan (Japan)

26.5-VI-1800VR&Gas185MWMizue Unit1 IPPGenex Co., Ltd. (Japan)

30.5-VI-2525(RT)Coal500MWShin Onoda Unit1&2Chugoku Electric Power Co., Ltd.

(Japan)

28.5-VIX-2225N.Gas&Oil350MWCairo West Unit 7&8Cairo Electricity Production Corp.(Egypt)

24-VIRX-2200Oil158 MWCarlos Manuel De Cespedes

Unit No. 4Cuba

30.5-VI-1625 (RT)Coal226MWBlue Waters Unit 1&2Griffin Energy Pty Ltd. (Australia)

AH typeFuelCapacityPlant nameCompany name

Reference List - DUNTM Heating element (excerpted)


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2nd topic General Explanation of Ljungstrom RegenerativeAir Heater

Page 8




Agenda


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W= VRPHV : Volume of rotor plenum (m3)

RPH: Rotor revolutions per hour

GAS

AXIALSEAL

BY-PASSSEAL

AIR

Radial Leakage

Axial Leakage

HOTSIDE

SIDECOLD

SECTORPLATE

RADIAL SEAL

SECTORPLATE

- Direct leakage

- Entrained leakage

Axial

seal

plat

e

ENTRAINED LEAKAGE

Sealing System

W=CA(2gP)C : Flow coefficient

A : Total areas of seal gap (m2)

g : Gravitational acceleration (m/s2

) : Specific weight of gas (kg/m3)P: Pressure difference between two

flows

Explanation of Leakage


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BY-PASS SEAL

ANGLE

BY-PASS SEAL

(HOT)

T BAR

AXIAL SEAL

BY-PASS SEAL

(COLD)

HOLDING

STRIPPOST SEAL

(COLD)

ROTOR POST

RADIAL SEAL

(HOT)

HOLDINGSTRIP

ROTOR DIAPHRAGM

POST SEAL

(HOT)

SECTORPLATE (HOT)

HOUSING

Sealing System

Rotor Seals (Typical)

T BAR

RADIAL

SEAL

(COLD)


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2nd topic General Explanation of Ljungstrom RegenerativeAir Heater

Page 8




Agenda


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Rotor Drive Unit

Bearing

Lubricant Oil Circulation Unit

Sootblower

Fire Detecting Device

Water Washing Device

Fire Extinguishing Device (for Hotside)

Auxiliary Equipment of AH for SHUQAIQ

Rotor Drive Unit

Guide Bearing

Soot Blower

Lubricant Oil Circulation Unit

Fire Detecting Device

Water Washing Device


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Auxiliary Equipment for SHUQAIQ

Rotor Drive UnitRotor Drive Unit (RDU) consists of speed reducer, main electric motor and

auxiliary air motor. A pinion gear is mounted to the output shaft which engages a

pin rack. The rotor assembly, containing the heating elements, is rotated by this

RDU through the air and gas streams at approximately 1.8 RPM. The air motor,

coupled to the main electric motor, is used as auxiliary motor for emergency and

maintenance operation.

Electricmotor

Speed

reducer

Air motor

(Utility)

Electric power : 7.5kw

Compressed air : 4.1barg

4.0m3/min.Pinion gearcover


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Auxiliary Equipment for SHUQAIQRotor Bearing

Guide Bearing : #23052

The guide bearing is responsible

for supporting the redial loads at

the top of the air heater

Bearing

(Self-aligning

roller

bearing)

Bearing

(Thrust self-aligning

roller bearing)

Support Bearing : #29456

The air heater rotor is supported

by the support bearing at the

bottom of the air heater


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Auxiliary Equipment for

SHUQAIQLubricant Oil Circulation Unit (for Guide Bearing)

(Utility)

Electric power : 0.75kwCooling water : 2.9barg, 3.6ton/hr

The purpose of this unit is to circulate the

lubricant oil for cooling when the

temperature of the oil in the guide bearinghousing reaches 50 degree Celsius.


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Type : Half Retractable Type

Steam condition (Cold side)

Blowing Press.

11.8barg

Consumption

1.7ton/hr

Electric power : 0.1kw

Cleaning Heating element surface by superheated

steam

Heating element

Steam


SHUQAIQSootblower (for Cold side)


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SHUQAIQ Fire Detecting System (FDS)

Detecting sensor : Thermocouple

Installation position of

Thermocouple :

Gas outlet duct : 4 pcs.

The purpose of the system is to monitorthe gas temperature leaving the air heater

and detect the fire at early stage. If hot

spot become present in the rotor, the gas

temperature will increase unexpectedly.


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SHUQAIQ

Type : Stationary Multi Nozzle Type

(at gas inlet & gas outlet duct)

Water Condition

Blowing Press. : 4.9barg

Consumption : 96ton/hr/each side

WaterWashing Device


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SHUQAIQ

Type : Stationary Multi NozzleType

(at gas inlet)

Water ConditionBlowing Press. : 4.9barg

Consumption : 192ton/hr

Fire Extinguishing Device (for Hot side)

The fire extinguishing device consist of 1

stationary multi nozzle pipe located in thegas 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.

Fire extinguishingdevice

Socket

Nozzle

Washing

Tube


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Operation and Maintenancefor

Ljungstrom Air Heater

Part.2


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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

1st Operation

Agenda


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2-1. Daily inspections

2-2. Periodical Inspections

2nd Maintenance

3rd Safety precautions

2-3. Water washing

Agenda


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1-1. Pre start-up checks







1st Operation

Agenda

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1-1.Pre start-up checks

To determine whether or not the Air Hater is ready for service,a complete inspection of the Air Heater and its auxiliary equipment

is required. The operator should be concerned with all components

being installed correctly, clean, and correctly lubricated.

Prior to start-up, the operator must pay particular attention to the

following areas to ensure safe and efficient operation of the AirHeater.

Instructions

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1-1.Pre start-up checks

FINAL CHECK-OUT

LUBRICATION

ROTOR INSPECTION

ROTOR SEALS

GUARDS AND COVERS

PLANT UTILITIES

ELECTRICAL CONNECTIONS AND CONTROL SYSTEM

ROTOR ROTATION

SOOT BLOWER STEAM PIPING

Instructions

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1-1. Pre Start-up checks







1st Operation

Agenda

PAGE 36B i f B ilB i f B il


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1-2.Cold running test

Hot-run adjustment

Confirm unobstructed operation by air motor drive

Continuous running test

Back-up test

- Start the auxiliary air motor by opening the hand valve.

- Observe the rotor for unobstructed operation.Finish

Fin ish

- Energize the main drive motor and run the rotor

- Check the motor temp.,

abnormal sound,vibration...etc.

- Test the automatic operation of the air motor solenoid valve

upon power loss to the main drive motor.Finish

Instructions


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1-3.Hot-run adjustment

NOTE: This adjustment should be done at 100%-load during hot-run test

b. Soot blower blowing pressure adjustment

(1) Blowing pressure: 11.8 barg (Cold Side)

Instructions



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1st Operation

Agenda



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1-4.Start-up

The following operation sequence should be used to place the air heater

into service.

A. Start the air heater's main drive motorbefore 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 stableboiler 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 sootblower

Instructions



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1st Operation

Agenda



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1-5.Shutting down

The following sequence should be used to remove the air heater from service.

A. Activate the soot blower to remove any deposits which may have

accumulated on the heating element surface.

B. Keep the FD & ID fans running during the cleaning operation so that the

air heater temperature will decrease more rapidly.

C. Deactivate the air heater soot blowers.

D. De-energize the air heater's auxiliary equipment control system.

E. Keep the rotor turning and the fans operating until the gas inlet temperatureat the heater inlet drops below 150C.This will evenly distribute the effects of thermal distortion, over the entire

rotor structure.

F. Shut down the FD & ID fans.

G. De-energize the rotor drive unit of the air heater.H. Close the manual valve to stop compressed air to the auxiliary air drive motor.

I. Deactivate the guide bearing oil circulation units.

Instructions



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1st Operation

Agenda



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1-6.Rotor stoppage due to motor failure

! CAUTION

Trip!!

Instructions

Back-up startAir Motor

(Aux. Drive)

Elec. Motor

(Main Drive)

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.

Over

running

clutch(ORC)



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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.

Non-uniform

thermal expansion

of the rotor

Air side

Gas side



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1st Operation

Agenda



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1-7.Operation procedure of Soot Blower

Frequency and occasion for soot blowing

(Standard operation frequency)

: once every 8 hours

for the cold side, in principle


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2nd Maintenance


2-3. Water washing

Agenda



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2-1.Daily Inspections

Rotor guide&support bearing

Check the rotating sound,oil level, gas leak.

Draft loss and temperatureCheck and record the draft loss

both side and temperature

Rotor drive unit

Check the temp., vibration,current, oil level.

Soot blower

Check the blowingpressure and leak.

Rotor

Visual Check the elementsand seals condition from

observation port.

Lubricant oil circulation unit

Check the oil pressure andcooling water.



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2nd Maintenance


2-3. Water washing

Agenda



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- Repair.

- Replacement

1.Visual check

2.Measuring the Weight, thicknessHeating element

- Repair

- Replacement

1.Thickness measurement

2.Visual check

AH proper

- Cold side partition plate,

Cold side housing panel,

...etc

- Repair.

- Replacement

1.Overhaul2.Visual check

3.Leak test

4.Functional test

Lubrication oil circulationunit

- Oil pump,filter,cooler,

Safety valve

- Repair.

- Replacement.1.Hammering

2.Visual check

Rotor trunnion

- Trunnion bolts,Locking bar

- Repair.

- Replacement.

1.Visual check

2.Measuring the thickness

3.Liquid penetrate testing

Rotor proper

- Rotor post,Rotor,Pin rack

T-bar

- Repair.- Replacement

1.Visual check

2.Hand check

3.Oil sampling

Bearings

- Support,Guide,

Air seal cover

Contents of inspection Measures at abnormalComponents parts

2-2.Periodical inspections (Summary)



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- Repair.

- Replacement

1.Overhaul

2.Visual check

3.Measuring

Rotor drive unit

- Speed reducer,Elec. motor

Aux motor,Pinion gear

- Repair.

- Replacement

1.Visual check

2.Measuring the thickness

Stationary water washing

Fire extinguishing device

- Nozzle,Tube

- Repair.- Replacement

- Readjustment

1.Hammering

2.Measuring the thickness3.Measuring the seal clearance

4.Measuring the degree

of parallelism

Rotor seal

- Post seal, Radial seal,

Bypass seal, Axial seal,

Static seal,Sector plate

- Repair.

- Replacement

1.Visual check

2.Overhaul

3.Measuring

Soot blower

- Speed reducer, Carriage,

Feed tube, Lance tube,Wall box, Flanges

1.Visual check

Contents of inspection

- Repair.

- Replacement

Others

- Manholes, doors

Observation port

Measures at abnormalComponents parts



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2nd Maintenance


2-3. Water washing

Agenda


2 3 W t hi


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2-3.Water washing

P Water

washing

OperationOut of service

Initial value

Water

washing

Operation

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.

Instructions

Out of service



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Operation procedure of water washing

Preparation

1) Make sure that the temperature of gas inlet is below 150.

It may cause damages on AH if it is higher than 150.

2) Line up the water line.3) Check the drain lines to be able to drain adequately.

4) Shut off steam valves for soot blower

5) Observe the condition of deposit on heating element.

Finish

Start water washing

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.

The auxiliary air motor drive should be used to reduce

the speed to approximately to RPM.

Instructions


Instructions


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Determine the completion

Complete

a) Completion may be determined from the difference of pH value

between washing water and drain water.

When the difference is less than 1, it may be completed in principle.

pHv

alue

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

Finish

pH Washing water

Drain water

-> pH value decreases due to sulfuric acid

Instructions



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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 CANBECOME FLOODED

CAUTION: INSUFFICIENT WATER WASHING HAS ADVERSE

EFFECTS TO THE HEATING ELEMENT AND INCOMPLETE

DRYING WILL CAUSE RAPID PROGRESSION OF CORROSIONAND ACCUMULATION OF DEPOSITS ON THE HEATIMNG

ELEMENTS WHEN RETURNING TO SERVICE.


A d


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2nd Maintenance


2-3. Water washing

Agenda


! IMPORTANT


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DANGER: NEVER ATTEMPT TO ENTER THE AIR HEATER UNTILTHE FOLLOWING CONDITIONS ARE MET.

ALL ELECTRIC POWER TO THE ROTOR DRIVE UNIT AND THE

SOOTBLOWER UNIT HAS BEEN ISOLATED.

THE LOCAL COMPRESSED AIR HAND VALVE AT THE AIR

MOTOR SHOULD BE SECURED IN THE OFF POSITION.

THE SURFACE TEMPERATURE OF THE AIR HEATER IS

BELOW 100F (38C).

O2 AND CO2 CONCENTRATION ARE SATISFIED TO ENTER.

For detail operation and maintenance instructions, please refer to:

Operation & Maintenance Manual

! IMPORTANT



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CAUTION: WHENEVER WELDING IS DONE ON THE ROTOR POST ORROTOR 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 ORPOSSIBLE PERMANENT DAMAGE TO THE SEALING SYSTEM.



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H-3 Power Point (Air Heater)

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