01 APH Dissn Feb 12

Dr V T Sathyanathan
APH and Boiler -

Their Interaction on
Performance
Dr V T Sathyanathan
Technical Advisor – CVL
(Former General Manager, BHEL, Trichy)
Mankind is in pursuit of truth, let us work towards this

Dr V T Sathyanathan
Dr V T SATHYANATHAN, M.E., Ph.D.

Ph.D.
Graduated in Mechanical Engineering from Coimbatore
Institute of Technology, Coimbatore in 1971.
Master Degree In “Design And Production Of Thermal
Power Equipment” From Regional Engineering College,
Tiruchi in 1984.
Ph.D Degree in Mechanical Engineering from Regional
Engineering College, Tiruchi, in 1998 “Prediction of
Unburnt carbon in tangentially fired boilers using Indian
coals”.
Joined BHEL In 1973, worked in Field Engineering
Services in various capacity, Head of FES, R&D,
Engineering, & Quality
Retired from BHEL in March 2008 as General Manager
Quality
Presently Technical Advisor to M/s CVL, Trichy

Dr V T Sathyanathan
Dr V T SATHYANATHAN, M.E., Ph.D.
Has specialized
In Coal, Oil & Gas Combustion, Boiler Pressure Parts Failure
Analysis
Trouble Shooting Of Coal , Oil And Gas Fired Boilers,
Chemical Recovery Boilers And Stoker Fired Boilers
Plant Betterment Of Old Boilers
Performance Testing & Performance Optimisation Of Boilers
Has vast experience in the area of Residual Life Assessment
of boiler pressure parts
Petrographic Analysis Of Coal
Was appointed as the enquiry committee member by Government
of Tamilnadu, for investigation of a severe explosion in the
Rotary Holding Furnace (RHF) in Copper Smelting Plant of M/s.
Sterlite Industries (I) Ltd., Tuticorin Tamilnadu
Has presented more than 35 papers in both National and
International Seminars.
Teach Special Subjects In Horticulture - Art Of Bonsai & Cacti

Dr V T Sathyanathan
Presentation Arrangement
Introduction
Emerging Market Challenges and Demands
The Fact
The Boiler
Why APH in Boiler System
APH & Boiler performance
Thermal
Availability
Maintenance
Tips for regular operation

Dr V T Sathyanathan
Introduction

Dr V T Sathyanathan
Heat Balance for Steam Process
Energy Input
Feed Water Steam @ Pressure
P1
Usefull
Energy Input Steam Process Energy
Air & Fuel Output
P1
Energy Energy Energy

Loss Loss Loss
Flue Blow Down Due to Piping
Gas Water Friction Loss
Equipment etc.
Energy Output = Energy Input - Losses

Dr V T Sathyanathan
PLANT EFFICIENCY & HEAT RATE
482.8 Mkcal/hr 420 Mkcal/hr 180.6 Mkcal/hr 172 Mkcal/hr
boiler 210
T
MW 200 MW
120.7 t/h auxpower 10 MW
4000 kcal/kg
87.0 % 2000 kcal/kwhr 43.0 %
2299 kcal/kwhr 37.4%
2414 kcal/kwhr 35.6 %

Dr V T Sathyanathan
Emerging Market
Challenges and Demands

Dr V T Sathyanathan
Scenario
Continual Reduction in Delivery time
Coal will remain as the fuel of future
Affordable cost of generation
Higher Efficiency
Optimal Aux Power Consumption
Higher Unit Sizes
Use of large varieties of fuel for BFBC
/ CFBC Boilers

Dr V T Sathyanathan
Scenario
Suitability for differing modes of
operation, and grid conditions
Free Governance Mode, Availability Based Tariff
Increasing environmental control
norms
High Reliability & Availability
Optimal life cycle cost
Leveraging IT
Life Extension of Power Plants &
capacity upgrades
Dr V T Sathyanathan
Impact
Shorter Engg & manufacturing
time
Advanced planning of materials
Expectations to erect and
commission in short cycle
Weight reduction measures
Elimination of non value added
activities and process at all levels

Dr V T Sathyanathan
Impact (Cont)
Very high availability & PLF to be
achieved
Better heat rate and low cost
power
Lower pollution levels
Better position in ABT
Low gestation period
Better MTBF & MTTR
Many OEM boilers addressed
Dr V T Sathyanathan
Concern
Making the optimal plant heat
rate
Handling the fuel quality change
Operational deviations
Reducing the damage
mechanisms
Increasing MTBF
Addressing old power plants
Dr V T Sathyanathan
Methodology to address concerns
Operational
feedback
Design
improvements
Design
Feedback
New
Design

Dr V T Sathyanathan
The Facts

Dr V T Sathyanathan
Electricity Generation by Fuel, 2004 and 2030

Report #: DOE/EIA-0383(2006)
4000
3500
3000
Billion kilowatthours
2500
2004
2000
2030
1500
1000
500
0
Coal Nuclear Natural Gas Renewables Petroleum

Dr V T Sathyanathan
You are under constant pressure
To increase boiler efficiency & output

To increase reliability & safety
To reduce risk & total cost of
operation

Dr V T Sathyanathan
Generating Capacity in the country
Generating Capacity as on Dec 11 – CEA Web

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan
Coal formation theories
In-situ coal formation

Drift theory of coal formation

Dr V T Sathyanathan
In-
In-situ Theory of
coal Formation
Coal formed from a particular place
Coal generally appear to have been
formed either in brackish or fresh water,
from massive plant life growing in
swamps, or in swamp interspersed with
shallow lakes.
Coal formed in this way have bands of
coal and inorganic sedimentary rocks
arranged in a sequence.

Dr V T Sathyanathan
Huge Tropical Ferns And Giant Tress In
Vast Swamp Areas
( Wilfrid Francis, 1961 )

Dr V T Sathyanathan
Drift Theory of Coal formation

Coal formed from plant material on dry land
The original plant debris transported by water
deposited under water in lakes or in the sea
No true soil found below the seam of coal.
Regular settling of inorganic and organic in
succession or togather
Deposition depend on water current
Subsequently by mineral matters, sand etc. and
result in coal seams.
Coal property vary widely due to deposition pattern
Difference in coal properties of Gondwana coals
led to formation of drift theory

Dr V T Sathyanathan
Gondwana land
( Stacks E., et al )

Dr V T Sathyanathan
The Boiler

Dr V T Sathyanathan
Boiler
In a thermal power plant boiler
has the role of converting the
Chemical energy available in
Coal/fuel to Heat energy in
steam.
The heat energy in steam is
converted to Electricity by a
Turbo-generator

Dr V T Sathyanathan

Dr V T Sathyanathan
Optimazation Of Boiler
Two Main Factors
Thermal Efficiency- The conversion of
chemical heat in fuel to production of
steam. Higher thermal efficiency will
reduce fuel cost.
Auxiliary Power Consumption - by
Fans,mills etc. Reduction in auxiliary
power will lead to increase in net power
available (NET POWER= power generated
- house auxiliary power consumption).

Dr V T Sathyanathan
Major Losses in Boiler

Dry Gas Loss
Unburnt Carbon Loss
Fuel Hydrogen Loss
Fuel Moisture Loss
Air Moisture Loss
Radiation Loss
Sensible Heat Of Ash Loss
Other Minor Losses

Dr V T Sathyanathan
Sikka Thermal Power Station 1x 120 MW
Customer Gujarat Electricity

Board, India
Parameters at
SHO/RHO
Steam flow t/h 383/343
Pressure Kg/Sq.cm(g) 137/26.8
Temperature Deg.C 540/540
Fuel Coal
Date of March 1988
Commissioning
Salient features Two Pass Natural
Circulation Balanced
Draft Tilting Tangential
Firing

Dr V T Sathyanathan
National Capital Thermal Power Project 4x 210 MW
Customer National Thermal Power

Corporation
Parameters at
SHO/RHO
Fuel Coal / Oil
Date of Contract December 1987
Salient features Two Pass

Natural Circulation
Balanced Draft
Tilting Tangential Firing

Dr V T Sathyanathan
Neyveli Thermal Power Station 4x 210 MW
Customer Neyveli Lignite

Corporation, India
Parameters at
SHO/RHO
Steam flow t/h 690/596.70
Fuel High Moisture Lignite
Date of 1991
commissioning
Salient features Single Pass Natural
Draft Fixed Jet,
Tangential Firing

Dr V T Sathyanathan
NTPC Singrauli 2x 500 MW
Customer National Thermal Power

Corporation, India
Parameters at
SHO/RHO
Fuel Coal
Date of December 1986
commissioning
Salient features Two Pass Controlled
Firing

Dr V T Sathyanathan
NTPC Talcher 2x 500 MW
Customer National Thermal

Power Corporation
Parameters at
SHO/RHO
Fuel Coal
Date of contract April 1989
Salient features Single Pass Once

Through Balanced
Firing

Dr V T Sathyanathan
Prai Thermal Power Station 3 x 120 MW
Customer National Electricity

Board, Malaysia
Parameters at
SHO/RHO
Pressure Kg/Sq.cm(g) 132 / 30
Fuel Oil
Date of September 1979
commissioning
Salient features Box Type Natural
Firing

Dr V T Sathyanathan
Trombay TPS Unit 5 - 500 MW
Customer Tata Electric Company,

India
Parameters
at SHO/RHO
Pressure Kg/sq.Cm(g) 178 / 38.5
Temp. Deg.C 541 / 541
Fuel Coal / Oil / Gas
Date of January 1984
commg
Salient Two Pass
features Controlled Circulation
Balanced Draft

Dr V T Sathyanathan
Trombay TPS - 6 - 500 MW

Customer Tata Electric Company,
India
Parameters at
SHO/RHO
Steam flow t/h 1614 / 1490
Pressure Kg/sqCm(g) 178/41.7
Temperature Deg.C 541 / 568
Fuel Oil / Gas
Coal (Future)
Date OF March 1990
commg
Salient 2 Pass Control
features Circulation with rifle
water wall tubes
Balanced draft

Dr V T Sathyanathan
Modern 860 MW coal-oil fired Boiler

Dr V T Sathyanathan
Boiler Performance

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan
Why APH in Boiler System

Dr V T Sathyanathan
APH - Tail ender

APH & Economizer are heat recovery
surface
Designers always look at this in pair
Economizer - self limiting characteristics
• Can steam if not properly sized
• Minimum 25 – 30 deg C Eco out F W &
saturation temperature
APH can be sized for any requirement
APH has ability to absorb changes

Dr V T Sathyanathan
APH & Boiler Performance

When we talk about performance it is
Thermal performance
Availability performance
• Forced outage performance - MTBF
Maintenance performance – MTTR
Applicable to all types of APH
Tubular
Regenerative
Steam coil

Dr V T Sathyanathan
Types of Air Pre-

Pre-heaters

Dr V T Sathyanathan
Tubular Air Pre-

Pre-heater

Dr V T Sathyanathan

Dr V T Sathyanathan
FLUE GASES PATH
AIR PATH

Dr V T Sathyanathan
Rotary airheater
Assembly of heating element

Dr V T Sathyanathan
Profile rolling
Auto feeding &

straightening
Rolled coils
Assembly line of rolling of heating elements

Dr V T Sathyanathan
Steam Coil Air Pre-

Pre-heater

Dr V T Sathyanathan
Thermal Performance

Dr V T Sathyanathan
Factors Affecting APH Thermal Performance

X ratio of APH
Mass flow of air x Avg Sp. heat of air / Mass flow of
FG x Avg Sp. heat of FG
A decrease in the X-ratio results in an increase in
the exit-gas temperature
• A 10 to 12% change in this ratio may alter exit-gas
temperature by as much as 30 to 35°F (15 to 20°C).
Factors that affect the X-ratio
• Tempering air
• Overall boiler-system infiltration
• Air pre-heater bypass for cold-end protection.

Dr V T Sathyanathan
Factors Affecting APH Thermal Performance

Air pre-heater leakage
Higher the leakage higher the loss
Low moisture coal than design
Need higher quantity of tempering air
This bypasses the APH – Increase exit gas temperature
High excess air
Blockage in air pre-heater
Corrosion of APH elements
Soot blowing frequency
High ambient temperature
Boiler operation with high overload
Slagging & fouling of boiler heat transfer surface
Low feed water temperature at boiler inlet

Dr V T Sathyanathan
Availability Performance
- MTBF

Dr V T Sathyanathan
Factors affecting Availability of APH
Inadequate soot blowing during boiler start

Leads to air pre-heater fires
Long forced outage
Malfunctioning of oil burners
APH motor failure – Only for rotary type
High level of corrosion
High level of blockage – Increase auxiliary
power consumption
Improper water washing

Dr V T Sathyanathan
Maintenance performance
– MTTR

Dr V T Sathyanathan
Factors Affecting MTTR

Ease of replacement – Tubes, Baskets
Reserve available
Regular optimization of boiler operation
Adhere to all routine & preventive
maintenance
Avoid reuse of old baskets while
changing
Follow designers recommendations

Dr V T Sathyanathan
Tips for Regular Operation

Dr V T Sathyanathan
Look for Parameter Changes

Coal property changes – Proximate analysis log
Moisture %
• Changes tempering air quantity
GCV
• Much lower value increases number of mills in operation – Change in
PA quantity
Eco outlet flue gas temperature

Higher temperature
Excess air level
Higher excess air lead to higher boiler loss
Soot blowing frequency
Maintain clean surface to achieve the optimal efficiency
Oil gun performance & number of start-ups

Dr V T Sathyanathan
Adopt good operating practices to

prevent air pre-
pre-heater fire.
Reduce number of startups of boiler to a bare minimum.
Avoid operating boiler in low loads requiring oil support for a prolonged
duration
It is a good practice to check oil viscosity characteristics on a periodic basis
and whenever there is a change in supplier.
Clean oil gun tips and lap the internals to satisfy the design requirements.
Never restart the oil burners without purging during startup.
Boiler startup operation must be avoided when air pre-heater soot blowers are
not available.
Always make it a practice to soot blow all the air pre-heaters, the non working
air pre-heaters also must be soot blown by keeping the isolation damper
marginally open to allow the soot to be blown out.
During startups, low load operation and shutting down make it a practice to
watch the trend of air and gas temperature leaving the air pre-heaters.
Operate air pre-heater soot blowers regularly
Any fire detecting device provided by supplier has to be kept active and tested
as and when possible.

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan

Dr V T Sathyanathan
Look for
Increase in APH exit gas temperature
20 deg C increase reduces boiler efficiency by
one percentage
If eco FG outlet temperature is close to prediction
the check APH fully
Evaluate X-ratio of APH
10 to 12% change alter exit-gas temperature 15 to
20°C
Evaluate air ingress in boiler & arrest
Keep mill outlet temperature to the maximum
possible – Bowl mills

Dr V T Sathyanathan
Look for
Evaluate the optimum seal setting for
your plant – Regenerative type
Ensure SCAPH online during each
boiler start
Replace APH elements when undue
increase in exit gas temperature or very
high pr drop
Evacuate Eco ash hopper regularly as
recommended
Dr V T Sathyanathan
Thank You All

Dr V T Sathyanathan
We can discuss Please

01 APH Dissn Feb 12

Hochgeladen von

Dokumentinformationen

Originaltitel

Copyright

Verfügbare Formate

Dieses Dokument teilen

Dokument teilen oder einbetten

Freigabeoptionen

Stufen Sie dieses Dokument als nützlich ein?

Sind diese Inhalte unangemessen?

Copyright:

Verfügbare Formate

01 APH Dissn Feb 12

Hochgeladen von

Copyright:

Verfügbare Formate

Dr V T Sathyanathan

APH and Boiler -

Mankind is in pursuit of truth, let us work towards this

Dr V T SATHYANATHAN, M.E., Ph.D.

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Heat Balance for Steam Process

Energy Energy Energy

Energy Output = Energy Input - Losses

Mankind is in pursuit of truth, let us work towards this

482.8 Mkcal/hr 420 Mkcal/hr 180.6 Mkcal/hr 172 Mkcal/hr

87.0 % 2000 kcal/kwhr 43.0 %

2299 kcal/kwhr 37.4%

2414 kcal/kwhr 35.6 %

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Methodology to address concerns

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Electricity Generation by Fuel, 2004 and 2030

Mankind is in pursuit of truth, let us work towards this

You are under constant pressure

To increase boiler efficiency & output

Mankind is in pursuit of truth, let us work towards this

Generating Capacity in the country

Generating Capacity as on Dec 11 – CEA Web

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Coal formation theories

In-situ coal formation

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Drift Theory of Coal formation

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Mankind is in pursuit of truth, let us work towards this

Major Losses in Boiler

Mankind is in pursuit of truth, let us work towards this

Sikka Thermal Power Station 1x 120 MW

Customer Gujarat Electricity

Mankind is in pursuit of truth, let us work towards this

National Capital Thermal Power Project 4x 210 MW

Customer National Thermal Power

Salient features Two Pass

Mankind is in pursuit of truth, let us work towards this

Neyveli Thermal Power Station 4x 210 MW

Customer Neyveli Lignite

Mankind is in pursuit of truth, let us work towards this

NTPC Singrauli 2x 500 MW

Customer National Thermal Power

Mankind is in pursuit of truth, let us work towards this

NTPC Talcher 2x 500 MW

Customer National Thermal

Salient features Single Pass Once