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  • Tanjung Jati B TrainingAIR HEATERS

  • Tanjung Jati B Training

    OPERATIONSAIR HEATERS

  • Tanjung Jati B Training

    Boiler Precipitator FGD Absorber

    2 x 660MW (net)

    P.T. Central Java PowerTanjung Jati B Units 1 & 2

  • Tri-Sector Air HeaterFunction

    Two (2) 50% capacity Ljungstrom Tri-Sector Air Heaterstransfer heat from the flue gas leaving the boiler to theincoming cold primary and secondary air.

    Tanjung Jati B Training

  • Secondary Air System

    FD Fan

    FD Fan

    SCAH

    SCAH

    Tri-SectorAir Heater

    Tri-SectorAir Heater

    N

    Tanjung Jati B Training

  • Tri-Sector Air HeaterSections

    The Air Heater is divided into three (3) sections

    Flue Gas Side

    Secondary Air Side (~4/5 of air side)

    Primary Air Side (~1/5 of air side)

    Tanjung Jati B Training

  • Tanjung Jati B Training

    Tri-Sector Air HeaterOrientation

    AIR HEATER A AIR HEATER B

    ROTATION ROTATION

    GAS SIDE GAS SIDE

    SECONDARYAIR SIDE

    SECONDARYAIR SIDE

    PRIMARYAIR SIDE

  • Tri-Sector Air HeaterAir Heater Components

    Terms to remember

    Rotor & Rotor DriveEmergency Air (Rotor) DriveHeating Elements or BasketsGuide & Support BearingsOil Circulating SystemsSector Plates & SealsThermocouple Temperature Monitoring PanelSootblowerWater Washing

    Tanjung Jati B Training

  • Tri-Sector Air HeaterFlow Paths

    Tanjung Jati B Training

    FLUE GAS IN

    PRIMARYAIR OUT

    SECONDARYAIR OUT

  • Tri-Sector Air HeaterHeating Elements (Baskets)

    Tanjung Jati B Training

    Baskets, which contain a multitude of corrugatedsteel plate, absorb the heat from the flue gas stream.

    HOT ENDLAYER

    (42)

    HOTINTERMEDIATE

    LAYER(12)

    COLD ENDLAYER

    (10)

  • Tanjung Jati B Training

    Tri-Sector Air HeaterHeating Elements (Baskets)

    CORRUGATED PLATE DESIGN

  • Tanjung Jati B Training

    Tri-Sector Air HeaterRotor Drive

    The Air Heater Rotor Drive consists of the followingmajor components

    30 HP, 380 VAC MotorSpeed ReducerFluid CouplingPinion Gear & Hub

  • Tanjung Jati B Training

    Tri-Sector Air HeaterRotor Drive

    43.5 LITER

  • Tanjung Jati B Training

    Tri-Sector Air HeaterEmergency Air (Rotor) Drive

    If the electric motor should lose power, an EmergencyAir Drive is used to insure the continuous operation ofthe Air Heater.

  • Tanjung Jati B Training

    Tri-Sector Air HeaterEmergency Air (Rotor) Drive

    SOLENOID VALVEFAILS OPEN UPONLOSS OF POWER

  • Tanjung Jati B Training

    Tri-Sector Air HeaterBearings

    The Air Heater has two (2) main bearings, oneGuide Bearing & one Support Gearing.

    The Guide Bearing is located at the top portionof the rotor assembly, while the Support Bearingis near the bottom.

  • Tanjung Jati B Training

    Tri-Sector Air HeaterBearings

    GUIDEBEARING

    SUPPORTBEARING

  • Tanjung Jati B Training

    Tri-Sector Air HeaterGuide Bearing

    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.

  • Tanjung Jati B Training

    The Integral Oil Circulating System has thefollowing components

    Oil PumpDual Oil FiltersOil Pressure GaugeDifferential Pressure Gauge with SwitchOil-Water Heat ExchangerPressure Relief Valve (set @ 75 psig)Thermometer ProbeAdjustable Temperature Controller (set @ 38oC)

    Tri-Sector Air HeaterIntegral Oil Circulating System(Guide Bearing)

  • Tanjung Jati B Training

    Tri-Sector Air HeaterIntegral Oil Circulating System(Guide Bearing)

  • Tanjung Jati B Training

    OIL REQUIREMENT:~43.5 LITERS

    Tri-Sector Air HeaterIntegral Oil Circulating System(Guide Bearing)

  • Tanjung Jati B Training

    Due to the potential for oil to leak and get underthe casing and insulation, there is always a potential for fires to start.

    It is recommended that an operator periodicallycheck the oil system.

    Tri-Sector Air HeaterIntegral Oil Circulating System(FIRE Potential)

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSupport Bearing

    The Support Bearing is equipped with an Oil CirculationSystem. The bearing itself is submerged in an oil bathrequiring approximately 185.5 liters.

  • Tanjung Jati B Training

    Tri-Sector Air HeaterExternal Oil Circulation System(Support Bearing)

    Unlike the Integral Oil Circulating System for theGuide Bearing, the Support Bearing has what iscalled an External Oil Circulating System.

    This system is similar but has no Oil-Water HeatExchanger.

  • Tanjung Jati B Training

    The External Oil Circulating System has thefollowing components

    Oil PumpMicro-Klean FilterPressure GaugeThermometerPressure Relief Valve (set @ 50 psig)Filter Differential Pressure Switch

    Tri-Sector Air HeaterExternal Oil Circulation System(Support Bearing)

  • Tanjung Jati B Training

    Tri-Sector Air HeaterExternal Oil Circulation System(Support Bearing)

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Seals

    The sealing systems are comprised of the followseals

    RadialCircumferentialAxialRotor

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Seals

    Our discussion will focus on the Radial Seals.

    The hot and cold sides of the air heater have theseseals which run from the center of the air heater toits outer circumference.

    Radial Seals, along with Sector Plates minimize AirHeater Leakage

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Radial Seals

    RADIAL SEALS(HOT END)

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Radial Seals(Leakage)

    Leakage occurs between the following Air andGas streams

    Primary Air stream to the Flue Gas streamPrimary Air stream to the Secondary Air streamSecondary Air stream to the Flue Gas stream

  • Flue Gas In

    Flue Gas Out Pri. AirIn

    Sec AirIn

    Pri. AirOut

    Sec. AirOut

    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.

    Tanjung Jati B Training

    Tri-Sector Air HeaterLeakage

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Radial Seals

    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.

    Sector Plates are used to set the gap between thePlate and the Radial Seals.

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Radial Seals

    1 of 3 SECTOR PLATES

    RADIAL SEAL

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates - Numbering

    1 2

    3

    Top View of Air Heater B(Mirror Image for Air Heater A)

    GAS SIDE

    PRIMARYAIR SIDE

    SECONDARYAIR SIDE

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Radial Seals

    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.

    The Rotor Position Sensor Assembly and Sector PlateDrive Assembly are located at the ends of the SectorPlate.

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates & Radial Seals

    The Sector Plate position can also be set manually.Each Sector Plate, numbered 1, 2 & 3, has itsown Local Control Panel to perform this function.

    CAUTION! An experienced operator or technicianshould be the only one to adjust the Sector Platesvia the Local Panel, otherwise Radial Seal damagecan occur.

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plates Drive Location

    AIR HEATER A AIR HEATER B

    ROTATION ROTATION

    GAS SIDE GAS SIDE

    SECONDARYAIR SIDE

    SECONDARYAIR SIDE

    PRIMARYAIR SIDE

    112 2

    33

  • Tanjung Jati B Training

    Tri-Sector Air HeaterSector Plate Local Panel

  • Tanjung Jati B Training

    Tri-Sector Air HeaterThermocouple Temperature Monitoring Device

    The Thermocouple Temperature MonitoringDevice (TTMD), is designed to measure the airtemperature leaving the Air Heater.

    The TTMD will alarm if a thermocouple detects anunexpectedly high local air outlet temperature.

    A high outlet air temperature could be an indicationof a FIRE internal to the Air Heater.

    Each Air Heater has one TTMD Panel.

  • Tanjung Jati B Training

    Tri-Sector Air HeaterThermocouple Temperature Monitoring Device

    The TTMD utilizes the following Thermocouples

    One (1) for Air Inlet Temperature

    One (1) for Gas Inlet Temperature

    Fourteen (14) for Air Outlet Temperature

  • Tanjung Jati B Training

    Tri-Sector Air HeaterThermocouple Temperature Monitoring Device

    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).

    All Thermocouple readings are routed to the TTMDPanel for evaluation or comparison.

    The TTMD panel will send an alarm signal to the DCSand alarm locally as well.

  • Tanjung Jati B Training

    T/C #1 th

    ru #14

    CUTAWAY OFROTOR

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