CONTINUAL AND SUSTAINED IMPROVEMENTS IN

APH PERFORMANCE BY LONG TERM AND SHORT

TERM MEASURES
IN
CAPTIVE POWER PLANT (120 MW X 10),NALCO.

R.S.DAS,

DY. GENERAL MANAGER(MECHANICAL), CPP, NALCO

 National Aluminium Company Limited
was incorporated in 1981, as a Public Sector Company,
under the Ministry of Mines.

The total Capital Cost of Rs. 2408 crore was funded through

Govt. of India contribution : Rs 1289 crore

Euro-dollar loan from
a consortium of International Banks : Rs 1119 crore
 PRODUCTS

ALUMINA ALUMINIUM METAL

Calcined Alumina
Standard Ingots

Alumina Hydrate
Sow Ingots

Speciality Aluminas & Hydrates
Wire Rods

Detergent Grade Zeolite
Billets

Cast Strips

Cold Rolled Sheets

 CAPACITIES & COSTS

MINES REFINERY SMELTER CPP

CAPACITY 24,00,000 8,00,000 TPY 2,30,000 TPY 720 MW
TPY ALUMINA METAL 6X120
BAUXITE
INITIAL
PROJECT
COST Rs.80 Rs.754 Rs.723 Rs.812 Rs.2369
CRORES CRORES CRORES CRORES CRORES

CAPACITY 48,00,000 15,75,000 3,45,000 TPY 960 MW

TPY TPY METAL 8X120
1ST PHASE
BAUXITE ALUMINA
EXPN
CAPACITY
COST Rs.78.63 Rs.1285.03 Rs. 1463.85 Rs.768.27 Rs.3595.78
CRORES CRORES CRORES CRORES CRORES

CAPACITY 63,00,000 21,00,000 4,60,000 TPY 1200 MW

TPY TPY METAL 10X120
BAUXITE ALUMINA
2ND PHASE
EXPN
CAPACITY COST Rs.72.27 Rs.1258.02 Rs.1609.41 Rs.1151.81 Rs.4091.51
CRORES CRORES CRORES CRORES CRORES
 LOCATIONS

New Delhi
Jaipur

Kolkata

Angul 

Mumbai
Silvasa
Bhubaneswar
Damanjodi

Paradeep

Bhiwandi

Registered Office


Visakhapatnam

Regional Offices
 Production Centres

Ports Bangalore Chennai

Bauxite Mines
Stockyards
 ALUMINIUM SMELTER

Located at Angul in Orissa

Integrated Casting & Rolling facilities

Energy-efficient State-of-the-art Pechiney technology (France)

In operation since 1987

Initial Capacity : 2,18,000 tpy

Expanded Capacity : 4,60,000 tpy
 CAPTIVE POWER PLANT

Located close to Smelter

Captive rail system for coal transport from Talcher Coalfields

Feeds uninterrupted power to Smelter

Connected to State Grid for sale of surplus power

Initial Capacity : 600 MW
Expanded Capacity : 1200 MW
BOILER TYPE:
ALL THE BOILERS ARE DESIGNED AND
SUPPLIED BY M/S BHEL.
NATURAL CIRCULATION
SINGLE DRUM
RH TYPE
BALANACED DRAFT
TILTING TYPE TANGENTIAL FIRED
PULVERIZED COAL
 SPECIFICATION OF NALCO 120 MW BOILER
MAKE BHEL
CIRCULATION NATURAL
TYPE PF,WATER
TUBE,REHEAT
DRAFT BALANCED
FLOW CAPACITY 430 T/HR-400 T/HR
TOTAL HEATING SURFACE AREA 13,844 M2 -1 –5
15683 M2 -6
17400 M2 - 7 & 8
17600 M2- 9 & 10
FURNACE SIZE- WIDTH 11201MM
-DEPTH 7696 MM
DESIGN PRESSURE 158.2 Kg/m2
EFFICIENCY 87.36% (MCR
87.33% (NCR)
 AIR PRE-HEATERS
THERE ARE TWO NO TRISECTOR ROTARY TYPE
( REGENERATIVE , LJUNGSTROM TYPE ) AIR HEATERS PER BOILER.
AIR PREHEATER SPECIFICATION

REGENERATIVE LJUNGSTROM TRISECTOR

24.5 V I M T 57.5
ELEMENT DEPTH
(27.5+18+12) in inches
TRISECTOR

MODULAR ROTOR
INVERTED

VERTICAL SHAFT

SIZE NUMBER Dia. of Rotor - 6890 mm

( large , Heat duty >200 M Kcal / Hr)
 ENERGY AUDIT BY TERI AND FINDINGS

Heat balance Design Boiler # 1 Boiler # 2 Boiler # 3 Boiler # 4 Boiler # 5 Boiler # 6

value

Dry flue gas loss (%) 4.47 7.45 8.03 7.73 7.48 6.89 8.89
Heat loss due to CO in flue gas (%) 0.02 0.05 0.01 0.01 0.00 0.01
Heat loss due to moisture in air (%) 0.21 0.24 0.26 0.25 0.27 0.23 0.29
Heat loss due to moisture and H2 in the fuel (%) 5.23 11.35 11.49 11.43 11.39 11.30 11.52
Heat loss due to unburnt in bottom ash (%) 1.50 2.46 2.64 2.18 3.24 1.08 2.21
Heat loss due to unburnt in fly ash (%) 0.23 0.14 0.64 0.26 0.14 0.13 0.23
Sensible heat loss in bottom ash (%) 0.48 0.48 0.48 0.48 0.48 0.48
Sensible heat loss in fly ash (%) 0.50 0.56 0.53 0.52 0.48 0.57
Surface heat loss (%) 0.36 0.31 0.40 0.30 0.47 0.31
Unaccounted loss (manufacturer’s margin) (%) 1.00
Total heat loss (%) 12.64 22.99 24.46 23.27 23.83 21.05 24.51
Thermal Efficiency (%) 87.36 77.01 75.54 76.73 76.17 78.95 75.49

HIGH DRY FLUE GAS LOSS

MOSTLY DUE TO HIGH AIR LEAKAGE IN APHS
 EnergySavings
SavingsbybyAPH
APHininone
one120MW
120MWunit
unit
Energy
Q =m Cp (T2 – T1)
= 5,50,000 X 0.27 X ( 333 – 140)
= 28660500 Kcal / Hr
= (28660500 Kcal / Hr ) / (3500 Kcal /Kg)
= 8188.7 Kg/ Hr of Coal
= 8189 Kg/ Hr of coal X 8000 hr/annum
= 65,512 tons of coal per annum
= 65,512 tons/ annum X Rs 1500 per ton
= Rs 9.82 Crores per annum per unit
 Corrected flue gas temperature with respect to air ingress & percentage air
leakage

%O2 bfr %O2 % Air Measured Corrected

Boiler APH after leakage (0C) (0C)
APH

#1 3.73 8.60 35.42 136.5 177.0

#2 2.88 7.05 31.28 145.0 197.0

#3 3.35 7.68 30.03 139.0 185.0

#4 2.90 7.63 30.31 139.0 187.0

#5 3.10 9.78 50.37 129.0 172.0

#6 4.33 7.45 20.68 157.5 200.0

 FOCUSSED IMPROVEMENT COMMITTEE
A FOCUSSED IMPROVEMEMT (KK) COMMITTEE WAS
FORMED WITH CROSS FUNCTIONAL TEAM MEMBERS
AS A TPM APPROACH

 TO REDUCE THE LOSS IN APHS

 TO ENHANCE THE PERFORMANCE OF APHS

 TO ENHANCE THE OVERALL EQUIPMENT EFFECTIVENESS

OF APHS
 EXPERT HELPS SOUGHT FROM

M/s GEECO ENERCON

M/s BHEL
MAJOR PROBLEMS FOUND IN AIR PREHEATERS

 Improper seal setting during annual overhauling.

 Damage of the seals during operation
 Damage of sector plates
 Damage of spool pieces
 Damage of sector plate tracking device
 High PA header pressure
 Chockage of Baskets
 Damage of Gear Boxes
 Failure of Support Bearings
 Rotor Blockage due to various reasons
 Damaged T bars
 Damaged axial seal plates
DAMAGED HE BASKETS
 DAMAGED CE BASKETS

CHOCKED

CORRODED
IMPROVEMENT ACTIONS IN AIR PRE HEATERS OF CPP
NALCO
SHORT TERM MEASURES:
Soft touch radial seals are being used to arrest inter sector
passing supplied by M/s GEECO.
Introduction of Less Depth Baskets at the hot end with
Basket By Pass Seals to reduce the replacement cost and for
the consistent air heater thermal performance.
( Future element by M/s GEECO)
Replacement of sector plates with modified design sector
plates designed by M/s GEECO ( with transition bar)
Replacement of T bars with “cast T bars”
Replacement of cold end gratings
Replacement of cold end baskets with “DU” profile baskets
Repair /replacement of cold end gratings
SHORT TERM MEASURES:

Damaged expansion bellows where ever possible are

being replaced.
A short term 5 years replacement plan has been made.
( baskets with future element and modified design
sector plates)
Warm intermittent APH washing is introduced to
clean and maintain the cleanliness of the basket
elements to improve heat transfer.
PA fan header pressure value is being maintained as
per the norm.
Off line flue gas analyzer is procured to assess the
APH performance on regular basis
APH annual over haulings are being done under the
supervision of ex-Bhel experts
CHANGE OF PROFILE TO IMPROVE HEAT TRANSFER

NF Profile DU Profile
INCORPORATION OF SOFT TOUCH SEAL AT HOT END
TO REDUCE LEAKAGE
INTRODUCTION OF FUTURE ELEMENT AT HE TO REDUCE
COST & O/H TIME

Future Element

Hot End

Hot Intermediate

Cold End
TRANSITION BAR FITTED IN SECTOR PLATES TO ENHANCE
SEAL LIFE

TRANSITION BAR

TRANSITION BAR

SUPPLIED BY GEECO
AIR LEAKAGE TRENDING OF ONE OF
OUR UNITS WITH SOFT TOUCH SEALS
BY M/s GEECO
UNIT-5 APH AIR LEAKAGE

50
45
40
35
% VALUE

30
APH-A
25
APH-B
20
15
10
5
0

Aug-07 Mar-08 Apr-08 May-08 Jul-08 Nov-08 Dec-08 Feb-09 Mar-09 Apr-09 Nov-09
APH-A 44.53 4.12 5.2 6.2 7.3 9 8.19 8.29 8.49 8.61 10.12
APH-B 43.75 6.5 7 7.3 8.1 9.5 10 12.5 13 13.5 14

MONTHS
AIR LEAKAGE TRENDING OF ONE OF OUR UNITS WITH MODIFIED
DESIGN SECTOR PLATES AND SOFT TOUCH SEALS BY M/s GEECO

UNIT-4 APH AIR LEAKAGE

ANNUAL OH
16
ANNUAL OH
14 WITHOUT TRANSITION
BAR
12
WITH TRANSITION BAR
10
% VALUE

APH-A
8
APH-B
6

0
Dec-08
Jan-09
Feb-09
Mar-09
Apr-09
May-09
Jun-09
Jul-09
Aug-09
Sep-09
Oct-09
Nov-09
Dec-09
Jan-10
Feb-10
Mar-10
Apr-10
May-10
Jun-10
Jul-10
Aug-10
Sep-10
Oct-10
Nov-10
Dec-10
Jan-11
Feb-11
Mar-11
Apr-11
May-11
Jun-11
Jul-11
Aug-11
Sep-11
Oct-11
Nov-11
Dec-11
Dec-08Jan-09Feb-09Mar-09 Apr-09May-09Aug-09Oct-09Dec-09Feb-10 Apr-10 Jun-10 Jul-10 Oct-10Dec-10Feb-11 Apr-11 Jun-11Aug-11Oct-11Dec-11
APH-A 6.23 6.5 6.7 7.5 7.51 8.5 9.14 9.5 10 10.6 11 12 12.5 6.5 6.6 6.8 7.3 7.6 8.2 8.4 8.8
APH-B 8.91 9.3 9.4 9.46 9.57 10.1 10.13 10.5 11 11.7 12.5 13 13.5 7 7.1 7.3 7.8 8.1 8.4 9 9.3

MONTHS
 LONG TERM MEASURES
AMR plan has been made for the replacement of the
major spares( axial seal plates, spool pieces, sector plates,
baskets, GB air seal assys etc.) for all the units.
R & M proposals are being planned for unit 1 and 2
for total renovation with all modifications like double
sealing system
Replacement of Support bearings in every 15 years
Replacement of Gear Boxes in every 7 years
( as a rotatable)
20 years replacement plan has been prepared.
Rotor–Single Seal

Rotor- Double Seal

29
 RESULTS OBTAINED
AIR LEAKAGE IN APHS HAS BEEN REDUCED DRASTICALLY.

PA,FD, ID FAN POWER CONSUMPTION HAVE BEEN REDUCED.

BOILER EFFICIENCY HAS BEEN INCREASED BY 2%.

ESP COLLECTION PERFORMANCE HAS BEEN IMPROVED.

HIGH EMPLOYEE MORALE .

 POWER SAVING IN FANS IN A MONTH

1. SAVING IN POWER 0.7 x 1.732 x 6.6kv x 9A x 1.545LAKH

CONSUMPTION IN PA FANS 24hrs x 30 days x Rs 3.00
CALCULATED for a month

2. SAVING IN POWER 0.70 x 1.732 x 6.6kv x 18A x 3.09 LAKH

CONSUMPTION IN ID FANS 24hrs x 30 days x Rs 3.00
CALCULATED for a month

3. SAVING IN POWER 0.7 x 1.732 x 6.6 kv x2A x 0.345 LAKH

CONSUMPTION IN FD FANS 24 hrs x
CALCULATED for a month 30 days x Rs 3.00

TOTAL SAVING IN A 4.124LAKH

MONTH/ UNIT
 BEFORE MODIFICATION

NO SPACE
MOUNTING
PROBLEM NO SUPPORT
 AFTER MODIFICATION

INT. BRACKET

MOTOR

PUMP

NEW SUPPORTS WELDED MORE SPACE

AND ACCESS
 BEFORE MODIFICATION

APH BODY

GB LUB OIL
SYSTEM
 AFTER MODIFICATION

MODIFIED PIPE
LINE

NEW LOCATION OF THE

SYSTEM
Long term Short term
measures measures

CONSISTENT AIR HEATER

PERFORMANCE
OUR EXPERIENCE WITH M/s GEECO
• QUALITY- EXCELLENT
• DELIVERY- EXCELLENT
• AFTER SALES SERVICE- EXCELLENT
• RESPONSE TIME- EXCELLENT
• COMMUNICATION-EXCELLENT
• TECHNICAL COMPETENCE- EXCELLENT
• COMMITMENT AND DEDICATION- BEYOND
EXPECTATION
 WISHING ALL SUCCESS TO GEECO

Thank You for your kind attention