Fans & Heaters technical seminar Howden APH field services Henry Castro

Improve Your Plant Reliability and Availability 1 Introduction to Howden field services 2 Air Pre-heater description 3 Air Pre-heater operation and maintenance 4 Air Pre-heater retrofit works 5 Best practice 6 What is next? Challenge Howden

Introduction to Howden Field Services Responsibilities and contributions Provide technical support to the day to day needs of plant personnel for the optimum operation and adequate maintenance of their equipment Provide guidance in programming of activities and supervision of works on air heaters maintenance Help with the implementation of industry proven improvements and best practices which are suitable to individual clients need Assure on site health and safety policy: Howden developed a Heater Rotation Procedure which emphasizes the personnel safety inside the APH

Air Pre-heater description

APH description Typical power plant schematic Air Preheater Gas-Gas Heater

APH description Rotating matrix (LJUNGSTROM) Rotating and stationary matrix APH Rotating matrix (LJUNGSTROM) Stationary matrix (ROTHEMUHLE) Typical Rotating Matrix Air Preheater Typical Stationary Matrix Air Preheater

Top Connecting Flanges Bottom Connecting Flanges APH Description Rotating Matrix Major Components Radial Seals Top Drive Unit Rotor Heating Elements Top Access Door Rotor Casing Guide Bearing Top Connecting Flanges End Pillars Axial Sealing Bottom Connecting Flanges Bottom Access Door Circumferential Seals

APH Description Commonly known as ROTHEMULHE Stationary Matrix Major Components Commonly known as ROTHEMULHE

APH operation and maintenance

APH operation and maintenance Operation checklist Typical operation checklist on Air Heater Temperatures Check that the incoming and outgoing air and gas temperatures are within the design values Check the Combined Cold End Temperature (CCET) is within the minimum required value Check the soot blower steam (if applicable) temperature is within the minimum required value Check the bearings and drive unit lube oil temperature are within the permitted level Pressures Check that the incoming and outgoing air and gas pressures are within the design values Check that the differential pressures across the equipment are within the permitted level. Others Check for the air leakage by monitoring the O2 and/or CO2 level upstream and downstream of the equipment Check for rotor seals rubbing, especially after replacement of seals Check for air/gas leakage on shaft packings Check for oil level on bearings and drive unit gear boxes.

APH operation and maintenance Maintenance checklist Typical list of maintenance work on Air Heater Replacement of Heating Element Replacement of rotor seals Overhauling of the soot blowers Overhauling or replacement of rotor support and guide bearing Overhauling or replacement of the drive unit General repair works on rotor, housing, and transition ducts Repair or replacement of the sector plates Repair or replacement of the sector plate static seals Repair or replacement of the axial plates Repair or replacement of the expansion joints Dry test of the fire protection and detection system

Basket replacement

Replacement of cold end baskets from the lateral side of the rotor Basket replacement Vertical shaft heater Replacement of cold end baskets from the lateral side of the rotor Replacement of hot and intermediate baskets from the upper end of the rotor

Basket replacement Horizontal shaft APH Replacement of hot and intermediate end baskets from the lateral side Replacement of sector baskets from the top end side of the APH

Horizontal shaft APHs Points to consider It must lock the rotor every time it is at a rest position to avoid possibility of movement due to imbalance. It is also recommended to install a provisional locking device in addition to the brake in the drive unit for additional safety measure. Replacement of the baskets should be done in a sequence where rotor imbalance is minimized to one sector. Rotor balancing should be conducted after completion of baskets replacement. Drive unit equipped with break assembly Rotor Additional Blocking

Horizontal APH Installation of balancing plates Balancing plates welded on the rotor shell after completion of baskets replacement

Seals replacement

Seals replacement Wireless seal plates levelness measuring device Howden developed a unique wireless laser measuring tool for a very precise measurement of the sealing plates, which results in an accurate and efficient setting of the rotor seals.

Seals replacement Radial seals

Outer circumferential seals Seals replacement Outer circumferential seals Replacement of Lower Outer Circumferential Seals Replacement of Upper Outer Circumferential Seals

Inner circumferential seals Seals replacement Inner circumferential seals Replacement of upper inner circumferential seals Replacement of lower inner circumferential seals

Seals replacement Axial seals

Seals setting chart and rotor reformation Seals replacement Seals setting chart and rotor reformation

APH retrofit works

Complete rotor replacement and conversion to double sealing APH retrofit works Complete rotor replacement and conversion to double sealing

APH retrofit works Replacement of the rotor bottom section and installation of new heating elements

APH retrofit works Complete replacement of the cold end side of a GGH for corrosion Issues

Replacement of the rotor due to fire incidence APH retrofit works Replacement of the rotor due to fire incidence

Installation of new jet blowers APH retrofit works Installation of new jet blowers

Installation of new fire detection and extinction system APH retrofit works Installation of new fire detection and extinction system

Best practice

Best practice For optimum sealing, verify the actual combined deformation of the rotor and the stationary components at unit full load. Set the rotor seals against these values. Always verify soot blowing steam quality, ascertain that pressure and temperature are within the recommended values and that the condensate drains are functioning well. Use health checks as preventive maintenance where comprehensive inspection reports are submitted and discussed with plant personnel. Ask for support from Howden experienced personnel. Our Service Technical Advisors have worked in more than 100 plants in 30 different country all over the world.

What can Howden do for you next? What next? Challenge Howden What can Howden do for you next? Outage Planning? Product Training? Spare Parts Audit? Maintenance Planning and Advice? Product Performance Analysis? Challenge Howden

Our experience at your service Thank you for your time