Air & Draft system

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Presentation Plan
Various auxiliary equipments in a boiler Need for Draft System Primary and secondary air system in Boiler and their fans Other fans in a boiler Basic of fans: Fan Types and selection Fan laws and factors affecting fan performance Performance curves

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Arrangement of Boiler Auxiliaries

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Need of Draft System

Combustion Air

Boiler

Flue Gases

Air needed for combustion

Flue are needed to be evacuated

Losses due to flow need to be overcome
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How to select a fan

Air or Gas flow -Kg/hr Density (function of temperature and pressure) System, resistance (losses) Major Fans in Boiler Draft System PA Fans FD Fans ID Fans

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PRIMARY AIR/MILL SEAL AIR SYSTEM

Ambient air is drawn into the primary air ducting by two 50% duty, motor driven axial reaction fans. Air discharging from each fan is divided into two parts, one passes first through a air pre-heater then through a gate into the P.A bus duct. The second goes to the cold air duct. The mix of both is used to carry the pulverized coal to the boiler.

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Components of PA Fan
Suction Bend With volume Measurement instruments Fan housing with Guide Vanes Main Bearings (Anti Friction) Rotor with impeller with adjustable blade with pitch control Guide vane housing with guide vanes Diffuser with pressure measurement instruments

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SECONDARY AIR SYSTEM

Ambient air is drawn into the secondary air system by two 50% duty, motor driven axial reaction forced draft fans with variable pitch control. Air discharging from each fan passes first through a air preheated then through a isolating damper into the secondary air bust duct. The cross over duct extends around to each side of the boiler furnace to form two secondary air to burner ducts. At the sides of the furnace, the ducts split to supply air to two corners. Then split again to supply air to each of nineteen burner/air nozzle elevations in the burner box.

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Burner Box Dampers

Coal/Air Dampers Secondary Air Dampers Oil/Secondary Air Dampers Bottom Tier Secondary Air Damper Over Fire Damper

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Primary and Secondary air System in the Boiler

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Axial Fans FD Application

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Induced Draft System

There are three induced draught fans per boiler, two operating and one standby In 500 MW fans are single-stage, double-inlet centrifugal fans. Principal fan elements of the fan are: Housing Inlet dampers Rotor with Bearing Shaft Seal

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ID Fan
The rotor consists of shaft and assembled impeller and runs in two sleeve bearings that are arranged outside of the housing. The impeller consists of a centre disc and two cover discs that are reinforced by forged rings. The bent blades are welded into position between the impeller discs. The blades are protected by screwed - on wear plates. The shaft is of hollow design. The fan shaft has been rated so that max. operating speed is below the critical speed. Impeller and shaft are connected by means of a flange. This screwing is protected by wear plates. The fan housing is sealed by means of two-part labyrinth seals. Bearings are lubricated with oil.

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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

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AIR AND FLUE GAS PATH TYPICAL 500 MW BOILER

TO MILLS

PAPH-A

SCAPH-A PRIMARY

PA FAN -A

ECO BYPASS

TO ESP

SAPH-A

AA205

AA203

SCAPH-A SECOND

AEROFOIL

AA202

AA201 HORIZONTAL S.H ECONOMISER -1 ECONOMISER -2 SA HDR AA204 HOT PA HDR FD FAN -B

DIVISION PANELETTE S.H

HOT

COMBUSTION CHAMBER

PLATEN S.H

ECONOMISER-3

RE HEATER

AA204

AA201

SAPH-B

AA205

AA203
SCAPH-B SECOND

AA202 FD FAN-A

AEROFOIL

COLD SEC. AIR COLD PRIM AIR HOT PRIMARY AIR HOT SEC. AIR FLUE GAS PNEUMATICALLY O/P KNIFE EDGE GATE MOTOR O/P LOUVER DAMPER PNEUMATICALLY O/P LOUVER DAMPER

ECO BYPASS BIPLANE DAMPER

SCAPH-B PRIMARY

TO ESP

DIVERTER DAMPER

TO MILLS PA FAN -A

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PAPH-B

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Scheme of Air and Gas Path

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ID Fan at Location

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Variation of Pressure in Boiler

Furnace P ressure At Vario us P o ints in B o iler
250 200 150 100 50 0 1 -50 2 3 4 5 6 7 8 9 10 11 12 13 14

1 2

FD Fan Inlet
FD Fan Outlet Airheater Inlet

Airheater Outlet
4

Windbox Pressure
5 6 7 8

Furnace Pressure

Furnace Superheater Platen Inlet Reheater Inlet

-100

9
-150 -200 -250 -300 Points in Boiler

LTSH Inlet Economiser Inlet Airheater Inlet

10 11 12 13 14

E.P. Inlet I.D. Fan Inlet I.D. Fan Outlet

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Basics on Fans

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Difference between fans, blowers and compressors

As per ASME the specific pressure, i.e, the ratio of the discharge pressure over the suction pressure is used for defining the fans, blowers and compressors as highlighted below :

Equipment Fans Blowers Compressors

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Specific Ratio Up to 1.11 1.11 to 1.20 more than 1.20

Pressure rise (mmWg) 1136 1136 2066 20

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Typical centrifugal fan operation

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Fan types

Centrifugal fan
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Axial fan
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Centrifugal Fan: Types

Paddle Blade (Radial blade)

Forward Curved (Multi vane)

Backward Curved

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Axial Flow Fan: Types

Tube Axial Vane Axial Propeller

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Fan Types and Efficiencies

Peak Efficiency Range Airfoil, backwardly curved/inclined 79-83 Modified radial 72-79 Redial 69-75 Pressure blower 58-68 Forwardly curved 60-65 Axial fan vanaxial 78-85 Tubeaxial 67-72 Propeller 45-50 Centrifugal Fans
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Axial-flow Fans Type Prope ller Characteristics Low pressure, high flow, low efficiency, peak efficiency close to point of free air delivery Medium pressure, high flow, higher efficiency than propeller type, dip in pressure-flow curve before peak pressure point. High pressure, medium flow, dip in pressure-flow curve, use of guide vanes improves efficiency Typical Applications Aircirculation, ventilation, exhaust HVAC, drying ovens, exhaust systems Type Radial

Centrifugal Fans Characteristics High pressure, medium flow, efficiency close to tube-axial fans, power increases continuously Medium pressure, high flow, dip in pressure curve, efficiency higher than radial fans, power rises continuously High pressure, high flow, high efficiency, power reduces as flow increases beyond point of highest efficiency Same as backward curved type, highest efficiency Typical Applications Various industrial applications, suitable for dust laden, moist air/gases Low pressure HVAC, packaged units, suitable for clean and dust laden air / gases

Tubeaxial

Forwardcurved blades

Vaneaxial

High pressure Backward applications curved including blades HVAC systems, exhausts Airfoil type

HVAC, various industrial applications, forced draft fans, etc.

Same as backward curved, but for clean air applications

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System characteristic curve

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System 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)

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Fan static pressure

Fan Static Pressure r SP = SP (Fan outlet) SP (Fan inlet)
SP (Fan outlet) Static pressure at fan outlet, mm WC SP (Fan inlet) Static pressure at fan inlet, mm WC

r SP = 0.05 (-10) = 10.05 mm W.C.

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Speed vs Power
% Speed
100 90 80 70 60

% Power
100 73 51 34 22

50
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Flow control Damper - Most Popular Variable Speed Drive

Recirculation Damper VFC

100

Power

75 50 25 25

VFD Ideal

50

Flow

75

100

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Impact of speed reduction

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Use of VSD: Boiler ID fan case study

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Use of VSD: Boiler ID fan case study (contd.)

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THANK YOU

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