AIR HEATER MAINTENACE/TROUBLE
SHOOTING AND REMEDIES
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1. Pre caution before maintenance .
A. Obtain a work permit.
B. Ensure that the air pre heater is electrically isolated and will
remain isolated while maintenance is being performed.
C. Remove inspection and access doors from the door to ensure
adequate ventilation.
D. Check for poisonous gases.
E. Ensure that air pre heater is adequately cooled down.
F. Ensure that the supplies to the soot blower and water washing
devices are shut off and will remain off .
G. A check must be kept on the oil temperature in the bearing
housing when the air pre heater is ruming with oil circulation.
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2. Pre cautions after maintenance :-
A. Ensure that all tools and extraneous equipment are removed from
the air heater.
B. Check that any components which have been serviced are properly
lubricated.
C. Rotate the rotor slowly by air motor for one complete revolution to
prove freedom of rotation.
D. Secure all access and inspection doors.
E. Ensure that electrical power is restored.
F. Ensure that the supplies to the soot blowers and water washing
devices are available .
G. Return work permit.
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performance.
4. Inspection for wear and corrosion:-
Check excessive wear and tear of
A. Heating surface elements :-
Check corrosion, erosion and checking of heating elements. Excessive
pressure from across AP is due to chocking of heating elements.
B. Sealing arrangement :-
Condition of the seals should be checked as well as the sealing surfaces.
C. Drive unit gear teeth :-
Drive unit gear teeth should be checked for undue wear or scuffing
which may be caused by the gear meshing too hard due to rotor
expansion.
D. Soot blower and washing device nozzles :-
The nozzles of the soot blowers and washing devices should be checked
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for corrosion.
5. Element washing :-
Normally water at 70-80˚c has been found to be most effective for
water washing but lower temperature water can also be used ,washing
at flue gas temperature @ 100˚c is desirable.For washing add soda ash
to the washing water until it has PH of 11 and continued till effluent
draining from element has a PH of 7 (i.e. neutral).
6.Element loading and Replacement :-
The heating surface elements are packed in reversible containers
(baskets) to facilitate removal during maintenance. When an inspection
reveals that one end of the elements are thin or the corrosion has
started the container should he removed from the rotor and replaced
upside down for the buckets of cold end as well as hot end.
7.Seal replacement and setting :-
The air pre heater seals should be set to run just clear of the sealing
surface during normal operation. They should be replaced when
excessive leakage occurs between the air and gas sides. When
replacing seals they should be set to the correct clearances
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8. Drive unit maintenance :-
Maintenance of drive unit consist of providing proper lubrication and
removing the unit for maintenance .
A. Disconnect electrical and air supplies .
B. Remove holding down bolts from air motor.
C. Disconnect air motor coupling and remove air motor.
D. Remove air motor bracket.
E. Remove pinion cover.
F. Remove holding down bolts from electric motor.
G. Disconnect electric motor coupling, remove electric motor and its
brackets.
H. Remove holding down bolts from gear box.
i. Slide the gear box on to a temporary stand .
Note :- when replacing the drive unit correct pinion gear and pinion
rack tolerances must be maintained.
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9. Oil circulation system maintenance:-
Maintenance of oil circulating system consist of filling the system with
oil, replacing the filter cartridge, cleaning the oil cooler and removing
the pump unit for maintenance. Do these maintenance as per correct
procedure laid down by the manufacture.
10. High temperature thread lubricant :-
This lubricant is use to avoid the siezing of nut and bolts due to high
temperature.
Lubricant :-
molycote (imported)
mahomaly anti-sieze thread lubricant.
11. Thread coating compound :-
It is use to avoid corrosion to the fastner due to high temperature of
flue gases and atmospheric airs.
Compound :-
Felproc 5A – (imported)
Moly sulf thread coating compound.
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12. Sealing compound :- it is use seal the various joints to avoid
leakages.
Compound :-
i. Arm cote-imported.
Ii. Molysulf dust tight joints sealant and thinner.
13. Gasket compound :-
It is applied to the gasket where ever use to avoid leakage.
14. Sealing compound :- As per the manufactures recommendations.
15. Trouble shooting ;-
The section contains trouble-shooting procedures that will assist
maintenance personal. Each fault that is likely to occur is listed along
with suggested remedies. When any fault occurs which does not have a
logical remedy, the manufacturer should be consulted.
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Fault Causes Remedy
Excessive leak between gas and Leaking seals Inspect all seals and adjust or
air side replace as necessary.
Excessive noise from rotor Warped rotor due to excessive Reduce boiler load or admit
expansion from heat more cold air.
Foreign object in rotor Stop rotor and visually inspect
it.
Bad bearing Repair or replace bearings.
Rotor does not turn Defective drive unit Ensure power is available to
drive unit.
Foreign object in rotor Inspect rotor and remove any
foreign objects.
Drive unit overheats Inadequate lubrication in drive Lubricate drive unit
unit. component.
Pinion gear and pin rack meshing Adjust drive for proper
too hard hard due expansion . tolerances.
Hard rubbing seals Adjust seals. 9
Bad bearing in gear reducer. Change the bearing.
Note : slight overeating due to hard rubbing seals may be relieved when the air pre
heater reaches normal running temperature or after the seals have worn in properly.
Noisy bearing Inadequate lubrication Check that oil is flowing
through the sight glass and
check oil line up, if necessary.
Oil temperature too high Insufficient cooling Check that adequate water flow
is going in to oil cooler.
Improper oil viscosity being replaces oil with proper type of
used oil
Absorption of radiation heat Insulate properly.
due to improper insulation
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Circulating oil foams Air enter the oil system Check for any air leak on the
suction side of the oil system.
Low oil level Leak in oil system Locate and arrest the leak
Soot blower not functioning Power failure mechanical Check electrical line up
binding Check the speed reducer
moveable parts for binding.
Swivel header travel incorrect Adjust travel of nozzle pipe.
steam pressure Ensure adequate steam supply is
available.
Check nozzle pipe for bad
nozzle.
Excessive pressure drop Badly fouled air pre heater Operate soot blower and check
soot blower steam for proper
pressure and temperature.
Excessive bluging. If soot blower is not effective
heater can be isolated and
water washed off load ( inworst
case, remove the basket and
clean them outside).
Thinned down and damaged ele Rectify and replaces 11 the
ments. element baskets.
Variation(periodic kick) in the Excessive rubbing of some seals Locate faculty seal and replaces.
main drive ammeter current faculty bearings Rectify for replace the bearings.
Abnormal increase in the Starting up of fire inside the air Immediately isolate air heater
temperatures heater and check for fire and quench
the fire with abundant quantity
of water. refer section Air Pre
heater fires in this manual CO2
foam, steam should not be used.
Increase in gas outlet Air heater stalled Isolate air heater and check for
temperature and steady fall of trouble in the drive system.
air outlet temperature.
Clean heating element
Heating element plugged
Oil filter choked Clean or replace the cartridge.
Excessive pressure build up by
lub oil pump
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PRESANTATION BY
ER. KHAN HABIB KHAN
ASSISTANT PROFESSOR
JIPT/TAMNAR, RAIGARH(C.G.)
07898905255/09420753717
DATE:- 02-04-2012
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