Challenge us to reduce heater leakage and running costs.
When Tucson Electric Power (TEP) Springerville Station was experiencing major air leakage issues, they called on Howden to rectify the situation. An inspection revealed major air leakage in the air preheaters, up to 40%. Howden recommended a double sealing modification and a new profile basket to improve the thermal performance and reduce air leakage. TEP took Howden's advice and engaged Howden Construction Services to perform a full Turnkey project on their Unit 2 secondary Air Preheaters. This became the first double sealing modification completed in North America.
Howden conducted multiple visits to collect the necessary data and do a complete inventory in order to properly plan for what was needed. The project was performed during the spring outage in 2014, thereafter a performance test was conducted, verifying all performances were met (i.e. to improve the thermal exchange, reduce the secondary air leakage from 40% significantly down to 10% or below).
TEP Springerville was facing similar issues with their Unit 1 the following year. Remembering Howden's previous year's success, they reached out to Howden Construction Services again to perform a full Turnkey project.
The secondary air preheater project was the critical path in TEP's 2014 spring outage. The main challenge for this project was that Howden was allotted just four weeks to complete the project, which normally requires a full 6+ week time frame.
The Air Preheater was in a congested area of the plant that caused frequent interruptions and delays. The unit was warped and corroded, adding more work and parts required to properly carry out the Turnkey project.
From the start of the planning phase, throughout the outage, and after startup, Howden took full project responsibility. Through coordination with Howden and the plant management, the crew worked around the clock, seven days a week until completion. Howden served as the single point of contact for the plant and led the project to completion.
Once the unit was online and in steady load, a performance test was conducted and it was found that Howden was successful in reducing the leakage to levels below 10%. After all the data was analyzed it was found that TEP Springerville saved $161,000 annually with their leakage reduction.
What you get
- An experienced team, led by a highly skilled construction/project manager, focused on key project milestones.
- Dedicated labor resourcing plans; optimizing utilization in line with project deliverables.
- Timely delivery of goods in line with agreed schedules.
- A fixed price contract enabling you to plan with confidence.
- Quality installation/replacement of equipment for assured and reliable performance: "We do not leave until the job is done right".
Full List of Case Study pages
The introduction of Howden's VN seal system to the air preheaters brought an immediate drop in leakage level from 26% to 5%.
Howden completed a retrofit of VARIAX ID fans on the 640MW unit 5 at Asnaes Power Station, Denmark.
The Howden Free Floating Piston is a proven unique technolgy that turns the weakest point to one of the strongest, which removes rider bands wear at a stroke
Berre Petrochemical Cluster, which includes polypropylene and polyethylene plants, trusted Howden to reduce its power costs by 7% within a 3 year return on investment.
VentSim CONTROL technologies result in impressive cost and energy savings while also raising productivity at Goldcorp Eleonore gold mine.
Fresnillo mine is one of the most technologically advanced deep mines in the world, and incorporates VentSim CONTROL ventilation management.
UPTIME provides advanced compressor performance analysis at Gunvor Petroleum in the Netherlands
Howden worked with a North American hard rock mine to introduce a Ventilation on Demand system using VentSim CONTROL technology.
Installing a bigger hub at Herningvaerket, reducing installation costs and future service expenses.
The understanding and knowledge provided by Howden is an essential factor when installing additional equipment on your compressors.
New integrally geared compressor (IGC) results in power savings up to 31MW/h a day
Replacement of primary plate heaters with Howden custom designed rotary air preheaters.
200 bar to 300 bar hybrid compressor retrofit for helium capacity filling
At Millmerran Power Station, Howden provides a tailored service that supports their needs of the plant to prepare for their upcoming major outage.
New boiler and FGD processes called for a total change of the ID booster fan at a power plant in Plzen
Howden develop method to drastically reduce the cylinder repair time of reciprocating compressors.
Upgrade your reciprocating compressor with our innovative coated liner solution.
The introduction of Howden's HC element to the air preheater resulted in extended operational times.
Huge savings were realised by using Howden's turnkey service to reduce heater leakage and running costs.
A large chemical plant on the east coast of the United States contacted Howden to perform a full Turnkey project on their critical path air preheaters.
Howden expertise solves long lasting problems with an axial fan at Uniper's Franken plant.
During the first few months after the deployment of Uptime, VEAS experienced two distinct challenges where the benefits of Uptime were clearly demonstrated.
VentSim CONTROL case study for three typical mining projects.
Replacement of existing blades at the Wangqu Thermal Power Station
Efficient engineering solves impeller failures at the Wibank coalfield.
At Tarmac (Dunbar cement plant, UK), their existing Raw Mill fan was replaced with an enhanced Howden design in 2007.
Building the world's biggest reciprocating compressor - a white paper and video.
If you would like to submit an enquiry please get in touch.