The document provides specifications and operational details of air preheaters used at a power plant. It includes specifications for different types of air preheaters, common outage reasons, analysis of past outages, and best practices for maintenance and improvement.
The document provides specifications and operational details of air preheaters used at a power plant. It includes specifications for different types of air preheaters, common outage reasons, analysis of past outages, and best practices for maintenance and improvement.
The document provides specifications and operational details of air preheaters used at a power plant. It includes specifications for different types of air preheaters, common outage reasons, analysis of past outages, and best practices for maintenance and improvement.
The document provides specifications and operational details of air preheaters used at a power plant. It includes specifications for different types of air preheaters, common outage reasons, analysis of past outages, and best practices for maintenance and improvement.
OUTAGES DUE TO AIRPREHEATERS (2005-06) Sl. REASON 200 500 MW No. MW PAPH SAPH
1 Failure of axial seal plate adjustor bolts 0 4 0
2 GB input shaft bearing failure 0 1 0
3 Support Bearing Failure 0 1 0
4 Falling of eroded bracing pipe. 2 0 0
Total Outages - 8 Hrs. Lost : 7+ 189 =196 Hrs. Forced Outage : 0.68 % OUTAGES DUE TO AIRPREHEATERS (2006-07)
Sl. REASON 200 500 MW
No. MW PAPH SAPH
1 Failure of axial seal plate adjustor bolts 0 1 0
2 GB input shaft bearing failure 1 0 0
Total Outages - 2 Hrs. Lost : 6+15 = 21 Hrs. Forced Outage : 0.04 % OUTAGES DUE TO AIRPREHEATERS (2007-08)
Sl. REASON 200 500 MW
No. MW PAPH SAPH
1 Falling of eroded EJ shroud Plate. 0 2 0
Total Outages - 2 Hrs. Lost : 45 Hrs. Forced Outage : 0.64% ANALYSIS OF OUTAGES
PAPH SUPPORT BEARING FAILURE
SUPPORT BEARING DESIGN: Type: Kingsbury Size 41BV Series 450, +SKF 23234 CCK/W33
REASON FOR FAILURE:
• Failure of Centre Bearing. • Shifting of rotor • Thrust pad failure.
ACTION TAKEN: • Regular Analysis of Lube oil at R&D for PQ index • Replacement of oil if PQ index found high • Inspection of bearing at the earliest opportunity. • Ensuring healthiness of Lube oil system. • Skilled maintenance staff. ANALYSIS OF OUTAGES
FAILURE OF AXIAL SEAL PLATE ADJUSTOR BOLTS
REASON FOR FAILURE:
• Failure of Adjuster Bolts. • Adjuster Guide arrangement problem
ACTION TAKEN: • Static seal on either sides. • Locking of the axial seal Plates (temp). • Inspect the locks at the available opportunity. • Modify the axial seal plate design. Guide
PAPH AXIAL SEAL PLATE
Guide
PAPH AXIAL SEAL PLATE
Guide
PAPH AXIAL SEAL PLATE
Guide at top & Bottom
MODIFIED AXIAL SEAL PLATE
MODIFIED AXIAL SEAL PLATE ANALYSIS OF OUTAGES
FALLING OF ERODED BRACING PIPES
REASON FOR FAILURE:
• Flue gas erosion of bracing pipes.
ACTION TAKEN: • Replacement of new bracing pipe • Replacement of Gassette plates • Angle protection to the bracing pipe. • Angle protection to the water manifold. • Removal of misc. bracing pipes/supports. ANALYSIS OF OUTAGES
GEAR BOX FAILURE
REASON FOR FAILURE:
• High Speed shaft Bearing failure.
ACTION TAKEN: • Regular servicing /inspection of the bearings ANALYSIS OF OUTAGES
FALLING OF ERODED SHROUD PLATES
REASON FOR FAILURE:
• Flue gas erosion of shroud plate welding. • Size of EJ : 8.5x3.4x 0.7 Mts
ACTION TAKEN: • Full welding with Bolting of shroud plates • Additional angle for protecting the welding. • Full welding of shroud joints • Removal of all patch welding plates. • Replacement of damaged FG inlet duct. EXPANSION JOINT SHROUD PLATE ARRANGEMENT
Angle Clits Angle
Full Welding + Bolting
EXISTING PROPOSED BEST PRACTICES :
1. Installation of oil carry over probe
2. Inspection ports view glass for CE. 3. Covering of Baskets inside the APH. 4. Motorised winch and hoists for basket removal 5. Steam cleaning & jet cleaning of baskets 6. Static seals on either sides of sector plate 7. Usage of flexi seals (radial & axial) 8. Supervision by Ex-BHEL 9. Regular monitoring of Guide & SB oil PQ index. 10. Sealing of guide bearing area & centre section 11. Repl. of worn out bracing pipes with angles. 12. Replacement of damaged ducts. 13. Use of wear plates in critical area in ducts. CONSTRAINTS:
1. SPACE CONSTRAINT IN APHS IN ST-II UNITS.
2. POOR APPROACH FOR TRANSPORTATION OF MATERIALS. 3. 100% BASKET JOB BEING DONE, TIME AVAILABILITY OF CARRYING OUT CRITICAL JOBS IS LESS. 4. GOOD VENDORS FOR SUPPLY OF SPARES 5. PROCUREMENT OF APH BASKETS 6. MAINTENANCE AGENCIES OTHER ISSUES 1. CARBON STEEL ELEMENTS FOR COLD END BASKETS
2. MODIFICATION OF HEATING ELEMENT PROFILE
3. USAGE OF SMALL HEIGHT BASKETS AT HOT END 4. SUPPORT BEARING – CONVERSION FROM BABBIT TO ANTIFRICTION BEARING. APH BASKET SPECIFICATIONS
1. RAW MATERIAL SPECIFICATION & INSPECTION
2. NO. OF PAIRS OF ELEMENTS IN BASKET 3. WEIGHT OF BASKET WITH TOLERANCE 4. METHOD OF PRESSING OF BASKET WHILE ASSY 5. ELEMENT PROFILE UNIFORMITY 6. TESTING FACILITY LIKE HEAT RECOVERY & PRESSURE DROP 7. MATERIAL FOR COVER SHEET OF CE ELEMENTS OIL CARRY OVER PROBE. THANK YOU
