GEECO Enercon Pvt. LimitedAn ISO 9001, 14001, 50001 & OHSAS 18001 Certified Company

RAPH | ESP | CFD | FEA | FES | TESTING | TRAINING

ABOUT US

ROTARY AIR PREHEATER

ELECTROSTATIC PRECIPITATOR

COMPUTATIONAL FLUID DYNAMICS

FINITE ELEMENT ANALYSIS

FIELD ENGINEERING SERVICE

TESTING

TRAINING

RESEARCH AND DEVELOPMENT

ABOUT US

GEECO Enercon Pvt. Limited, a successful engineering organization had its inception in the year 1985 & ventured into Rotary Air

Preheater spares manufacturing. After proving our uniqueness & stand-alone capability in Air Preheaters & putting forth Energy

Conservation, we enhanced our notion towards Environmental Conservation with Electrostatic Precipitator System (ESP) solutions.

GEECO's various functional areas include 'Design, Engineering, Research & Development, Manufacturing, Supply, Erection,

Commissioning & Service Supervision'. Our Company operations are efficiently managed by established ERP systems.

Our Administrative, Design, Commercial & Marketing operations are supported by Head Office located at Tiruchirapalli, India &

other activities which include Production, Quality & Warehousing are being carried out at our wide spread factory spanning 20 acres

located at Thanjavur, India. GEECO's manufacturing facility is established in a total covered area of 1,54,000 Sq.ft.

With our global exposure & technical expertise, the consequences of global warming are being solved through APH & ESPs using

customized designs based on our customer requirements.

VISION➔ To be a world class engineering organization that provides the best products & services

MISSION

We commit to be the most admired company by:

➔ Providing the products & services that exceed customer expectations

➔ Innovating & Deploying total business solutions

➔ Empowering our employees & creating an environment for them to perform at their highest potential

MANAGEMENT TEAM

Mr. V. Rajagopal - Chairman & Managing Director

A Post Graduate in Mechanical Engineering with vast experience in Air Preheater since starting with BHEL in

1975. He was first trained at Combustion Engineering, USA and later headed the Air Preheater Division at Alstom. He

has worked with most of the Air Preheater designs available around the globe and is actively involved in its selection,

design and field engineering. A multifaceted personality who develops strategical plans towards company growth.

Mr. C. Gunasekaran - Director

A versatile entrepreneur who holds an Manufacturing Industry for Boiler components since 1982 with “Indian

Boiler Regulation” certification and has huge experience in manufacturing components for Cement & Steel Plants. He

guides & monitors the overall work flow of GEECO with extra care on Financial activities and is instrumental in

making sound investment decisions. He monitors financial outcome against the Company's plans and budgets.

Mr. M. Amirthalingam - President

Since his graduation as Mechanical Engineer, joined Asia’s largest power plant manufacturer M/s. Bharath Heavy

Electrical Limited (BHEL), Trichy in 1970 and reached the General Manager level in his 44 years tenure. His areas of

expertise include Materials Management, Commercial, Marketing, Project Management & Manufacturing. He is

persistent towards attracting more customers and develops strategies for promoting GEECO's products.

Mr. V. R. Vi jayaprakash - Technology Management Advisor

A Mechanical Engineering graduate with dual Masters from Germany, one in Management & other in

Computational Engineering. He has handled various customers around the globe during his tenure with Bombardier &

CD-adapco. Has been a tremendous contributor to GEECO's success by actively involving in Management, R&D,

Engineering & IT. He is also leading TEFUGEN Technologies Pvt. Ltd., which offers CFD / FEA / IT solutions.

STRENGTH & CAPABILITIES➔ Supply of Quality Spares for any make and size of Air Preheater up to 1000 MW

➔ Supply of New Air Preheaters

➔ Carrying out CFD / FE Analysis

➔ In-house Research & Development (R&D)

➔ Undertaking Assessment Studies

➔ Undertaking R&M Jobs

➔ Field Engineering Support

➔ Conducting Air Preheater Performance Test

SPARES SUPPLIED BY GEECO

Rotor Assembly / Heating Elements / Baskets / Seals / Housing / Connecting Plate / Sector Plates / Support Bearing / Guide

Bearing / Rotor Drive / Oil Circulation System / Cleaning device / Wash Pipe & Deluge Assembly / Fire Sensing Device / Rotor

Stoppage Alarm.

ROTARY AIR PREHEATER

ENGINEERING CAPABILITIES➔ Complete In-house design

➔ Development of a validated software program for selection of Air Preheaters

➔ Computerized performance prediction

➔ Analysis & Optimization of flow with the help of advanced CFD techniques

➔ Structural Design & Optimization by Finite Element Analysis

MANUFACTURING CAPABILITIES➔ Manufacturing Capacity of 1600 MT per month

➔ Concurrently, 4 numbers of bigger size APH 36 VI can be manufactured

➔ Equipped with all the machines required for our In-house machining

NEW AIR PREHEATER

Executed a contract to M/s. Bharat Aluminium Company Ltd., Power Plant – II for the replacement of existing Air Preheaters [size

24VIT] with the New Air Preheaters [2-numbers of size 25.5 VITM 1900 (2100)] including Design, Engineering, Manufacturing, Supply

& Site Supervision for one of their 135 MW unit, to their entire satisfaction. This APH is consistently running with desired parameters.

Contract was awarded and completed for the total supply of New Air Preheaters [Two Numbers of size 27 VIT - 2100] to M/s.

Ansaldo for their Nagai – I Power Plant.

GAS TO GAS HEATER

RENOVATION & MODERNIZATION - ADVANTAGES➔ Reduced Leakage

➔ Increased Heat Transfer Area

➔ Reduced Differential Pressure across the APH

➔ Assured Highest possible efficiency

➔ Reduced Fuel Quantity

➔ Reduced fan current

➔ Increased Revenue

ROTARY AIR PREHEATER

We have executed a "Major Order" from the leading power producer in India, TATA

Power, for the replacement of existing Gas to Gas Heaters to New Gas to Gas Heaters [1 -

number of size 27 VIM 84”] including Design, Engineering, Manufacturing, Supply & Site

Supervision for their 500 MW Trombay unit.

MAJOR SUCCESSFUL PROJECTS

Tuticorin Thermal Power Station

(210MW), TANGEDCO

Three contracts for Unit 3, Unit 4 & Unit 5, Converting existing Air Preheater to Modular

Air Preheater with Double Sealing Arrangement was executed.

Executed a contract involving Design, Engineering, Manufacturing & Supply including Site

Supervision during Erection & Commissioning for Air Preheater with increase in size.

Executed a contract for 5 Boilers, involving Design, Engineering, Manufacturing, Supply &

Site Supervision for Air Preheater.

Talcher Thermal Power Station

(110MW), NTPC Ltd.

Contract was executed involving Design & Supply of Complete Support Bearing Assembly

including Erection & Commissioning for Air Preheater.

Executed a contract through M/s. NASL, India, involving Design, Detailed Engineering,

Manufacturing & Supply of Air Preheater with Sector Angle Modification.

Hindalco Industries Limited (Renukoot

Power Division)

Hindalco Industries Limited (Renusagar

Power Division)

Tuticorin Thermal Power Station

(210MW), TANGEDCO

Mettur Thermal Power Station

(210MW)

The existing Air Preheaters were replaced with higher sized Air Preheaters.

National Aluminium Co. Ltd.

Damanjodi

Replacement of existing Air Preheaters with higher size Air Preheaters to increase the heat

transfer area.

Bharat Petroleum Corporation Ltd.

(Kochi Refinery)

The existing Air Preheaters were replaced with higher sized Air Preheaters.

ELECTROSTATIC PRECIPITATOR

MANUFACTURING CAPABILITIES➔ Manufacture of ESP Components within our shop floor

➔ International Quality Standards in manufacturing

SPARES SUPPLIED BY GEECO

All types of Emitting Electrodes & Collecting Electrodes / Rapping Shafts / Plain Bearing / Set Ring / Coupling / Firm & loose

type shock bars / Shock pads / Shock Bar guide front & rear / 'U' guide / Inner arm / Outer arm for collecting & Emitting systems / Pin

wheels / Grip couplings / Bush bearing / Gear motor / Rapping timer systems / Heaters for Hoppers, Shaft insulators & Support insulators

/ Thermostats / Ash level indicators / Rapper Coil for EMIGI / Hyplan Boot with SS Clamp / Inlet / Outlet GDs Screen / Screen Tubes /

Conical & Cylindrical support Insulators / Shaft Insulator, Pin Insulator & Bushing Insulator / TR set panel & Accessories / plunger /

Mech. Safety rods / Torque Wrench / Stretching tools / Purge air system.

ENGINEERING CAPABILITIES➔ Sizing & Selection of ESP for any type of applications &

for a wide variety of fuels including fossil and biomass

➔ Design & Engineering for both Tumbling Hammer

Rapping Mechanism & Electro Magnetic Impulse Gravity

Impact (EMIGI) Rapping Design

➔ Compliance with stringent emission norms as low as

20mg/Nm3.

➔ Structural frame analysis using FEA

➔ Computational Fluid Dynamics model study

PROCESS CAPABILITIES

GEECO being an IMS certified company, the following procedures are

adopted as a routine while manufacturing the components of ESP in shop floor and

during installation at sites.

➔ Product - specific Quality Control procedures

➔ Standard Welding & Painting procedures

➔ Standard Quality Plans

➔ Field Quality Control procedures

With the remarkable progress achieved in the field of computer technology,

Computational Fluid Dynamics (CFD) would be a useful low-cost optimization tool for

internal flows through duct / pipe networks. Using CFD models, pressure, velocity &

temperature fields are visualized through the existing component for a particular operating

point. As a result of sudden geometry changes like sharp bends & abrupt expansion /

contraction in the existing geometry, problematic areas such as flow recirculation & non-

uniform velocity zones that contribute to the excessive pressure drop are identified.

Multiple optimization cycles are carried out in order to arrive at a final optimized design,

which has the minimum possible pressure drop for the duct system & uniform velocity

distribution. The Boundary Conditions are arrived by manually testing the flow onsite.

The Streamlines depict the flow inside the Electrostatic Precipitator & the Flue gas

outlet duct vividly showcases the reduction in wall pressure between the initial &

optimized designs.

Electrostatic Precipitator

Duct System

Init ial Design

Optimized Design

COMPUTATIONAL FLUID DYNAMICS

Pressure (Pa)-1900 -1860 -1820 -1780 -1740 -1700 -1660 -1620 -1580 -1540 -1500

Velocity Magnitude (m/s)

18

16

14

13

11

9

7

5

4

2

0

Transient Analysis of various Air Preheater Heating Element profiles was carried out in a test

environment to provide a detailed comparison of Temperature, Pressure, Velocity, Boundary Heat Transfer,

Turbulent Kinetic Energy & Nusselt Number. The results are used to select the most appropriate heating

element profile for the plant operating condition. CFD Analysis is also carried out to study the flow pattern &

establish a uniform flow upstream of the Air Preheater.

The velocity flow streamlines depict the flow behaviour & possible stagnation zones. These zones are

studied for their turbulence characteristics & efforts are taken to minimize flow losses.

DU VAR1 PROFILE FNC PROFILE DU VAR2 PROFILENF6 PROFILE CU PROFILE

Time Step : 0.2 secs

Unsteady Heat Transfer

Study of APH Heating

Elements.

Temperature Plot.

Time Step : 20 secs

Unsteady Heat Transfer

Study of APH Heating

Elements.

Temperature Plot.

Geometries of APH

Heating Elements.

30 94 158 222 286 350Temperature (C)

Flow through Air Preheater

FINITE ELEMENT ANALYSIS

FEA Process Cycle

1

2 3

4

Geometry

Discritization

FEA

Solver

3D CAD

Geometry

Implementation

& Production

Finite Element Analysis, an advanced computational program based on numerical methods for evaluation of structures & system is

used to accurately predict components' response when subjected to thermal & structural loads. It verifies design integrity & identifies

critical location on a component, thereby design improvements can be done before building the component.

FEA is being used extensively at GEECO during the Product Design & Development stage to ensure safe operation and longer life

of the products. It accurately predicts the induced stresses and the resulting deformation during operation of the component and thus paves

way for optimized product design. The picture given below illustrates the FEA process cycle deployed during the design of a typical

bearing housing at GEECO.

Manufacturing Process

GEECO uses FEA for various

manufacturing process optimization. One

such example is the cold rolling of heating

elements simulation to optimize the

process for ensuring best heating elements

profile accuracy during manufacturing.

The method is applied in

➔ Forming Process

➔ Tool Wear & Tear

➔ Residual stress

➔ Weld sequence & Clamping

Thermal Loading

FEA is used for the prediction of stresses

& distortions resulting from Thermal

loadings on APH & ESP components.

Rotor deformations resulting from thermal

loads during the APH operation are

simulated & based on the FEA report,

modifications are done to the rotor design

accordingly. Thermal loadings are also

checked for

➔ Center Section

➔ Rotor

➔ Supporting Joints

Structural Loading

Structural loading stresses & deformations

on APH & ESP components are predicted

using FEA. Housing, which holds the

weight of the rotor assembly including

baskets are simulated for deformation and

stresses. This helps to ensure safe

operation of the components at the Client

location. Structural analysis is also done

for

➔ Bearing Housing

➔ Center Section

➔ Seals

➔ Trunnion

FEA APPLICATIONS

0 25 50 75 90

Stress (MPa)

FIELD ENGINEERING SERVICE

CAPABILITIES➔ Dedicated & Technically competent Engineers

➔ Quick Troubleshooting

➔ Imparting knowledge to the Customer

➔ Fast Response & Customized solutions

➔ Identify even the smallest problem that may lead to performance loss

➔ Suggest performance improvements

➔ Maintain long-term customer relationship

➔ Increase the reliability of operation

SUPPLY / SERVICES RENDERED➔ Smallest size 15 HSX (Ø 2600mm) to Biggest Size 35 VI (Ø 16400mm)

➔ Horizontal Type

➔ Vertical Type

➔ Rothemuhle Type

➔ From 30 MW to 1000 MW

➔ Any dry type & any capacity of ESP

EXPERT SITE SERVICE➔ Field Engineering consultancy services for Boilers & Auxiliaries

➔ Site surveys

➔ Inspection & Plant Evaluation

➔ Preventive maintenance & maintenance advice

➔ Support during Annual Overhauling & Unplanned Shutdowns

➔ Performance improvement & combustion optimization

➔ Boiler Tube failure investigation

➔ Replacement & repair recommendations for pressure parts & auxiliaries during overhaul

➔ Recommendations & execution of R & M

➔ Boiler explosion analysis & remedial recommendations

➔ Troubleshooting of Boiler & Auxiliaries

0

TESTING

AIR IN LEAKAGE TEST

The air in leakage test is conducted to ensure that the erection weldments are sound & leak proof.

The purpose of the test is to proactively identify the leakage sources & to arrest them appropriately with

suitable welding, thereby reducing the possible leakages when ESP is in operation. This is done as a part

of erection activity before insulation work is taken up.GEECO possesses necessary expertise & has

advanced test instrumentation consisting of venturi meter with blower & U tube manometers to assess the

leakage constants of the precipitator casing & quantify the leakages.

GD TEST

As the ESP cross section area is huge & the gas velocity is reduced from 15 m/s to less than 1

m/s, the flue gas flow across the cross section should be uniform so as to achieve effective utilization of the

collecting area provided for collection of dust particles. GD test is mandatorily done in all precipitators as part

of precommissioning test. GD test is carried out conforming to domestic & ICAC standards by GEECO's

experienced team using equipments like vane type digital anemometer suitable for measuring velocities from

0.3 m/s to 40 m/s.

VALIDATION TEST

Pre-tests are conducted for all layouts connecting APH with ESP & ESP with ID Fan

systems to get required inputs for CFD optimizations. The purpose is to ensure uniform flow

distribution across the cross section in the medium through which fluid is allowed to flow. This

distribution also aids in reducing pressure drop across the equipment by which it operates at its

best efficiency. This is also further ascertained by conducting post-tests with pitot tubes,

micromanometers & vane type anemometers by doing grid measurements.

AIR LOAD TEST

In ESP, upon completion of all erection activities, air as a medium of load, the voltage is let through the emitting & collecting

electrode system gradually. This is to ascertain the healthiness of the particular field. The current is increased in steps of 50 mA till the

field receives the full power & the equipment (TR. Set) reaches its full load capacity. During the gradual increase of current &

corresponding voltage, there should not be any sparking. During air load test, if the voltages are nearer to the RMS voltage of full

capacity, then it can be concluded that the field is healthy. This procedure shall be repeated for other fields of the ESP.

PERFORMANCE TESTING➔ GEECO is equipped with test equipments required for conducting full scale performance testing

conforming to Domestic Standard (IS11255) & International Standard (EPA Method 17)

➔ Involves velocity measurement & particulate sampling which is done at iso-kinetic conditions

➔ Possesses instruments such us Air-neutronics to assess the pressure drop across the System

➔ Possesses wattmeter for conducting power measurement

CAPABILITIES OF TESTING GROUP

Having experience of over three decades in Engineering, Manufacturing, Field support service, we are specialized in all types of

combustion including Oil, Gas, PF & bed firing systems. GEECO conducts Performance testing, Residual Life Assessment study, Tube

failure analysis during commissioning, execution of R&M & regular operation of Boiler & Auxiliaries.

Performance Guarantee testing is done as per performance test codes & standards of Boilers & Auxiliaries to prove the contractual

guarantee. Performance Evaluation testing of Boilers & Auxiliaries (APH, ESP & Pulverisers) is done to assess the present condition &

also to meet out the influences of different coal properties for further improvements.

Other testings include Air / Gas flow equalising test, Cold air velocity test for boiler, Clean / dirty air flow test for pulverisers.

TRAINING

TRAINING OFFERED TO➔ Engineering & Management Professionals

➔ Power Plant O&M Engineers

➔ Newly recruited Power Plant Engineers

➔ Power Sector Consultants

➔ Technicians & Operators of Power Plant

➔ Students

AREAS OF TRAINING

Air Preheater➔ Principle of Working

➔ Construction & Features

➔ Improvements

➔ Problems & Solutions

➔ Case Studies

➔ O&M Practices

Electrostatic Precipitator➔ Principle of Working

➔ Construction & Features

➔ Developments

➔ Erection Methods

➔ O&M Practices

Computational Fluid Dynamics➔ CFD – An overview

➔ Application of CFD in Power Plants

➔ Case Studies

Boiler Performance➔ General Boiler Performance

➔ Combustion Optimization

RESEARCH AND DEVELOPMENT

CAPABILITIES➔ Develop new Product & Technology to meet customer needs

➔ In-depth product / process knowledge & expertise

➔ Optimize operating conditions to significantly improve

Performance & Thermal Efficiency

➔ Research to minimize leakage & enhance the life of seals

➔ Development of new element profiles for high heat recovery

& easy cleanability

➔ CFD, FEA & Numerical Modeling to understand & improve

product functioning

APH Simulator: Predicted Fluid Temperatures

as a function of APH Height

Cold End

Hot End

X

Y

GAS

PA

SA

CORE ACTIVITIES➔ Comparison & development of heating element profiles for efficient heat recovery, lower pressure drop & easy cleanability

➔ Development of Diagnostic tool to continuously monitor the health of APH

➔ Identification of suitable geometry & wear-resistant material for seals to minimize indirect leakage

➔ Optimization, Automation & Modification of cold rolling process of heating elements

➔ Criterion for Basket Replacement, fouling & cleanability of heating elements

➔ Installation of Guide Vanes at inlet & outlet ducts for uniform fluid flow through APH

➔ Development of APH Simulator to predict transient steady-state metal temperature

➔ Prediction of thermal deformation of rotor using FEA & numerical methods

➔ Surface Modification of Hot End Elements for Erosion Resistance

➔ Improvement of Soot Blowing Process

R & D - ADVANTAGES➔ Deeper Insight

➔ Innovative Design

➔ Optimized Solution

➔ Cost Saving

➔ Better Reliability

➔ Continual Improvement

DESIGN | ENGINEERING | RESEARCH & DEVELOPMENT | MANUFACTURING | TESTING | ERECTION | SERVICE

Head Office (India)

GEECO Enercon Pvt. Limited,

D/C 6, SIDCO Industrial Estate,

Thuvakudy,

Tiruchirapalli - 620 015.

Tamil Nadu, India.

Tel : +91 431 2501239

+91 431 2501312

E-mail : geeco@geeco.in

Fax : +91 431 2500705

Office (Malaysia)

GEECO Power Mech SDN BHD,

No.50-1 A, Pusat Perniagann Barat,

Jalan Raya Barat, 41100 Klang,

Selangor Darul Ehsan, Malaysia.

Tel : +603 33744306

E-mail : geeco.my@geeco.in

Factory ( India)

GEECO Enercon Pvt. Limited,

103, Muthandipatti (Post),

Pudupatti, Sengipatti (Via),

Thanjavur - 613 402.

Tamil Nadu, India.

CONTACT DETAILS

www.geeco.in