Standard Operating Procedure (SOP) for Fan Sizing

A) Minimum Technical Requirements for fan sizing :

1) First of all take correct P8475 run & P140 Input / Output file to extract air & gas streams flowrate , density & other parameters. 2) Calculate FD & PA fans air flowrate from B & W mill sheet / Quotation for mill. 3) Mass Balance is to be carried out around air heater using Air Heater Balancing sheet to get the flue gas flow quantity. 4) Fill the fan data spread sheet to calculate duty shaft power for fans. But before filling the data sheet, Design engineer must understand the manual calculation for inlet dynamic pressure, outlet dynamic pressure, static pressure rise, fan static pressure & fan total pressure rise.Check the no. of mill in operation, by reduction in one mill, the pressure head for fan increses,so no. mills in operation will be selected in a such a fashion that duty shaft power should not increase very high. 5) Design Engineer has to indicate the Inlet trasition duct area & outlet transition duct area in the fan specifications based on the flue gas velocity mentioned in the tender. 6) if not, consider FD & PA fan air velocity = 13 meter/sec & ID fan flue gas velocity = 16 meter/sec. Vendor to design the fan model with highest fans static efficiency of 88 ~ 90% @ 100% TMCR for guaranteed coal(fuel).This is only recommendation. 7) Calculation for fan duty shaft power consumption. 8) Confirm Motor rating for fans. 9) Confirm Power guarantees for fans. 9) Evaluation of different vendor offers along with our technical data. Design Engineer has to cross check that every vendor should have equal volumeflow to avoid confusion in giving power guarantees at same volume flow & same static pressure rise. Vendor to provide total weight of fans. 10) Vendor to provide vendor datasheet for different fan components. 11) Vendor must locate the pressure at each & every section or plane of the fan.

B) Scope of supply :

1) For FD fan : From bird screen inlet to the outlet of outlet transition duct. 2) For PA fan : From bird screen inlet to the outlet of outlet transition duct. 3) For ID fan : From Inlet of inlet transition duct to the outlet transition duct where vendor will account the losses for the same but inlet transition duct wont be provided by the vendor. 4) Design Engineer has to include the sketches for the fans along with the specification to the vendors.For sample refer sketches attached below. 5) Vendor to provide locations of pressure tapping at the fan inlet & outlet along with the sketches.

C) Guarantees : 1) Vendor should give the fan duty shaft power guarantees based on volumetric flowrate & static pressure rise by considering the following points : - Zero Test Tolerence ( FW - YES / TLT - YES ) - No Uncertainity Allowed ( FW - YES / TLT - YES ) - No System Effects (FW - NO / TLT - YES ) - Fan Efficiency Margin (FEM) ( FW - YES / TLT - NO ) - In/Out Average ( FW - NO / TLT - NO )

D ) Performance Test Codes For Fans : 1) AMCA 203 -90 2) ASME PTC 11 3) BS - 848 Incase vendor has not considered above margins then correct for the above margins before giving guarantee to customer.

Take one case study of ESSAR SALAYA - REV. 6 to calculate duty shaft power by different vendors

DUTY SHAFT POWER CALCULATION PROCEDURE BY FLAKTWOODS - SWEDEN

ID FANS - Extract mass flowrate of flue gas at the inlet of ID fan from air heater balancing sheet.

m=

425.32 kg/sec

- Take site barometric pressure from MSL given in the tender or assumed value

P=

29.8 inch Hg

- Take Temperature of the medium at the inlet of fan as given in the tender ***. ***Note : If Tender has mentioned that fan inlet temperature is corrected/uncorrected or with air heater leakage or without leakage, Take that only, if not take corrected gas temperature only to optimise the volumetric gas flow at fan inlet. T= 140 Deg C

- Density of medium at NTP condition at the inlet of fan is to be taken from P8475 Run.

- Density of medium @ NTP Condition (kg/m3)=

1.287

kg/nm3

- Density of medium at operating temperature (kg/m3)

( 273.15 ) * (Density of medium @ NTP condition) * (Barometric Pressure) * (Atm. Press. - Static Inlet Pressure ) ( 273.15 + Temp. of medium ) * 30 * Atmospheric pressure * Density of medium at NTP condition *

- Atmopheric Pressure = 10332.3 mmWC = 273.15 X 1.287 X 29.8 X ( 10332.3 - 270 ) (273.15+ 140 ) X 30 X 10332.3 = 0.8231 kg/nm3

- Volume flow of medium (m3/sec) =

Massflowrate of medium Corrected Density

425.32 0.8231

516.7

m3/sec

- Static Inlet Pressure (mmwg) = Pressure at the inlet of inlet transition duct ( Plane 1 as per Sketch )

-270

mmwg

- Static Outlet Pressure (mmwg) = Pressure at the outlet of outlet transition duct ( Plane 2 As Per Sketch )

mmwg

- Static Pressure Rise - SPR (mmwg) = Differential pressure between Plane 1 & Plane 2 As Per Sketch. Static Outlet Pressure -Static Inlet Pressure = (-270+9) 279 mmwg

- Inlet Dynamic pressure (mmwg) It is the pressure gain from inlet Plane A1 to an eye of an impeller.

13.4

mmwg

( Calculated by vendor only )

- Outlet Dynamic pressure (mmwg) = Pressure exerted by the tip of an impeller

12.5

mmwg

( Calculated by vendor only )

- Fan static pressure - FSP (mmwg) = Static Pressure Rise - Inlet Dynamic Pressure

= (279-13.4)

265.6

mmwg

( Calculated by vendor only )

- Connection Loss = Outlet Transition Duct Losses 8.1 mmwg ( Calculated by vendor only )

- Total Pressure Rise - TPR (mmwg) = Connection Loss - Static Inlet Pressure

= ( 8.1) - ( -270 )

278.1

mmwg

( Calculated by vendor only )

- Compressibility Factor The compressibility factor (Z), also known as the compression factor, is a useful thermodynamic property for modifying the ideal gas law to account for the real gas behaviour.

0.991

( Calculated by vendor only )

- Fan Efficiency (FE)

The fan efficiency is the ratio between power transferred to the airflow and the power used by the fan.

87.1

( Vendor Input )

- Fan Total Efficiency (FTE)

84.7

( Vendor Input )

- Fan Static Efficiency (FSE) - Duty Shaft Power Calculation =

80.9

( Vendor Input )

( 516.7 X 279 X 0.991 X 9.80665 ) ( 80.9 / 100 ) X 1000 1732 KW

Duty Shaft Power

Guaranteed Shaft power for FLAKTWOODS -SWEDEN Test Uncertainty In/Out Average FEM (Fan Eff. Margin) - Ref. B & W standard margins plot Zero Tolerances Allowance No System Effects Final Margin % % % % % %
At 100% TMCR Condition Only 0 2

0 0 3 5

GUARANTEED SHAFT POWER FOR FAN =

1818 KW

Take one case study of ESSAR SALAYA - REV. 6 to calculate duty shaft power by different vendors DUTY SHAFT POWER CALCULATION PROCEDURE BY TLT BABCOCK - USA ID FANS - Extract mass flowrate of flue gas at the inlet of ID fan from air heater balancing sheet. m= 425.32 kg/sec

- Take site barometric pressure from MSL given in the tender or assumed value P= 29.8 inch Hg

- Take Temperature of the medium at the inlet of fan as given in the tender. T= 140 Deg C

- Density of medium at NTP condition at the inlet of fan is to be taken from P8475 Run. - Density of medium @ NTP Condition (kg/m3)= - Density of medium at operating temperature (kg/m3) = 1.287 kg/nm3
( 273.15 ) * (Density of medium @ NTP condition) (Barometric Pressure) * (Atm. Press. - Static Inlet Pressure ) * Density of * medium at NTP condition * ( 273.15 + Temp. of medium ) * 30 * Atmospheric pressure

273.15 X 1.287 X 29.8 X ( 10332.3 - 270 ) (273.15+ 140 ) X 30 X 10332.3 0.8231 425.32 0.8231 kg/nm3 516.71 m3/sec

= - Volume flow of medium (m3/sec) = Massflowrate of medium Corrected Density =

- Static Inlet Pressure (mmwc) = Pressure at the inlet of inlet transition duct ( Plane 1 as per Sketch ) - Static Outlet Pressure (mmwg) = Pressure at the outlet of outlet transition duct ( Plane 2 As Per Sketch ) - Static Pressure Rise - SPR (mmwg) = Differential pressure between inlet of fan casing & inlet of chimney Static Outlet Pressure -Static Inlet Pressure - Inlet Dynamic Pressure (mmwg) It is the pressure gain from inlet of the casing of the fan to an eye of an impeller - Outlet Dynamic Pressure (mmwg) Pressure exerted by the tip of an impeller - Total Outlet Pressure (mmwg) Pressure at the inlet of a chimney - Total Inlet Pressure Static Inlet Pressure + Dynamic Inlet Pressure - Inlet Transition Loss It is the loss accounted between inlet of inlet trans. Duct to outlet of outlet trans duct. - Carnot loss It is the loss when the media leaves the tip of an impeller - Round to square loss From outlet of outlet transition duct to chimney inlet - Compressibility Factor The compressibility factor (Z), also known as the compression factor, is a useful thermodynamic property for modifying the ideal gas law to account for the real gas behaviour. - Fan Total Pressure Rise ( mm -WC ) Summation of Static Pressure Rise + Inlet transition loss + Carnot loss + Round to square loss - Fan Total Efficiency (FE)
The fan efficiency is the ratio between power transferred to the airflow and the power used by the fan.

-270

mmwg

mmwg

( Calculated by vendor only )

=( - 270 + 9 )

279 13.4

mmwg mmwg ( Calculated by vendor only )

12.4

mmwg

( Calculated by vendor only )

-3.4

mmwg

( Calculated by vendor only )

= ( 279 -13.4 )

-256.6

mmwg

( Calculated by vendor only )

3.48

mmwg

( Calculated by vendor only )

0.18

mmwg

( Calculated by vendor only )

2.54

mmwg

( Calculated by vendor only )

0.991

( Calculated by vendor only )

= ( 279 + 3.48 + 0.18 + 2.54 )

285.2 mm-WC

88

( Vendor Input )

- Fan Static Efficiency (FSE) - Duty Shaft Power Calculation =

80.9

( Vendor Input )

( 516.7 X 279 X 0.991 X 9.80665 ) ( 80.9 / 100 ) X 1000

- Aerodynamic Power - Miscelleneous Power Shaft Power

1732 20 1752

KW KW KW ( Calculated by vendor only )

Guaranteed Shaft power for TLT BABCOCK - USA Test Uncertainty In/Out Average FEM (Fan Eff. Margin) - Ref. B & W standard margins plot Zero Tolerances Allowance No System Effects Final Margin % % % % % %
At 100% TMCR Condition Only 0 2 1.6 0 3 6.6

GUARANTEED SHAFT POWER FOR FAN =

Fan Design SOP Description

1867 KW
AMIT NMP Prepared By Checked By NMP Approved By 6th January , 2011 Date

FD FAN With Inlet Silencer & Outlet Duct Sketch :

PA FAN With Inlet Silencer & Outlet Duct Sketch :

ID FAN With Inlet Duct & Outlet Duct Sketch ( Axial Fan ) :

ID FAN With Inlet Duct & Outlet Duct Sketch ( Radial / Centrifugal Fan ) :