VFD Proposal for ID Fan

By Santosh Mestry , Sr. Manager (OPN)

Flow of Presentation

Company & Plant Profile Background Principle Of Hydraulic Coupling Hydraulic Coupling Losses Loss Calculation by Heat Loss method Validation by Slip Loss method Efficiency Aspect Recommendation Benefit

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Company Profile

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Plant Profile

2 x 250 MW Thermal Plant, Supplies Electricity to Mumbai.

DTP S

Amongst top performers in the world, on all operational parameters:

o o o o

lowest heat-rate. highest capacity utilisation. least secondary fuel consumption. highest plant availability.

Certified for Integrated Management System (ISO9001, 14000, 18000), SA 8000, ISMS 27000. Energy efficiency at core.
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Dahanu Thermal Power Plant (DTPS)

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Background : Function of ID Fan

Thermal power plant has several fans such as Induced draft (ID) fans, Forced draft (FD) Fans, Primary air fans (PA fans). These fans contribute to significant auxiliary power consumption. ID fans alone contribute to about 12% of total auxiliary power consumption The function of Induced Draft fan is to suck the gases out of furnaces and push them into the stack. Boiler is provided with two nos. of Induced Draft Fans. Each ID fan is provided with regulating damper control and scoop control for controlling the loading on fans, Inlet/Outlet gates for isolation to facilitate startup/maintenance of fan.

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Background : Function of ID Fan

MAIN AIR AUX TE 3no s HYD. COUP GD-5 GD-9 PT PT GD-17 PT O2 ANA. GD-1 MAIN AIR AUX O2 ANA. GD-7 GD11

ID FANA
GD-19
TE PT

APH-A
GD-3 O2 ANA. GD-6

EP-A
GD-13 GD-10 HYD. COUP GD-18 PT TE GD-15 CO ANA.

S T A C K

TE 3nos FROM ECO

ID FANB
GD-20

TE PT

TE 3nos

APH-B
GD-2 GD-4 PT TE 3no s GD-8

EP-B
GD-14 GD-12

GD-16

FLUE GAS PATH

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Technical specification of ID Fan

General specification: Application : ID Fan No per boiler : Two Type : NDZV 33 Sidor Medium handle : Flue gas Orientation : 45 degree inclined suction horizontal delivery Fan Design rating: Capacity : 258 cu.m /sec Total head developed : 496 mmwc Temp. of medium : 145 degree C Speed : 701 RPM (Max at 100% scoop) Type of Regulation:Speed & damper Drive Motor: Motor Make : BHEL- Haridwar Rating : 1850 KW Speed : 745 RPM

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ENERGY CONSERVATION OPPORTUNITIES FAN LAWS

Flow Speed
Q1 N 1 = Q2 N 2
SP1 N 1 = SP 2 N 2
2

kW 1 N 1 = kW 2 N 2

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Principle of Hydraulic Coupling

The ID fans are controlled with VFC control. The variable fluid coupling works on the principle of hydrodynamics. It consists of an impeller and rotor(runner) enclosed in a Casing. The impeller is connected to the prime mover, while the rotor is connected to the driven machine. The coupling is filled with fluid, usually mineral oil. The speed of the driven equipment is varied by varying the quantity of fluid Supplied between the impeller and the runner.

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Principle of Hydraulic Coupling

P Pump impeller T Turbine wheel S Scoop chamber 1. Main lube oil pump 2. Input shaft 3. Output shaft 4. Gear 5. Working oil pump 6. Scoop tube (adjustable) 7. Scoop tube control (VEHS)

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Hydraulic Coupling Losses:There are two Types of Losses of power in VFC: Hydraulic Losses Mechanical Losses

Mechanical Losses (W. R. T. Speed)

Hydraulic Losses (W.R.T. Slip)

Speed (RPM)

Slip (%)

Losses (KW)
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Hydraulic Coupling Losses: SLIP

A difference between input & output speed is essential in a fluid coupling in order to enable it to transmit torque. Difference between input & output speed is normally expressed as percentage of the input speed & refereed to as slip.

(I/P speed- O/P speed) Slip % = I/P speed x100

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Hyd. Loss : Heat Loss Method

Total heat loss (KW) = ECW flow in m3/h x ECW Temp. Gain in C x 1000 860 Kcal/hr

Hydraulic loss:-

SR. NO.

PARAMETER

UNIT

UNIT-1 ID FAN-1A ID FAN-1B

UNIT-2 ID FAN-2A
89

AVERAGE

ID FAN-2B
105 94

Cooling Water Flow of Working Oil Cooler

M3/Hr

104

78

Temp. Rise of CW Across WO Cooler Scoop Position

Deg. Celsius

2.2

2.6

2.8

2.65

55

54

53

54

54

D = (A*B*1000) 860

Total Heat Loss in VFC

KW

266.04

235.81

310.46

341.861

288.54

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Validation

SLIP Loss Method

O/P Power I/P Power = 1 - Slip x100

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Validation of Hydraulic loss by slip loss calculation

SR. No.

PARAMETER

UNIT

UNIT-1 ID FAN1A ID FAN1B

1243.00 96.00

UNIT-2 ID FAN2A
1257.00 96.00

AVERAGE

ID FAN2B
1289.00 96.00 1253.25 96.00

A B

Motor I/P Power ID fan Motor Efficiency Scoop Position Motor Speed Fan Speed Slip VFC, I/L Power

KW %

1224.00 96.00

C D E F = 100 * (F-G) F G = A*B 100 H=G*(1-F/100)

% RPM RPM % KW

55.00 733.00 574.00 21.69 1175.04

54.00 734.00 576.10 21.51 1193.28

53.00 731.80 568.20 22.36 1206.72

54.00 733.50 573.00 21.88 1237.44

54.00 733.08 572.83 21.86 1203.12

Fan Shaft I/L Power

KW

920.15

936.58

936.95

966.67

940.09

I=G-H

VFC Loss

KW

254.89

256.70

269.77

270.77

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Efficiency Aspect

Efficiency of variable fluid coupling is= 1- slip. Fan driving system efficiency can be improved by regulating fan speed by digital Variable Frequency Drive(VFD) instead of VFC. Fan driving system efficiency driving= motor* VFC = motor*(1-slip)

MOTOR

VFC

FAN I/P Power = P * motor % * VFC % at Fan Shaft

I/P Power = P

motor= 96%

VFC= 1-slip

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Present Efficiency Calculation

Average Slip of VFC =21.86%.

SR. NO.
A B C=(1-B/100)100 D=A*C/100

PARAMETER
motor Slip vfc driving

UNIT
% % % %

old
96 21.86 78.14 75.0144

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Recommendation

Installing a Variable Frequency Drive for this variation in flow requirements will result in substantial energy savings. The speed of the fan can be varied to attain the desired flow. There are two options: 1. To install variable frequency drives for the ID fans with VFC in place. In this case, fan speed is varied by VFD keeping VFC scoop 100% open.Design VFC slip at scoop 100%: - 3.4%

SR. NO.
A B C=(1-B/100)100 D=A*C/100

PARAMETER
motor Slip vfc driving

UNIT
% % % %

new
96 3.4 96.6 92.736

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2. To install variable frequency drives for the ID fans & remove VFC . In this case VFC slip loss is nil since slip =0

SR. NO.
A D=A*C/100

PARAMETER
motor driving

UNIT
% %

old
96 96

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Cost-Benefits:
(New Efficiency-Old efficiency) % Energy Saving = ------------------------------------------ * 100 New efficiency

SR. NO.
A B C D=100*((C-B)/C) E=A*C/100

PARAMETER
AVERAGE MOTOR I/P POWER old

UNIT
A %

Value
1253.25 75.01 VFD WITH VFC OPERATING AT FULL SPEED (SCOOP=100%) VFD WITHOUT VFC

new ENERGY SAVING KW SAVING

% % KW

92.73 19.10 239.48

96 21.86 274.02

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In DTPS, there are 4no. ID fans. Above energy saving calculation is for one fan. If cost of unit- 3.50 Rs/KWH & annual Operating Hrs. =8200 Hr, benefit & simple payback period is shown in the following table:

SR. NO.

PARAMETER

UNIT

Value
VFD WITH VFC \OPERATING AT FULL SPEED(SCOOP=100%) VFD WITHOUT VFC

A B C=A*B D E F G=C*D*F F=12*(E/G)

ENERGY SAVING/FAN NO.OF FAN

KW No

239.48 4 957.92 3.5 5.6 8200 2.74 24.44

274.01

TOTAL ENERGY SAVING KW COST/UNIT TOTALINVESTMENT ANNUAL OPERATING HRS ANNUAL SAVING SIMPLE PAYBACK PERIOD Rs. Rs.CR. Hrs. Rs CR Month

1096.04 3.5 5.6 8200 3.14 21.36 confidentia

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Thank you