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Standard Operating Procedure for

Forced Draft Fan
An ISO: 9001, ISO:
2X300 MW Deenbandhu Chhotu Ram
14001 & OHSAS:
18001 Certified
Thermal Power Plant
company

Strictly Private
and Confidential
Document No DCT/SOP/BLR-01 Area Boiler

Date of issue December 2017 Revision No. 00

Total Number of
Prepared by PwC 14
pages

Checked by AE/ AEE (Name/ Designation) (Sig.)

Rechecked by XEN (Name/ Designation) (Sig.)

Reviewed by SE (Name/ Designation) (Sig.)

Approved for
Accepted by CE/DCRTPP
implementation by CE /Planning
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Standard Operating Procedure (SOP) for FD Fan operation

Following table captures items covered in this SOP

Sl. No. Procedures

Abbreviations
Introduction to FD Fan scheme in power plant
1 FD Forced draft
FD fan technical details
2 UCB Unit control board room
FD Fan interlocks and permissive
3 KSC Kg/cm2
FD Fan protection, alarm
EPB Emergency Push Button
4 LUBE Lubrication
FD Fan prestart checks
5
FD Fan starting procedure
6
FD Fan shut down procedure
7
FD Fan local operation check
8
FD Fan isolation procedure for permit work (PTW) and normalization
9
FD fan emergency instruction
10
FD fan emergency instructions
11

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Introduction to FD fan scheme in power plant

Introduction to FD fan scheme in power

plant

• FD fan supplies air to furnace for combustion

• FD fan is to be started before the light up to maintain air flow in

the boiler.

• Two FD fans are there with one unit and one fan capacity is 80%

of maximum continuous rating of boiler. Plant can be run with

one FD fan at part load below 80%

• One of the Air Pre Heater and ID Fans is required to be running

before the FD fan can be taken in the service.

◦ FD fan has Adjustable blade pitch control

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FD fan schematic diagram

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FD fan Technical details
Key technical specifications FD fan Key technical specification of FD fan Lube oil System
Type Adjustable Efficiency 81.28
Lubricating system pressure 8 kg
moving-blade
axial flow type
FAF23.7-16-1
Speed 1470 rpm Total Pressure 3624
Air flow 122.8 m3 Internal 1778 mm Oil tank volume 0.25 m3
diameter of the
fan
Pressure 4426 pa Diameter of the 944 mm
impeller hub
Shaft 678 kw Inlet 47 o C Nominal flow
power temperature 25 L/min GD-17

MI 133 Blade material HF-1

Stage Diameter 336 mm
number 1 hydraulic
cylinder Hydraulic system pressure 35 kg/cm2
Number of 16 Impeller -25e.+20e
blades per adjustment
stage range
Gap 1.78~3.56mm
between
internal
fan

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FD fan technical details
Key technical specification of FD fan motor

Type/model YKK-500-4 Current

Power 800 kW Rotating speed

Voltage 6.6 kV Quantity 2

GD-17

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FD Fan interlocks and permissive

Start Permissive Interlock

1. Outlet damper interlocks
1. FD fan blade pitch position minimum
a. Fan start, outlet damper opens automatically
2. FD outlet damper closed
b. Fan stop/trip, outlet damper will close automatically
3. FD Fan hydraulic liquid oil pressure >25 kg/cm2
2. LOP interlock
4. Any LOP running
a. LOP B trip then LOP A starts & vice versa
5. FD Fan oil flow to bearing >3LPM (Oil filter DP not hi)
b. LOP B on and lub oil pressure low, LOP A starts and vice versa.
6. At least one APH and one ID Fan is running
c. LOP B fails to start then LOP A starts & vice versa
7. Fan bearing temperature <85 Deg C
d. LOP B on and control oil pressure low, LOP A starts and vice versa
8. Motor bearing temperature <85 Deg C
e. FD fan made off, LOP should remain in running condition till
9. Motor winding temperature <110 Deg C
normal temperature of bearings. LOPs should be stopped manually
10. FD Fan no trip condition
after bearing temperature reach normal value
11. FD Fan no disturbance
3. Interlock of electric heater of lubricant oil tank
12. FD Fan no electrical trip command
a. Temperature of oil tank is lower than 25℃, heater ON ; while
13. All secondary auxiliary air dampers open
temperature is higher than 35℃, heater OFF
14. FD Fan on remote and EPB released

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FD Fan protection and alarm

Alarm
1. Fan bearing temperature more than or equal to 85℃
2. Bearing temperature of motor is more than or equal to 85℃
3. Motor winding temperature is more than or equal to 110℃
4. Bearing vibration is more than 8mm/sec
5. Surge of FD fan
Protection
FDF a trip logic
1. FD fan lub oil pump not running (time delay 10 sec)
2. APH not running with time delay of 5 seconds
3. FD fan running & outlet damper closed
4. Corresponding ID fan stopped
5. Both FD fan running and ID fan A & C running OR ID fan B&C
running and ID fan C stopped
6. Both FD fan running and ID fan A & B running ID fan B stopped
7. FD fan motor stalling
8. All ID fans stopped
9. Furnace pressure high >325 mm wc
10. MFT operated with time delay of 20 seconds
11. FD fan A/B oil outlet pressure very low with time delay of 10 seconds
12. Electrical trip
13. FD fan A/B motor bearing temperature very high >=90 Dec C
14. FD fan A/B fan bearing temperature high >=90 Deg C
15. FD fan A/B winding temp very high> 130 Deg C
16. FD fan motor bearing vibration high > 4 mm/sec
17. FD fan bearing vibration high > 11mm/sec

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FD Fan prestart checks

Pre start Checks

Sr. No Action Observation Remarks

1 Check before 1. No pending PTW on the FD fan

starting the 2. Motor and LOPs power supply normal
FD fan, all 3. EPB of main motor and lube oil pump are released
start 4. APH is running
permissive 5. Atleast one ID fan running
are satisfied 6. Instrument air pressure is normal and instrument air supply
to SADC is normal
7. Wind box manholes are closed
8. One No. DMCW is running normal
9. Lube oil tank level is adequate
10. Fan lube oil system is lined up and oil coolers are charged
from water and oil side
11. Any one LOP is ON and lube oil pressure is normal
12. Hydraulic/control oil pressure is normal (more that 25
kg/cm2)
13. Ensure availability of standby LOP
14. Lube oil standby filter is clean
15. Ensure that there is no leakage in the lube oil system
16. Fan blade pitch is minimum and outlet damper is closed
17. Fan bearing and motor winding temperature is normal
18. Blade pitch controller is operational
19. APHs' secondary air isolating dampers are open
20. Fan outlet damper are closed
21. LOP DP should be normal

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FD Fan starting procedure
Starting Procedure:

Action Observation Remarks

Check before 1. All pre-start checks are over

starting FD Fan.

Start the FD fan 1. FD fan breaker on

motor 2. Fan takes starting current and comes down to no load current within 10
seconds
3. Outlet gate starts opening
4. FD fan discharge pressure increases

Check bearing 1. Monitor fan/motor bearing temperature and vibration

vibration and
temperature

Adjust the blade 1. Fan discharge pressure increases. Monitor furnace draft
pitch controller to 2. Fan current changes accordingly.
get desired airflow 3. Furnace draft varies accordingly.
4. Wind box pressure also varies with FD fan loading

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One FD Fan shut down procedure
Shut down procedure:

Action Observation Remarks

Reduce unit load to 1. Take machine in manual mode of running in CCS mode • Track furnace draft trend
50% of unit 2. Gradually reduce load set point to 50% of unit capacity
capacity 3. Maintain furnace draft and drum level
4. Reduce loading of FD fan to be stopped and increase the loading
on the other fan
5. Maintain required air flow
6. Completely unload the fan to be stopped by minimizing blade pitch • Continuously watch the current of the other loaded fan to
and further increase loading on the other FD fan avoid overload tripping
7. Monitor the furnace draught and flame • Take oil support if flame condition is poor
8. Close outlet gate of the FD fan to be stopped • Watch overloading of the FD fan, Air flow and oxygen
level

Stop FD fan 1. Switch off the FD Fan from the DCS

2. Breaker will open

Monitor other 1. Control the loading of other FD fan to desired air flow
running FD fan 2. Monitor bearing temperature, vibration and FD fan current

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FD Fan local operation check

Local operation during routine running

Operator to check and report 3 times in the shift to control engineer following status:

• Selection of LOPs

• Lube oil pressure

• Control oil pressure

• Lub oil tank level

• Lube oil tank temperature

• Cooler inlet and outlet temperatures

• Motor and fan bearing temperature

• Report any abnormal noise and vibration

• Report any water and oil leakage

• Lub. Oil station DP

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FD Fan isolation procedure for permit to work and normalization

FD fan isolation FD fan Normalization process

After the return of all the permits instruct operators for normalization
Electrical isolation of FD fan motor
Mechanical side normalization
• Ensure that breaker is in trip condition
• Switch off DC supply of the closing circuit Lub oil system
• Remove the closing circuit fuses • Open inlet and outlet manual isolation valves of lub oil pumps
• Rack out the breaker • Normalize cooler from water side
• Put the closing circuit fuses in lockout box • Start lub. Oil heater if temperature is less than 25 °C
• Put isolation danger tag on breaker • Please check selection of lube oil pump as per shceme
• Remove danger tag
Electrical isolation of outlet damper and Lub oil pumps A and
B Electrical side
• Switch off the lub oil pumps A and B and close the out damper
• Switch off the modules of lub oil pumps A & B and the outlet gates Normalization of LT modules:
• Remove the fuses from the electrical module and put them in lockout • Take the fuses from lockout box and send to operator for normalization
box • Insert the fuses in module and keep the knob/handle in remote position
• Put isolation danger tag on module
Normalization of HT breakers:
Mechanical side isolation • Insert the fuses of closing circuit
Lub oil system • Rack in HT breaker
• Switch on DC supply
• Close inlet & outlet manual isolation valves of lub oil pumps • Put the breaker switch on remote
• Isolate cooler from water side • Release EPBs of motor
• Put the danger tag

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FD Fan emergency instructions

Tripping of one FD fan

Steps Activity
1 Corresponding ID fan will also trip

2 Take machine in manual mode

3 Ensure that top running one mill is tripped (if 4 mills are running) and its CAD has closed

4 Take running ID & FD fan in manual mode and maximize air flow with one running FD fan. Maintain currents of running ID & FD Fans
within limits
5 Maintain furnace draft within limit (-5 to -10 mm WC), reduce coal firing and air flow accordingly

6 Take appropriate oil guns in service and reduce coal flow so as to maintain oxygen > 3%

7 Watch flame scanners, boiler drum pressure, furnace pressure, wind box pressure and excess oxygen percentage

9 Identify the cause of tripping and rectify the problem

10 After rectifying the problem, start ID fan.

After opening of the outlet dampers, increase the hydraulic coupling scoop gradually and balance the loading of both ID fans. During this
process monitor furnace draught
11 Put ID fan on auto and then take FD fan in service, normalize the air flow by increasing the blade pitch

12 Maintain furnace draft within limit and increase coal firing

13 Increase unit load as per Drum pressure, coal firing rate and M.S & R.H temperature trend

14 Put the machine in manual mode after stabilization of the parameters

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