Abstract: A method for constructing a rotor of an air preheater having a plurality of diaphragm plates dividing the rotor into a number of wedge-shaped compartments. Each compartment includes compartment components such as a rotor shell plate, a hot end rotor angle, a cold end rotor angle, and one or more stay plates and means for locating at least a portion of each of the components within the compartment. The diaphragm plates are manufactured by marking at least one index location associated with each compartment component on each diaphragm plate blank utilizing a template identifying the index locations and forming an opening at each index location. Each compartment is assembled by positioning a first diaphragm plate adjacent to a second diaphragm plate and locating each compartment component between the adjacent diaphragm plates by engaging the locating means of the component in an associated opening in one of the diaphragm plates.

Abstract: A bypass seal for a rotary regenerative air preheater includes primary and secondary seal leaves that are joined at a single position longitudinally intermediate their first and second sends. The first end portion of the primary seal leaf extends longitudinally beyond the first end of the secondary seal leaf and the second end portion of the secondary seal leaf extends longitudinally beyond the second end of the primary seal leaf. When installed in the air preheater, the first end portion of the primary seal leaf of each bypass seal in one of the seal rings overlaps the second end portion of the secondary seal leaf of an adjacent bypass seal in the seal ring.

Abstract: A method for adding additional axial seals and radial seals within existing air preheaters. The installed heat transfer baskets, radial seals, axial seals, and gratings are all removed from the air preheater. The existing stay plates are modified, if they are to be reused, or replaced with new stay plates. An intermediate diaphragm plate is positioned in each original compartment and mounted to the stay plates. Additional hot and cold end axial seal support bars are mounted to the rotor shell and intermediate diaphragm plate. Axial seals are installed on the original and additional axial seal support bars and radial seals are installed on the axial edges of the original and intermediate diaphragm plates. Finally, new heat transfer baskets are inserted into each of the compartments formed by the original diaphragm plates, the intermediate diaphragm plates, and the rotor shell.

Abstract: A bypass seal for a rotary regenerative air preheater includes primary and secondary seal leaves that are joined at a single position longitudinally intermediate their first and second sends. The first end portion of the primary seal leaf extends longitudinally beyond the first end of the secondary seal leaf and the second end portion of the secondary seal leaf extends longitudinally beyond the second end of the primary seal leaf. When installed in the air preheater, the first end portion of the primary seal leaf of each bypass seal in one of the seal rings overlaps the second end portion of the secondary seal leaf of an adjacent bypass seal in the seal ring.

Abstract: A method for constructing a rotor of an air preheater having a plurality of diaphragm plates dividing the rotor into a number of wedge-shaped compartments. Each compartment includes compartment components such as a rotor shell plate, a hot end rotor angle, a cold end rotor angle, and one or more stay plates and means for locating at least a portion of each of the components within the compartment. The diaphragm plates are manufactured by marking at least one index location associated with each compartment component on each diaphragm plate blank utilizing a template identifying the index locations and forming an opening at each index location. Each compartment is assembled by positioning a first diaphragm plate adjacent to a second diaphragm plate and locating each compartment component between the adjacent diaphragm plates by engaging the locating means of the component in an associated opening in one of the diaphragm plates.

Abstract: A method for constructing a rotor of an air preheater having a plurality of diaphragm plates dividing the rotor into a number of wedge-shaped compartments. Each compartment includes compartment components such as a rotor shell plate, a hot end rotor angle, a cold end rotor angle, and one or more stay plates and means for locating at least a portion of each of the components within the compartment. The diaphragm plates are manufactured by marking at least one index location associated with each compartment component on each diaphragm plate blank utilizing a template identifying the index locations and forming an opening at each index location. Each compartment is assembled by positioning a first diaphragm plate adjacent to a second diaphragm plate and locating each compartment component between the adjacent diaphragm plates by engaging the locating means of the component in an associated opening in one of the diaphragm plates.

Abstract: A method for adding additional axial seals and radial seals within existing air preheaters. The installed heat transfer baskets, radial seals, axial seals, and gratings are all removed from the air preheater. The existing stay plates are modified, if they are to be reused, or replaced with new stay plates. An intermediate diaphragm plate is positioned in each original compartment and mounted to the stay plates. Additional hot and cold end axial seal support bars are mounted to the rotor shell and intermediate diaphragm plate. Axial seals are installed on the original and additional axial seal support bars and radial seals are installed on the axial edges of the original and intermediate diaphragm plates. Finally, new heat transfer baskets are inserted into each of the compartments formed by the original diaphragm plates, the intermediate diaphragm plates, and the rotor shell.

Abstract: A method for adding additional axial seals and radial seals within existing air preheaters. The installed heat transfer baskets, radial seals, axial seals, gratings, and stay plates are all removed from the air preheater. An intermediate diaphragm plate is positioned in each original compartment, mounted to the rotor shell and a diaphragm inner support plate. Hot and cold end plates mounted to the post and an inboard portion of the diaphragm plates forming the original compartment provide additional support. New gratings and/or stay plates are installed. Additional hot and cold end axial seal support bars are mounted to the rotor shell and intermediate diaphragm plate. Axial seals are installed on the original and additional axial seal support bars and radial seals are installed on the axial edges of the original and intermediate diaphragm plates.

Abstract: A method for adding additional axial seals and radial seals within existing air preheaters. The installed heat transfer baskets, radial seals, axial seals, and gratings are all removed from the air preheater. The existing stay plates are modified, if they are to be reused, or replaced with new stay plates. An intermediate diaphragm plate is positioned in each original compartment and mounted to the stay plates. Additional hot and cold end axial seal support bars are mounted to the rotor shell and intermediate diaphragm plate. Axial seals are installed on the original and additional axial seal support bars and radial seals are installed on the axial edges of the original and intermediate diaphragm plates. Finally, new heat transfer baskets are inserted into each of the compartments formed by the original diaphragm plates, the intermediate diaphragm plates, and the rotor shell.

Abstract: The rotor of an existing rotary regenerative air preheater is retrofitted with deeper cold end baskets for general performance enhancement and/or for the tolerance of ammonium bisulfate deposits. the normal cold end support gratings are removed and the support of the cold end baskets of increased depth is at least partially from the existing rotor stay plates.

Abstract: A heat transfer element basket assembly for a rotary regenerative heat exchanger having a basket framework including oppositely disposed first and second side shells, means for holding the side shells in a spaced relationship, and heat absorbent material is disposed within the framework. The inboard end portions of first and second substantially planar flange plates are mounted to the outboard end portions of the first and second side shells, respectively. The outboard end portions of the first and second flange plates are each mounted to an adjacent diaphragm plate to install the basket assembly in the heat exchanger rotor. The first and second side shells of the basket assemblies define an angle therebetween which is substantially equal to the angle of the diaphragm plates. The outboard end portions of the first and second flange plates may be mounted to a diaphragm plate by bolting, welding or a combination where one of the flange plates is bolted and the other flange plate is welded.

Abstract: The support grating system for the heat exchange baskets of a rotary regenerative air preheater is arranged to be able to make full use of the rotor volume for the heat absorbent material. Support gratings can be located inside of the volume of the rotor enclosed by the pin rack assembly and baskets can still be loaded. This is accomplished by installing certain of the support gratings or portions thereof after the baskets have been loaded into position in the basket layer inside of the pin rack assembly.

Abstract: A swing-arm sootblower for a rotary regenerative air preheater is mounted to sweep across the air preheater rotor at an adjustable constant speed or angular velocity. The sootblower has means for sootblowing with a relatively low pressure medium such as air or steam or with high pressure water. The nozzle unit is equipped with a low pressure nozzle and a plurality of high pressure nozzles. The high pressure nozzles are arranged in a row and the nozzle unit is mounted so that the row is at an angle to the swing arm such that the row of high pressure nozzles is parallel to the heat transfer plates and tangential to the rotor at the outside of the swing of the arm.

Abstract: The gas flow bypass around the heating elements in a regenerative air preheater is reduced by the use of floating bypass seals which are placed in the rotor compartments between stacked heating elements. The seals comprise a frame with an open center with the peripheral frame portion bridging the gaps between the heating elements and the sides of the compartments. The seals may be adjustable and may include a deformable edge seal to actually contact and seal against the sides.

Abstract: A lifting device for engaging lifting openings in a splitter plate of a heat transfer element basket assembly has first and second opposed hook bodies. Each hook body has an upper engagement portion and a lower portion offset from the upper portion. The hook bodies further define hook openings. A fastener releasably fastens the upper portions of the hook bodies wherein the hook openings define a through-bore and the lower portions define a splitter plate gap. Each hook body further defines a hook portion extending from the offset portion forward the other hook body and across the splitter plate gap. The hook portions are adapted to extend through the lifting openings of the splitter plate when the hook bodies are fastened by the fastener.

Abstract: A rotary regenerative air preheater having a rotor mounted to a central rotor post for rotation within a surrounding housing whereby heat absorbent material carried in the rotor is alternately exposed to a flow of heating gas and a gas to be heated. A radial seal assembly including a flexible sealing strip is mounted to the hot end edge of each radially extending partition of the rotor to establish a seal between the partitions and the confronting face of the sector plate of the housing as the rotor is rotated. The flexible sealing strip has a tapered configuration such that the distal edge of the sealing strip and the confronting face of the sector plate define a controlled radially extending gap when the air preheater is in a hot-operating condition. A protective tip is mounted on the distal edge of the flexible sealing strip to prevent premature failure due to edge fracturing.