FM Global

Property Loss Prevention Data Sheets 6-8

Reaffirmed October 1990
Revised January 2000
Page 1 of 11

COMBUSTION AIR HEATERS

Table of Contents
Page

1.0 SCOPE ................................................................................................................................................... 2

1.1 Changes .......................................................................................................................................... 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 Protection ......................................................................................................................................... 2
2.2 Equipment and Processes .............................................................................................................. 2
2.3 Operation and Maintenance ............................................................................................................ 3
2.3.1 Regenerative Air Preheaters ................................................................................................. 3
2.3.2 Gas Turbines ......................................................................................................................... 3
2.3.3 Boilers .................................................................................................................................... 3
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 3
3.1 Detection .......................................................................................................................................... 3
3.1.1 Thermocouples ...................................................................................................................... 3
3.1.2 Thermistor Cable ................................................................................................................... 3
3.1.3 Infrared Detection .................................................................................................................. 3
3.2 Extinguishment ................................................................................................................................ 3
3.2.1 Regenerative Air Preheaters ................................................................................................. 4
3.2.2 Recuperative Air Preheaters ................................................................................................. 4
3.3 Loss History ..................................................................................................................................... 4
3.3.1 Cause .................................................................................................................................... 4
3.3.2 Regenerative Air Preheaters ................................................................................................. 4
3.3.3 Recuperative Air Preheaters ................................................................................................. 5
4.0 REFERENCES ....................................................................................................................................... 5
4.1 FM Global ........................................................................................................................................ 5
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 5
APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 5
APPENDIX C DESCRIPTION ....................................................................................................................... 5
C.1 Recuperative Air Preheaters ........................................................................................................... 5
C.1.1 Tubular Type ......................................................................................................................... 5
C.1.2 Plate Type ............................................................................................................................. 6
C.1.3 Coil Type ............................................................................................................................... 6
C.2 Regenerative Air Preheaters ........................................................................................................... 6
C.2.1 Rotating Plate ....................................................................................................................... 7
C.2.2 Stationary Plate .................................................................................................................... 7

List of Figures
Fig. 1. Regenerative Air Preheater Installation in Flue Gas System of Steam Generator. ........................... 6
Fig. 2. Two-Pass Tubular Recuperative Air Preheater Installed in Flue Gas System of Steam Generator. . 7
Fig. 3. Five-Pass Tubular Recuperative Air Preheater. ................................................................................. 8
Fig. 4A. Rotating Plate Regenerative Air Preheater Showing Combustion Air and Flue Gas Flow. ............ 9
Fig. 4B. Cut-Away View of Rotating plate Regenerative Air Preheater Showing Location of Water
Spray System. ................................................................................................................................ 10
Fig. 5. Stationary Plate Regenerative Air Preheater Showing Location of Water Spray System. .............. 11

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6-8 Combustion Air Heaters
Page 2 FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet covers combustion air heaters (also called air preheaters) used to heat combustion air for
gas turbines, boilers, ovens, and furnaces. It includes descriptions, loss experience, and suggested
recommendations.

1.1 Changes
June 1999. This revision of the document has been reorganized to provide a consistent format.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Protection
2.1.1 Install a water spray system to protect the upper surface on a vertical shaft rotor. The water density
should be 0.60 gpm/ft2 (24 mm/min) (Figs. 4 & 5). Water spray should be installed to protect both sides of a
horizontal shaft rotor. The density on each side should be 0.3 gpm/ft2 (12 mm/min). Consider the cross-
sectional area of the rotor or stator as the design protected area. (See Data Sheet 4-1N, Water Spray Fixed
Systems for Fire Protection).
2.1.2 The water spray system should be capable of remote actuation form the control room and manual
actuation from the preheater area. A master fuel trip should be carried out immediately on detection of a fire
in a preheater. The preheater should be isolated where possible by dampers. Drains should be opened. The
water spray should then be actuated.
2.1.3 Provide access ports for use of hose streams. Ports should be easily opened. One port should be
provided easy access every 10 ft (3 m) of rotor or stator diameter. For horizontal units access ports should
be provided on both sides of the rotor or stator. For vertical units provide access ports above the rotor or
stator. For units under 20 ft (6 m) in diameter, provide one port below the rotor or stator. Provide two ports
for larger units. A hose station should also be provided. An observation port should also be provided.
2.1.4 Size drains to handle the combined water discharge from the water wash cleaning system and from
the fire protection system, plus a 500 gpm (1900 dm3min) hose stream demand. The drains should be
equipped with either remotely operated or readily accessible valves.
2.1.5 Install an infrared or thermistor detection system to give early warning for preheaters 20 ft (6 m) or
larger in diameter. Infrared detectors should be arranged to monitor rotor or stator surfaces on either the air-in
or air-out side of the preheater. Thermistors are an alternative to infrared detection.
2.1.6 Provide a zero speed switch on the rotor shaft or on the output shaft from the fluid coupling or gear
reducer. Loss of shaft rotation may indicate failure of the drive motor with increased danger of overheating.
It will also warn against binding of the rotor against the housing in rotating plate heaters, or the air hoods
against the stator in stationary plate preheaters.
2.1.7 Monitor oil temperatures and either oil pressures or oil flow rates for external lubrication systems of
bearing assemblies on the main shaft
2.1.8 Maintain motors, couplings, bearing assemblies, etc. in accordance with manufacturer’s instructions.
Data Sheet 13-7, Gears, also provides guidance in this area.

2.2 Equipment and Processes

2.2.1 Provide temperature sensors in the inlet and outlet ducts for both flue gas and air. Temperature readings
in the control room should be clear and readily identifiable to operators. Establish setpoints. The
recommended setpoint is 50°F (30°C) above normal operating temperature. Provide an alarm to warn
operators in the event setpoints are exceeded.
2.2.2 Provide pressure sensors to monitor pressure drop across the air preheater as an aid to detect plugging.
(See Data Sheet 6-6, Boiler Furnace Implosions.)

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Combustion Air Heaters 6-8
FM Global Property Loss Prevention Data Sheets Page 3

2.3 Operation and Maintenance

2.3.1 Regenerative Air Preheaters

[Link] Periodic cleaning with a water wash, steam, and/or compressed air system should be done regularly.
Periodic use of a chemical agent such as a hot potassium hydroxide solution may result in more efficient
cleaning.

2.3.2 Gas Turbines

[Link] Provide proper maintenance and adjustments of settings for starting devices and controls.

2.3.3 Boilers
[Link] Maintain proper firing mixtures to minimize the amount of unburned fuel. Consider the installation
of a continuous oxygen/combustibles analyzer in the flue gas stream to provide the operator with an indication
of combustion efficiency.
[Link] Follow the boiler manufacturer’s start-up procedure. During start-up of the unit, if normal warm-up
periods are extended substantially for any reason, i.e., equipment failure, the air preheaters should be isolated
and water washed.

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 Detection
Early detection and quick response is vital to prevent a major fire loss in an air preheater. Several types of
detection systems are available and have been used with varying degrees of success.

3.1.1 Thermocouples
Thermocouples are often used to monitor inlet and outlet air and flue gas temperatures. They can be used
as a fire detection system, provided alarm setpoints have been established and readings are easily
identifiable to control room operators. It is probably the most easily maintained detection system. Because
of operating characteristics, however, this may be the least sensitive method. Given the large volume of flue
gas and air, a fire may be well developed before it is detected.

3.1.2 Thermistor Cable

This method of detection is effective in the stationary plate regenerative heater. Thermistor cable can be
placed in the area between the cold end and the intermediate layer of baskets, with thermistor wire arranged
to pass through each section. This system can also be used for rotary plate regenerative heaters by
installation on a metal frame work independent of the rotor.

3.1.3 Infrared Detection

Two types of infrared detection systems have been developed. In both types several infrared sensors are
used to scan specific areas on the surface of the rotor. Rotation of the rotor brings all surfaces past the infrared
sensors. The sensors are located in water- or air-cooled housings with soot blowers arranged to clean the
lenses.
In one design the sensing head rotates on an arm with detectors looking into the baskets along the axis of
the rotor shaft Because fires often start between intermediate and cold-end baskets, this arrangement is
likely to be particularly sensitive. The sensing head can be ‘‘parked’’ in a well in the side of the housing when
the preheater is washed or when maintenance work must be done on the sensor.
The second type uses infrared sensors mounted in a fixed position in a housing in the shell of the preheater.
Each sensor scans part of the rotor surface.

3.2 Extinguishment
A preheater fire should be fought with water. Hose streams are too slow to be effective in the early stages
of a fire. A fixed water spray system is the most effective method of getting large quantities of water onto
preheater surfaces quickly. Water should be sprayed over the upper surface of a vertical preheater and on

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6-8 Combustion Air Heaters
Page 4 FM Global Property Loss Prevention Data Sheets

both surfaces of a horizontal preheater. Water provides cooling capability to prevent major structural damage
and it extinguishes the fire by lowering the temperature of burning residues and oil below their autoignition
temperatures.

3.2.1 Regenerative Air Preheaters

[Link] Rotating Plate

Water wash systems are not effective in fire fighting. The water wash system covers a relatively small area
of the rotor and depends on rotor rotation to cover the entire surface. In several fires the rotor has jammed
and the fires have had to be controlled by hose streams.

[Link] Stationary Plate

Water wash systems are usually designed to cover the entire stator surface areas. If this area includes the
area under the hoods (see Fig. 5), it should be adequate for fire protection.

3.2.2 Recuperative Air Preheaters

Reported fire experience has not been sufficient to justify the installation of a water spray system.

3.3 Loss History

Most losses reported to FM Global have been fire losses occurring in regenerative air preheaters serving
oil or pulverized coal fired boilers. Fires occur most frequently in preheaters used in electric utilities and the
pulp and paper industry.

3.3.1 Cause
Fires occur after the accumulation on preheater surfaces of appreciable quantities of combustible residues
from incomplete burning of fuel. This is most likely to occur on start-up. At this time preheater surfaces are cold
and products of incomplete combustion may condense and accumulate. When firing on oil this may result
in a heavy film of oil which on a vertical unit may be seen dripping off the bottom surfaces of the preheater.
When pulverized coal burners are started, unburned coal may adhere to the heavy film of oil increasing the
combustible loading.
Incomplete combustion on oil firing may be caused by low oil temperatures, improper oil or atomizer pressure,
fouling of atomizer components, etc. Incomplete combustion on pulverized coal units may be caused by
changes in quantity of coal, moisture content, particle size, etc. It is important for operators to observe burner
flames and make adjustments as necessary.
Ignition results when the temperature of the combustibles is raised above their autoignition temperature, or
from hot embers from the boiler. Once ignition occurs, the result may be either a ‘‘hot spot’’ or a fully
developed fire. A hot spot usually damages a small area of the preheater. The effect on preheater efficiency
is minimal and may not be noticed until baskets are removed for replacement. A fully developed fire involves
large areas of the preheater and may warp and melt metal plates in the baskets. Diaphragms may also be
damaged. While baskets are relatively easy to replace, diaphragms are major structural assemblies which
require extended periods of time to remove and replace.

3.3.2 Regenerative Air Preheaters

Twenty losses were reported to FM Global in regenerative air preheaters since 1961; eight occurred in electric
utilities and eight in paper manufacturing. The other preheater losses involved the mineral processing and
hardboard industries.

[Link] Electric Utilities

Five of the eight reported losses occurred on start-up, two occurred during load change, and one during
shutdown.
Oil was being fired at the time the fires were detected in four of the losses and pulverized coal in the other
four. Two of the losses involving pulverized coal occurred shortly after the boiler was brought up to load with
oil-fired ignitors.

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Combustion Air Heaters 6-8
FM Global Property Loss Prevention Data Sheets Page 5

The first indication of a problem in the unit was most often overload on the rotor drive motor or high
temperatures in the combustion air-out or flue gas-out of the preheater. In some losses warning was received
from other instrumentation. One fire was detected after repeated smoke alarms were received (smoke alarm
was installed on stack to ensure compliance with emission control requirements). In another loss low
amperage and bearing trouble signals were received from an ID fan.
The water wash system proved effective in extinguishing fires if the rotor could still turn. In many cases,
however, heat from the fire resulted in binding and ‘‘freezing’’ of the rotor. In these losses fire hose had to
be used through access ports. Frequently there were not enough access ports and additional openings had
to be cut in the housing, delaying fire fighting operations.

[Link] Pulp and Paper Manufacturing

Eight losses have been reported since 1961. Two losses occurred during start-up, two during load change,
two during frequent changes in type of fuel fired, and two occurred during normal operation. All losses
involved regenerative air preheaters. Losses were detected most often by visual inspection by the operator
or other plant personnel after a substantial problem had been noted on the boiler (e.g., a drop in steam
production, problems with the FD fan, decrease in excess oxygen, etc.).

3.3.3 Recuperative Air Preheaters

Four losses were reported to FM Global in recuperative air preheaters, three occurred to preheaters serving
gas turbines in electric utilities, and one occurred in paper manufacturing.

4.0 REFERENCES

4.1 FM Global
Data Sheet 4-1N, Water Spray Fixed Systems.
Data Sheet 6-6, Boiler-Furnaces Implosions.
Data Sheet 13-7, Gears.

APPENDIX A GLOSSARY OF TERMS

Refer to Appendix C, Description, for terms used in this data sheet.

APPENDIX B DOCUMENT REVISION HISTORY

This document does not have any revision history.

APPENDIX C DESCRIPTION
Combustion air heaters, more commonly called air preheaters, are used to preheat combustion air. Air
preheaters are heat exchangers which raise air temperatures by recovering heat from flue gas or other heated
media. Air preheaters are used on gas turbines, boilers, ovens, and furnaces to preheat incoming combustion
air to increase efficiency (Figs. 1 and 2). In the case of pulverized coal firing, preheated air may also be used
to dry and transport pulverized coal to the burners.
There are two types of air preheaters: recuperative and regenerative. Recuperative air preheaters are
generally used on small boilers, furnaces, and gas turbines where high heat recovery is not economically
justified. Regenerative air preheaters are generally used on large boilers or furnaces.

C.1 Recuperative Air Preheaters

There are three main types of recuperative air preheaters.

C.1.1 Tubular Type

Tubes are used to transfer heat from flue gas to combustion air (See Figs. 2 and 3). Most tubular air preheaters
are arranged so that flue gas enters at the top and passes down through the tubes. Air enters at the bottom
and flows around the tubes. Tube diameters range from 1-1⁄2 in. (3.8 cm) to 4 in. (10 cm) OD.

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6-8 Combustion Air Heaters
Page 6 FM Global Property Loss Prevention Data Sheets

Fig. 1. Regenerative Air Preheater Installation in Flue Gas System of Steam Generator.

Depending on the type of fuel burned and the size of the unit, soot blowers and/or water wash systems may
be provided. Soot blowing may be done with either air or steam and is designed so that each tube can be
cleaned as required. Water wash systems are designed for use when the unit is out of service.

C.1.2 Plate Type

Thin, flat plates arranged parallel to one another transfer heat from flue gas to combustion air. Spacing
between plates is alternately wide and narrow. Flue gas passes through the wide spaces; air through the
narrow spaces.

C.1.3 Coil Type

Coils are used to transfer heat from steam or a heat transfer medium such as ethylene glycol to the air. Coil
heaters are often used to heat air before it enters large regenerative air preheaters. This increases the
average cold end temperature reducing the quantity of sulfuric acid vapors condensing in the preheater,
thereby reducing corrosion.

C.2 Regenerative Air Preheaters

Regenerative air preheaters consist of a large metal drum subdivided into a number of pie-shaped sections
by steel diaphragms. Each section has two or three layers of baskets. The baskets are made from closely
spaced flat or corrugated sheet metal. The baskets are arranged to allow passage of air and flue gas while
exposing the maximum surface area. Heaters are designed so that baskets can be replaced after several
years’ use. Diaphragms are integral parts of the drum and are only replaced if damaged. There are two types
of regenerative air preheaters.

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Combustion Air Heaters 6-8
FM Global Property Loss Prevention Data Sheets Page 7

Fig. 2. Two-Pass Tubular Recuperative Air Preheater Installed in Flue Gas System of Steam Generator.

C.2.1 Rotating Plate

The drum (rotor) revolves alternately through the flue gas stream, where it absorbs heat, and through the
air stream, where it releases heat (Fig. 4). Gas flow can be horizontal or vertical. In larger diameters it is
vertical. The rotor is driven by electric motor at 1 to 3 rpm. An air-operated motor capable of turning the rotor
at one-half normal operating speed is provided for inspection and maintenance of the rotor. It can serve as
a temporary backup to the electric motor. Both motors drive through the same coupling to a common output
shaft with a drive pinion. Older, smaller preheaters may be equipped with hand cranks instead of the
air-operated motor.
Metal radial and axial seals are provided in the air preheater to minimize air leakage into the flue gas stream.
Radial seals reduce air infiltration across the face of the rotor. Axial seals reduce air infiltration between the
circumference of the rotor and the preheater housing.

C.2.2 Stationary Plate

The drum (stator) is stationary. Two hoods, one above and one below, rotate over the stator (Fig. 5). Air flows
from the cold air hood, through the stator to the hot air hood, to the windbox or coal pulverizers. Flue gas
flows outside the air hoods, counter-current to the flow of air inside the hoods. The hoods are rotated at 1 rpm
by an electric motor. A backup air-operated motor is usually installed to rotate the hoods at 1⁄2 rpm for
maintenance and inspection. It can also serve as temporary backup. Both motors are on separate shafts
to a gear reducer to one output shaft with drive pinion. Older, smaller preheaters may be equipped with hand
cranks instead of the air-operated motor.
Cast iron seals are used to seal the rotating hoods against the stator face (hood seals) and to seal the air
hoods against the stationary central air ducts (collar seals).
Both units use steam or compressed air and water spray to clean the plates. Steam or compressed air can
be used while the heater is in operation. The frequency of cleaning depends on the type of fuel fired and
firing conditions.

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6-8 Combustion Air Heaters
Page 8 FM Global Property Loss Prevention Data Sheets

Fig. 3. Five-Pass Tubular Recuperative Air Preheater.

Water wash systems are also used. A typical system for a rotating plate preheater consists of a fixed pipe
between the axis and the side of the unit with closely spaced nozzles directed at the heat transfer elements.
Water is supplied under high pressure to clean the plates. Valves in the lower part of the heater must be
open to drain the water. Water washing is usually done with the boiler out of service. It may be done on multiple
preheater installations while the boiler is in operation if the preheaters can be isolated from the flue gas
stream. The load on the boiler must be reduced, one of the preheaters isolated, and the drains opened to
prevent carryover of water into the windbox or the precipitator.

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Combustion Air Heaters 6-8
FM Global Property Loss Prevention Data Sheets Page 9

Fig. 4A. Rotating Plate Regenerative Air Preheater Showing Combustion Air and Flue Gas Flow.

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6-8 Combustion Air Heaters
Page 10 FM Global Property Loss Prevention Data Sheets

Fig. 4B. Cut-Away View of Rotating plate Regenerative Air Preheater Showing Location of Water Spray System.

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Combustion Air Heaters 6-8
FM Global Property Loss Prevention Data Sheets Page 11

Fig. 5. Stationary Plate Regenerative Air Preheater Showing Location of Water Spray System.

©2002 Factory Mutual Insurance Company. All rights reserved.