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<ul><li><p>Tanjung Jati B TrainingAIR HEATERS</p></li><li><p>Tanjung Jati B Training</p><p>OPERATIONSAIR HEATERS</p></li><li><p>Tanjung Jati B Training</p><p>Boiler Precipitator FGD Absorber</p><p>2 x 660MW (net)</p><p>P.T. Central Java PowerTanjung Jati B Units 1 &amp; 2</p></li><li><p>Tri-Sector Air HeaterFunction</p><p>Two (2) 50% capacity Ljungstrom Tri-Sector Air Heaterstransfer heat from the flue gas leaving the boiler to theincoming cold primary and secondary air.</p><p>Tanjung Jati B Training</p></li><li><p>Secondary Air System</p><p>FD Fan</p><p>FD Fan</p><p>SCAH</p><p>SCAH</p><p>Tri-SectorAir Heater</p><p>Tri-SectorAir Heater</p><p>N</p><p>Tanjung Jati B Training</p></li><li><p>Tri-Sector Air HeaterSections</p><p>The Air Heater is divided into three (3) sections</p><p>Flue Gas Side</p><p>Secondary Air Side (~4/5 of air side)</p><p>Primary Air Side (~1/5 of air side)</p><p>Tanjung Jati B Training</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterOrientation</p><p>AIR HEATER A AIR HEATER B</p><p>ROTATION ROTATION</p><p>GAS SIDE GAS SIDE</p><p>SECONDARYAIR SIDE</p><p>SECONDARYAIR SIDE</p><p>PRIMARYAIR SIDE</p></li><li><p>Tri-Sector Air HeaterAir Heater Components</p><p>Terms to remember</p><p>Rotor &amp; Rotor DriveEmergency Air (Rotor) DriveHeating Elements or BasketsGuide &amp; Support BearingsOil Circulating SystemsSector Plates &amp; SealsThermocouple Temperature Monitoring PanelSootblowerWater Washing</p><p>Tanjung Jati B Training</p></li><li><p>Tri-Sector Air HeaterFlow Paths</p><p>Tanjung Jati B Training</p><p>FLUE GAS IN</p><p>PRIMARYAIR OUT</p><p>SECONDARYAIR OUT</p></li><li><p>Tri-Sector Air HeaterHeating Elements (Baskets)</p><p>Tanjung Jati B Training</p><p>Baskets, which contain a multitude of corrugatedsteel plate, absorb the heat from the flue gas stream.</p><p>HOT ENDLAYER</p><p>(42)</p><p>HOTINTERMEDIATE</p><p>LAYER(12)</p><p>COLD ENDLAYER</p><p>(10)</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterHeating Elements (Baskets)</p><p>CORRUGATED PLATE DESIGN</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterRotor Drive</p><p>The Air Heater Rotor Drive consists of the followingmajor components</p><p>30 HP, 380 VAC MotorSpeed ReducerFluid CouplingPinion Gear &amp; Hub</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterRotor Drive</p><p>43.5 LITER</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterEmergency Air (Rotor) Drive</p><p>If the electric motor should lose power, an EmergencyAir Drive is used to insure the continuous operation ofthe Air Heater.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterEmergency Air (Rotor) Drive</p><p>SOLENOID VALVEFAILS OPEN UPONLOSS OF POWER</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterBearings</p><p>The Air Heater has two (2) main bearings, oneGuide Bearing &amp; one Support Gearing.</p><p>The Guide Bearing is located at the top portionof the rotor assembly, while the Support Bearingis near the bottom.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterBearings</p><p>GUIDEBEARING</p><p>SUPPORTBEARING</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterGuide Bearing</p><p>Due to the Guide Bearing being located in a hotenvironment, an Integral Oil Circulating System is provided to maintain oil viscosity and provide a bath of clean oil.Cooling water is from the CCCW System.</p></li><li><p>Tanjung Jati B Training</p><p>The Integral Oil Circulating System has thefollowing components</p><p>Oil PumpDual Oil FiltersOil Pressure GaugeDifferential Pressure Gauge with SwitchOil-Water Heat ExchangerPressure Relief Valve (set @ 75 psig)Thermometer ProbeAdjustable Temperature Controller (set @ 38oC)</p><p>Tri-Sector Air HeaterIntegral Oil Circulating System(Guide Bearing)</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterIntegral Oil Circulating System(Guide Bearing)</p></li><li><p>Tanjung Jati B Training</p><p>OIL REQUIREMENT:~43.5 LITERS</p><p>Tri-Sector Air HeaterIntegral Oil Circulating System(Guide Bearing)</p></li><li><p>Tanjung Jati B Training</p><p>Due to the potential for oil to leak and get underthe casing and insulation, there is always a potential for fires to start.</p><p>It is recommended that an operator periodicallycheck the oil system.</p><p>Tri-Sector Air HeaterIntegral Oil Circulating System(FIRE Potential)</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSupport Bearing</p><p>The Support Bearing is equipped with an Oil CirculationSystem. The bearing itself is submerged in an oil bathrequiring approximately 185.5 liters.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterExternal Oil Circulation System(Support Bearing)</p><p>Unlike the Integral Oil Circulating System for theGuide Bearing, the Support Bearing has what iscalled an External Oil Circulating System.</p><p>This system is similar but has no Oil-Water HeatExchanger.</p></li><li><p>Tanjung Jati B Training</p><p>The External Oil Circulating System has thefollowing components</p><p>Oil PumpMicro-Klean FilterPressure GaugeThermometerPressure Relief Valve (set @ 50 psig)Filter Differential Pressure Switch</p><p>Tri-Sector Air HeaterExternal Oil Circulation System(Support Bearing)</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterExternal Oil Circulation System(Support Bearing)</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Seals</p><p>The sealing systems are comprised of the followseals</p><p>RadialCircumferentialAxialRotor</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Seals</p><p>Our discussion will focus on the Radial Seals.</p><p>The hot and cold sides of the air heater have theseseals which run from the center of the air heater toits outer circumference.</p><p>Radial Seals, along with Sector Plates minimize AirHeater Leakage</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Radial Seals</p><p>RADIAL SEALS(HOT END)</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Radial Seals(Leakage)</p><p>Leakage occurs between the following Air andGas streams</p><p>Primary Air stream to the Flue Gas streamPrimary Air stream to the Secondary Air streamSecondary Air stream to the Flue Gas stream</p></li><li><p>Flue Gas In</p><p>Flue Gas Out Pri. AirIn</p><p>Sec AirIn</p><p>Pri. AirOut</p><p>Sec. AirOut</p><p>Leakage occurs because the pressure onthe air side is greater than the pressure onthe gas side. Also, Primary Air pressure isgreater than Secondary Air Pressure.</p><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterLeakage</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Radial Seals</p><p>Sector Plates are also located on both the Hot andCold End of the Air Heater. The Sector Plates are essentially pie-shaped plates and are adjustableon the Hot Side and stationary on the cold side.</p><p>Sector Plates are used to set the gap between thePlate and the Radial Seals.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Radial Seals</p><p>1 of 3 SECTOR PLATES</p><p>RADIAL SEAL</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates - Numbering</p><p>1 2</p><p>3</p><p>Top View of Air Heater B(Mirror Image for Air Heater A)</p><p>GAS SIDE</p><p>PRIMARYAIR SIDE</p><p>SECONDARYAIR SIDE</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Radial Seals</p><p>The Hot Side Sector Plates, which are adjustable,incorporate an automatic system which checksand sets the gap between the plate and the RadialSeals. A Rotor Position Sensor is utilized for thistask.</p><p>The Rotor Position Sensor Assembly and Sector PlateDrive Assembly are located at the ends of the SectorPlate.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates &amp; Radial Seals</p><p>The Sector Plate position can also be set manually.Each Sector Plate, numbered 1, 2 &amp; 3, has itsown Local Control Panel to perform this function.</p><p>CAUTION! An experienced operator or technicianshould be the only one to adjust the Sector Platesvia the Local Panel, otherwise Radial Seal damagecan occur.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plates Drive Location</p><p>AIR HEATER A AIR HEATER B</p><p>ROTATION ROTATION</p><p>GAS SIDE GAS SIDE</p><p>SECONDARYAIR SIDE</p><p>SECONDARYAIR SIDE</p><p>PRIMARYAIR SIDE</p><p>112 2</p><p>33</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSector Plate Local Panel</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterThermocouple Temperature Monitoring Device</p><p>The Thermocouple Temperature MonitoringDevice (TTMD), is designed to measure the airtemperature leaving the Air Heater.</p><p>The TTMD will alarm if a thermocouple detects anunexpectedly high local air outlet temperature.</p><p>A high outlet air temperature could be an indicationof a FIRE internal to the Air Heater.</p><p>Each Air Heater has one TTMD Panel.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterThermocouple Temperature Monitoring Device</p><p>The TTMD utilizes the following Thermocouples</p><p>One (1) for Air Inlet Temperature</p><p>One (1) for Gas Inlet Temperature</p><p>Fourteen (14) for Air Outlet Temperature</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterThermocouple Temperature Monitoring Device</p><p>The 14 Thermocouples are located internally alongthe radius of the rotor with a spacing of approximatelyone foot (305 mm) and as close as possible tothe heat transfer surface (baskets).</p><p>All Thermocouple readings are routed to the TTMDPanel for evaluation or comparison.</p><p>The TTMD panel will send an alarm signal to the DCSand alarm locally as well.</p></li><li><p>Tanjung Jati B Training</p><p>T/C #1 th</p><p>ru #14</p><p>CUTAWAY OFROTOR SECTION</p><p>Tri-Sector Air HeaterThermocouple Temperature Monitoring Device</p><p>THERMOCOUPLESLOCATED IN THE</p><p>AIR OUTLET STREAM</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterTTMD Panel Alarm Potential Fire</p><p>When the TTMD Panel has a High TemperatureAlarm, immediate attention should be given toit by an operator and I&amp;C technician.</p><p>First, push the alarm acknowledge button andsee if the alarm clears or resets.</p><p>If not, check to see if the Thermocouple is functioningproperly, for example, the thermocouple has notfailed (infinite resistance).</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterTTMD Panel Alarm Potential Fire</p><p>At first evidence of a fire from temperature indicationor otherwise, inspection of the Air Heater should bemade.</p><p>If the temperature continues to rise or if a fire isvisible, the fans should be shut down and water shouldbe admitted to the Air Heater in sufficient quantitiesto quench the fire.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterTTMD Panel Alarm Potential Fire</p><p>If it is possible to isolate the area of the fire, then stopthe Air Heater so that the water can be directed atthe fire.</p><p>On the other hand, if the fire is burning in several areas,continue to rotate the Rotor as long as it will turn.</p><p>Note: If the fire has progressed to the metal HeatingElements, temperatures could range from 1093oC to2204oC.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterTTMD Panel Alarm Potential Fire</p><p>DO NOT CONSERVE ON WATER!!</p><p>GET AS MUCH WATER AS POSSIBLE ON THE FIRE!! </p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterOut of Service Water Washing</p><p>Over time, Air Heater air and gas pressure differentialmay increase. Air heater inspection and water washingmay be necessary.</p><p>A Water Wash system with wash nozzles is providedto serve this task.</p></li><li><p>Flue Gas In</p><p>Flue Gas Out Pri. AirIn</p><p>Sec AirIn</p><p>Pri. AirOut</p><p>Sec. AirOut</p><p>Pressure DifferenceAcross ElementsPin - Pout</p><p>Pressure DifferenceAcross ElementsPin - Pout</p><p>Tri-Sector Air HeaterOut of Service Water Washing(Pressure Drop)</p><p>Tanjung Jati B Training</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSootblower</p><p>The extendable lance sootblower is used tominimize the buildup of combustion byproductson the Air Heaters heat transfer elements.</p><p>It also minimizes No. 2 fuel and fuel ash depositionduring relatively cold start-up conditions.</p></li><li><p>Tri-Sector Air HeaterTypical Sootblower Arrangement</p><p>Tanjung Jati B Training</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterPlugged Heating Elements</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSootblower</p><p>Since there is no auxiliary boiler, and if both unitsare cold, compressed air is used. Service AirCompressors provide this air.</p><p>Steam which is generally more economical, shouldbe used when auxiliary steam is available.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterSootblower</p><p>During boiler start-up, the Air Heater Sootblowershould be operated on a continuous basis. Thisis due to the greater potential for the accumulationof No. 2 Oil combustion byproducts and oil itself.</p><p>Once the Boiler is up and operating, the sootbloweris used periodically (typically once per shift).</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterStart-Up &amp; Shutdown</p><p>The Air Heater is started prior to firing theBoiler and the sootblower is operated on acontinuous basis.</p><p>During normal operation, periodically checkthe operation of the Air Heater and be surethe Emergency Air Drive air isolation valveis open.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterStart-Up &amp; Shutdown</p><p>During normal operation, check for unusualnoises. A periodic or repetitive noise can bea sign of excessive rubbing between the RadialSeals and the Sector Plate(s).</p><p>When shutting down the Boiler, the sootblowershould be operated continuously prior toextinguishing the fires.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterLoss of Air Heater during Unit Operation</p><p>Most often, the reason for an Air Heater tostop during Unit Operation is due to electricaloverload of the Main Drive Motor.</p><p>This is generally due to excessive rubbingbetween the Radial Seals and the Hot EndSector Plates.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterLoss of Air Heater during Unit Operation</p><p>If this should occur, the Emergency Air MotorDrive will not be able to rotate the Air Heateras well.</p><p>Provisions should be made to reduce Unit Loadas quickly as possible so that the Air Heater canbe isolated from the incoming Flue Gas, if thisshould become necessary.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterLoss of Air Heater during Unit Operation</p><p>At the time of Air Heater Rotor Stoppage, theOperator should immediately go to the Air Heaterand Retract all three (3) Sector Plates by wayof the Local Control Panel.</p><p>Once this is done, try to restart the Air HeaterDrive Motor.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterLoss of Air Heater during Unit Operation</p><p>If the Main Drive Motor is successfully restarted,continue to operate the Air Heater with the SectorPlates in the retracted position.</p><p>Once the Unit is stable at the reduced Unit Load,the Sector Plates can be extended by automaticcontrol.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterLoss of Air Heater during Unit Operation</p><p>If the Main Drive Motor will not restart, andwhen Unit Load permits, close all IsolationDampers to isolate the Air Heater.</p><p>The main reason for retracting the Sector Platesas soon as possible is to avoid damage of theRadial Seals.</p></li><li><p>Tanjung Jati B Training</p><p>Tri-Sector Air HeaterLoss of Air Heater during Unit Operation</p><p>All Operators should thoroughly familiar withthe Air Heater operating instructions found inthe Operations &amp; Maintenance Manual.</p></li><li><p> High LeakageIncreases fan power requirementsPossible load curtailmentReduced thermal performanceNegative effects on precipitators and scrubbers</p><p> High Pressure DropIncreases fan power requirements</p><p> Low Thermal PerformanceHigh gas outlet temperatureLow air outlet temperatureLowers unit efficiencyIncreases leakage</p><p>Tri-Sector Air HeaterPerformance</p><p>Tanjung Jati B Training</p></li><li><p>Build up and blockage of heating surface flow paths by ash and corrosion productsEffects</p><p>Increases pressure dropIncreases leakageReduces thermal performance and effects boiler operationShortens element lifeLimits unit capacity</p><p>ControlSootblowingWater washingCold end temperature control</p><p>Tri-Sector Air HeaterPerformance</p><p>Tanjung Jati B Training</p></li><li><p>Surface PluggingIneffective sootblowingLow cold end metal temperatureIncomplete water washingAsh carryover</p><p>High LeakageDeteriorated sealsIncorrect seal adjustmentImproper operationsRotor or sector plate problems</p><p>Tri-Sector Air HeaterPerformance</p><p>Tanjung Jati B Training</p></li><li><p>Tanjung Jati B Training</p><p>OPERATIONSAIR HEATERS</p><p>(END)</p></li></ul>