Fans InPower Plants

Fans in Power Stations
PMI
Power Plant Schematic
ESOE 505221 Fluid Mechanics
Chapter 1: Basic Concepts
Need of Fans
Combustion Air
Boiler
Flue Gases
Air needed for combustion Flue are needed to be evacuated Losses due to flow need to be overcome
ESOE 505221 Fluid Mechanics 3 Chapter 1: Basic Concepts
Fan Operation
Fans cause pressure increase by:
Centrifugal force created by rotation of the column of air trapped between two blades Kinetic energy is supplied to the air through the impeller Total pressure = velocity head + static pressure
4 Chapter 1: Basic Concepts
Selection Considerations
Quantity of air to be moved per unit time Estimated system resistance and expected variations Amount of noise permitted Space available for fan Economic implications
SYSTEM RESISTANCE
When a gas is forced through a duct system, a loss in pressure occurs. This loss in pressure is called system resistance. System resistance is composed of two components: Friction losses and Dynamic losses.
Variation of System Resistance with Flow
Draft Losses
Total losses
Furnace, SH & RH Losses Economizer Losses Ducts & dampers losses Percent Boiler Rating
Fan Classification
Designated as dynamic pumps
Centrifugal
Further classification by entry and exit of fluid/gas through impeller
4 aerodynamic classifications:
Axial flow Radial flow : referred to as centrifugal fan Cross flow Mixed flow
Centrifugal Fans
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Components of Centrifugal Fan
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Centrifugal Fan Operation

Fans cause a pressure increase through two methods
Centrifugal force is created by the rotation of the column of air trapped between two blades. Kinetic energy is supplied to the air through the impeller Total pressure = velocity head + static pressure
Blades are airfoil-type, backward-curved, forwardcurved, or radial (straight)

Airfoil-types are complex and expensive but very efficient;
theyre used for large systems where the cost is justified.
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Wheel Blade Types and Rotation
Applications where the fans will handle clean air or clean gas, the highly efficient backward inclined airfoils are the preferred design. In an application where the fan is subject to erosion due to heavy dust loading, a straight radial type fan provides erosion resistance, but at the expense of efficiency.
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Backward-Curved Fan Blades

Have a self-limiting power characteristic, so if sized correctly the motor wont overheat or burn out even if conditions change. High efficiency and stable operation make this blade type popular. Choose the operating point to be just to the right of the peak pressure flow rate to achieve both high efficiency and a stable flow rate. This type of fan operates stably because the pressure difference provided by the fan drops if the flow rate goes up. If the opposite were true, increased an increased flow rate would cause increase fan power, which is unstable.
Section of a Centrifugal Fan
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Radial Blades
Similar performance to a backward-curved except that its easier to overheat because as flow rate goes up, so does power. Easier to maintain, so its used in dirty situations (easy to clean straight blades, and they dont collect as much) Blades are stronger than other types. Used primarily in industrial systems in a corrosive or erosive environment, such as material handling of airborne particulate or where high static pressure is required.
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Airfoil-blade centrifugal fan
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Forward-Curved Blades
Have problems with instability because a specified pressure rise can fit three different flow rates. Burnout can also be a problem because fan power increases with flow rate. Quieter than other fans; used for most furnace blowers Usually limited to clean service applications
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Axial Flow Fans

Common types: propeller, tubeaxial, vaneaxial Tubeaxial: impeller is inside a tube to guide airflow and improve performance Vaneaxial: like a tubeaxial except vanes either up or downstream of the impeller are used to reduce swirl and improve performance Used to deliver large flow rates but small increase in pressure Examples include fans used for ventilation without ductwork, mobile room fans, and fans used to cool computers
Two-Stage Axial Fan Assembly
20
Axial-flow fan for induced-draft service
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System Pressure Effects

Fan curves are typically given in terms of total pressure vs. volumetric flow rate A typical fan running at a fixed speed can provide a greater volumetric flow rate for systems with smaller total pressure drops (if were to the right of the peak in the fan curve). Total pressure loss=static pressure loss+dynamic pressure loss
If exit and inlet area of a duct are about the same, the dynamic pressure loss (or gain) may be minimal.
22
Effect of Blade Type on Erosion Resistance and Efficiency
23
Fan Curves
Manufacturer will provide a fan curve for each fan The fan curves predict the pressure-flow rate performance of each fan. Choose a fan that gives you the volumetric flow rate you need for your system pressure drop. Choose a fan that has its peak efficiency at or near your operating point. Sometimes will provide data in a table rather than in a graph.
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Centrifugal Fan Performance Curve.
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Fan Laws
Flow ? Speed Pressure ? (Speed)2 Power ? (Speed)3
Q1 N 1 = Q2 N 2
SP1 N 1 = SP 2 N 2
kW 1 N 1 = kW 2 N 2
Varying the RPM by 10% Varying the RPM by 10% decreases or increases air decreases or increases the delivery by 10%. static pressure by 19%.
Varying the RPM by 10% decreases or increases the power requirement by 27%.
Where Q flow, SP Static Pressure, kW Power and N speed (RPM)

Fan Laws
Law 1 relates to effect of changing size, speed, or density on volume flow, pressure, and power level Law 2 relates to effect of changing size, pressure, or density on volume flow rate, speed, and power Law 3 shows effect of changing size, volume flow, or density on speed, pressure, and power The laws only apply to aerodynamically similar fans at the same point of rating on the performance curve.
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Fan Applications in Power Plant
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Scheme of Air and Gas Path
13 June 2011 Mechanics ESOE 505221 Fluid
PMI Revision 00 29
Draught System Pressure Variation

Pressure drop calculation in air & gas path and its comparison with design value. Assessment of ID and FD fan power as a function of furnace pressure. Assessment of effective kinetic rate coefficient as a function of furnace pressure.
FD Fan
Duct APH
Duct Furnace Back pass
Duc t
Duct APH
ESP
ID Fan
Duc t
Chimney
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Pressure Variation
Furnace Pressure At Various Points in Boiler
1
250
FD Fan Inlet FD Fan Outlet
2
200
Airheater Inlet
3
150
Airheater Outlet
4
100
Windbox Pressure
5 6 7
1 2 3 4 5 6 7 8 9 10 11 12 13 14
50 Furnace Pressure 0 -50 -100 -150
Furnace Superheater Platen Inlet Reheater Inlet
8 9 10 11
LTSH Inlet Economiser Inlet Airheater Inlet
-200
12
-250
E.P. Inlet I.D. Fan Inlet I.D. Fan Outlet
13
-300 Points in Boiler
14
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Induced Draft Fans

Move the combustion flue gas through the boiler, air heater, and precipitator or the baghouse, scrubber, and chimney to the atmosphere typically consume approximately 2% of the gross electrical output. ID fans have the largest design margins of any major equipment in a fossil-fueled power plant. typically 15% on flow, 30% on head, and 15C on temperature. Large margins are intended to allow for the following
Uncertainty in determining system requirements Allowance for wear Operating flexibility Allowance for pluggage and leakage Air infiltration
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Gas to be handled by ID fan

Theoretical air for combustion Excess air required at burner Infiltration Leakage air-to-gas through the air heater
33
Forced Draft & PA Fans

FD fans provide combustion air for boilers In pulverized coal-fired boilers, approximately one-third of the combustion air is PA that is used to transport the pulverized coal to the burners. The PA fan application is similar to the FD fan; The FD fans for a coal-fired plant consume approximately 0.7% of the gross electrical output. The design margins on FD fans are typically smaller than the margins on ID fans but still larger than on other major equipment. Margins of 15% on flow and 30% on head at the maximum expected ambient temperature are common.
Two-Stage Axial Fan Impeller
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Balanced Draft
The draft to be provided by the fan is determined by losses through the following boiler components:
Furnace Boiler and Super-heater Economizer Air heater Precipitator or Bag-house Ductwork Flue gas desulfurization system (scrubber) Stack
Other Fans in The System

Ignitor Air Fan: Provide combustion air to the ignitors. Take suction air from the atmosphere and supplies air to the ignitor wind box. Scanner Air Fan: Supplies cooling air to flame scanners. Normally there are two fans taking suction from FD Fan discharge duct. Mill Seal air fan: Seal air fans provide air for the sealing of Mill bearing. Suction is from cold Primary air and pressure is boosted up to maintain the differential pressure
13 June 2011 Mechanics ESOE 505221 Fluid
PMI Revision 00 37
Fan Controls
Inlet Vanes
Inlet vanes introduce a swirl to the flow entering a fan. The major disadvantage of inlet vanes is poor efficiency at lower loads. Inlet vanes are subject to erosion if ash concentrations are high
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Inlet Dampers
Inlet dampers control air flow by introducing a swirl in the flow and pressure drop. Inlet dampers have a low initial cost, are simple, and are not as prone to erosion as inlet vanes. inlet vanes and can be located completely outside the duct. The biggest disadvantage of inlet dampers is their low efficiency at low loads.
39
Two-Speed Motors
The fan selection with two-speed motors is the same as with inlet vane control or inlet damper control. The fans for two-speed motors are often sized so that the fan can operate on low speed at full load and at normal operating temperature. The high speed provides the design margin.
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Fluid Drive
Fluid drive is a method of varying the fan speed for flow control. The fan selection is essentially the same as the inlet damper alternative, except that a fluid drive is located between the motor and the fan to control the fan speed. Inlet dampers are typically used in addition to the fluid drive to increase the speed of response to avoid furnace pressure excursions during transients The use of the dampers for control during normal operation is typical but can be eliminated in most installations. Using speed control with the dampers full open can result in a significant power savings
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Hydraulic Coupling
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Variable-Speed Motors
Variable-speed motors are directly connected to the fan. The speed of the motor is continuously variable from approximately 10% up to the full speed. Synchronous or induction motors can be used with variable frequency drives, and the frequency of the power to the motor is controlled by an electronic system. The incoming ac power is converted to adjustable voltage dc power by a thyristor. The adjustable dc power is connected to an inverter, which converts it to an adjustable ac power output.
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Variable-Pitch Blades (For Axial Fans )

Axial fans can be controlled by varying the blade pitch or speed or by using variable inlet vanes. Either varying the blade pitch or using variable inlet vanes controls the flow by operating on the same principle as do variable inlet vanes on a centrifugal fan. Varying the blade pitch is more efficient than using variable inlet vanes because the flow resistance of the vanes is absent. Variable-pitch blades can provide efficiency as high as that of variable-speed control over most of the load range for a lower initial cost. Variable-pitch blades are the most common method of control; variable inlet vanes are used occasionally, and variable-speed control is rare.
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Variable-Pitch Axial Fan Components
45
Bearings
Both centrifugal and axial fans can use either ball or roller bearings; however, ball and roller bearings are more common on axial fans. Sliding contact bearings are more common on centrifugal fans. Ball and roller bearings consist of four major components:
Outer race Inner race Rolling elements Spacer for the rolling elements
Sleeve Bearing Components
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Lubrication Systems
Static lubrication in which each bearing has a fixed supply of oil in their sumps is very common. This method is simple and very cost-effective; however, it relies on operator vigilance to detect low oil levels or poor oil quality. Use of temperature sensors to provide remote warning to the control room operators, in case of a hot bearing, offers added protection for this method. A gear pump attached to the input shaft of the driver is a second method used to provide lube oil to fan and motor bearings. A third method, the use of fluid drives to supply oil to the bearings, is also used on some fans. A fourth method involves the use of a dedicated circulating lube oil system.
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Fans InPower Plants

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Fans in Power Stations

Power Plant Schematic

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

4 Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

5 Chapter 1: Basic Concepts

Variation of System Resistance with Flow

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

9 Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Components of Centrifugal Fan

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Centrifugal Fan Operation

Blades are airfoil-type, backward-curved, forwardcurved, or radial (straight)

theyre used for large systems where the cost is justified.

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Wheel Blade Types and Rotation

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Backward-Curved Fan Blades

Section of a Centrifugal Fan

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Airfoil-blade centrifugal fan

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Axial Flow Fans

Two-Stage Axial Fan Assembly

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Axial-flow fan for induced-draft service

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

System Pressure Effects

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Effect of Blade Type on Erosion Resistance and Efficiency

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Centrifugal Fan Performance Curve.

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Where Q flow, SP Static Pressure, kW Power and N speed (RPM)

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts

Fan Applications in Power Plant

ESOE 505221 Fluid Mechanics

Chapter 1: Basic Concepts