AIR HEATER

DOUBLE SEALING
ARRANGEMENT
 NEED FOR APH R&M
 Under-Performance of Air preheater
(i) Heat Recovery inadequate
(ii) High Air Leakage
(iii) Drive, Bearing need Attention
(iv) Reduction in Boiler Efficiency
 High Flue Gas exit Temperatures
 High Fan loading
 Increased Generation Cost
 Introduction of latest State of Art
 BENEFITS FROM R&M
 APH, that is more Reliable.
 APH, which brings down Air Leakage
 Efficiency of APH improves
 Fan loading reduces - Reduction in % APC
 ESP performs better with lesser Gas handling
 Reduction in Coal Consumption & Mill loading
 Maintenance Cost reduced with Sacrificing Baskets
 REQUIRED MATERIAL UNDER R&M
Hot End Connecting
Plate Assembly(AIR SIDE) Hot End Connecting
Plate Assembly(GAS SIDE)

Hot End Sector Plates

Guide Bearing Assembly

Axial Seal Plate

Main Pedestal
AIR SIDE Housing
Assembly
Assembly
Rotor Module
Rotor Drive
Assembly GAS SIDE
Main Pedestal Housing Assembly
Assembly
Support Bearing
Assembly
Cold End Sector Plates

Cold End Connecting Cold End Connecting

Plate Assembly(AIR SIDE) Plate Assembly (GAS
SIDE)
 MAJOR MATERIAL REQUIRED UNDER R&M
 Modular Rotor Assy. includes all heating element baskets.
 Pin rack Assembly.
 Axial Seal Plates & Sector Plates.
 Housing Modification materials.
 Hot End Tracking Spool & Cold End Stationary Spool.
 Support Bearing & Guide Bearing Air Seal Assy.
 Soft Touch Radial Seals, Soft Touch Axial Seals, By Pass Seals with
Machined T-Bar.
 Gas Side Housing Panels.
 TYPICAL TIME CYCLE FOR APH R&M

Supply of Material 45 DAYS

Erection &
Commissioning 35 DAYS

Supply to
60 DAYS
completion
MATERIAL INDENTS RASIED FOR APH OVERHAUL
(i)APH Baskets Rs.2.9 Crores

(ii) Seals, Bypass Angles & T-Bars Rs.20 Lakhs

(iii) Pinion & Pin Rack Spares Rs.13 Lakhs

(iv) Gratings Rs.5 Lakhs

(v) Connecting plates & Axial seal plates Rs.30 lakhs
(v) Other Consumables ( CS plates, Electrodes etc.,) Rs.30 Lakhs
-----------------------
Rs. 3.98 Crores
 ANTICIPATED COST SAVINGS BASED ON
IMPROVED BOILER EFFICIENCY
 Design boiler efficiency @ 3030 Kcal/Kg : 87.23 %
 Boiler efficiency as reported in
NPC Energy audit report @3185.29 Kcal/Kg : 85.69 %
 Improvement in Boiler Efficiency by
reducing air Leakages in APH &
reduction of FG temperature as reported by NPC 2.60%

Note: i) The boiler efficiency computed during energy audit is for fuel with gross calorific value
3185 Kcal/kg. However, the boiler efficiency may reduce when design GCV of fuel is fed.
ii) For every 20°C rise in flue gas exit temperature, the boiler efficiency drops by 1 %
 ANTICIPATED COST SAVINGS BASED ON
IMPROVED BOILER EFFICIENCY RECOMMENDED BY NPC
Energy Savings by Reducing APH Leakages & reduction in FGT of Unit-IX
Mass flow rate for kg of Flue gas at eco outlet 5.12 kg/kg fuel
Present Corrected FGT 214.10 °C
Ambient temp 31 °C
Recommended Air Leakage as per PG Test (Inlet O2 3.57% & Outlet O2 5.5%): 8%
GCV of Fuel 3185.29 Kcal/Kg
Estimated Corrected FGT after APH 150 °C
Boiler Efficiency improvement 2.60 %
Existing coal consumption per hour 194.82 TPH
Landed cost of coal Rs/Ton 2900
Coal Saving by improvement of Boiler Efficiency is Rs/yr 1161.7 Lakhs
 ANTICIPATED COST SAVINGS BASED ON
IMPROVED BOILER EFFICIENCY
Coal Savings calculation
Present fuel flow 184.81 TPH
GCV of Fuel 3000 Kcal/kg
Total heating value 554438.01 Kcal
Design Boiler Efficiency 87.23%
Net Utilization 483636.27 Kcal
Reduction in Unit IX boiler Efficiency 2.6%
Operating Heating valve 469331.7 Kcal
Coal savings 4.768 Tons/hr
Additional coal required to maintain full load per day: 114.43 TPH
Additional coal required to maintain full load per month: 3433.08 TPH
Additional coal required to maintain full load per month: 41196.96 TPH
 ANTICIPATED COST SAVINGS BASED ON
IMPROVED BOILER EFFICIENCY
(i)Fuel consumption before modification 189.58T/hr.
(ii)Fuel Consumption after modification 184.81T/hr.
(iii)Saving in fuel 114.43T/day.
(iv)Saving in fuel per day at Rs.2900/MT
=Rs.2,900x114.435 Rs. 3,31,861
(v)Savings in fuel per year
(assuming 328.5 days) = 3,31,861x328.5 Rs.10.90 Crores
 ANTICIPATED COST SAVINGS BASED ON
REDUCED POWER CONSUMPTION
Rated Rated Present Present Anticipated
Name of the Anticipated Power
Voltage current Running Power Power
Motor Amps Factor
(KVolts) (Amps) Amps ( in KW) ( in KW)
ID FAN
1.2 495 580 350 0.9 4339.827 2618.86
Motor
PA FAN
6.6 155.7 110 90 0.85 2137.697 1749.02
Motor
FD FAN
6.6 75.8 30 30 0.85 583.008 583.00
Motor

Power consumption of all fans (PA,FD & ID) 7060.532 4950.894

 ANTICIPATED COST SAVINGS BASED ON
REDUCED POWER CONSUMPTION

(i) Present Power consumption of all fans (PA,FD & ID) 7060.532 KW
(ii)Anticipated Power consumption of all fans (PA,FD& ID) 4950.894 KW
(iv)Savings in Power 2109.637 kW
(v) Power savings per day 0.0506 MU
(vi) Power savings per annum 16.632 MU
(iv) Improvement in % APC 0.8% guaranteed reduction

(v)Savings per Annum Rs.4.324 Crores

(assuming 328.5 days, unit cost at Ps.260) = Rs.2.60x0.0506*328.5)
 ANTICIPATED COST SAVINGS

Fuel Savings Per annum Rs. 10.90 Crores

Power savings per annum Rs.4.324 Crores
Total Savings Rs.15.224 Crores
Investment to be made Rs.6.5 Crores ( approx.)

Payback period of 5 Months

IMPROVED SEALING SYSTEM
 SECTIONAL VIEW OF APH

SACRIFICING

HOT END HOT END

HOT INTERMEDIATE HOT INTERMEDIATE

COLD END COLD END

SECTIONAL VIEW WITHOUT SECTIONAL VIEW WITH

SACRIFICING BASKET SACRIFICING BASKET
27VIT72(74) 27VITM 2000
1824mm