KNOW ABOUT FANS & APPLICATION [Compatibility Mode]

CONFIDENTIAL 10/21/2016

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KNOW ABOUT FANS & APPLICATIONS

Presented by U Jeyaganthan Cell:+91 9940085705U Jeyaganthan- Cell:+91 9940085705

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Introduction on centrifugal fans

INDEX

Basic principlesTypes of fansFan TerminologyFans application in the process sectorsRequirements for selecting a fanCustomers / OEM'sNeed of Retrofit

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The purpose of a “fan” is to

PURPOSE OF FANS

move a mass of gas or air at

the desired velocity with an

appreciable rise in pressure

to overcome some kind of

resistance in flowresistance in flow(Centrifugal& Axial)

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Air or gas enters the impeller eye axially

CENTRIFUGAL FANS-BASIC PRINCIPLE

and leaves radial.

The pressure is developed due to the centrifugal force imparted on the gas trapped between the blades.

The partial vacuum creates further suction imparting continuous air / gas flow.

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A) FORCED DRAUGHT FANS:

TYPES OF FANS

These fans collect air from atmosphereand deliver into the system. (Fan Inlet open/ Outlet connect to system)

Ex: Cooler fans in a Cement Plant

B) INDUCED DRAUGHT FANS

These fan Inlet and outlets normallyyconnect with systems. ID fan collect air/gas from one system and deliver intothe next system or Exhaust to air

Ex: Raw Mill ID & BH Fans

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FAN- BLADE PROFILES

Airfoil (AF) Eff:90%

Backward-curved (BC)

•Different types of fans characterized by

their blade type Backward curved (BC) Eff:85%

Backward-inclined (BI)Eff: 78%

Radial-tip (RT)Eff:70%

their blade type

•Different applications

require different

blade type

Forward-curved (FC)Eff: 65%

Radial blade (RB)Eff: 60%

yp

•Each type has different fan performance curves

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FAN SELECTION INPUTS

Volumetric Flow

Static Pressure at Fan Inlet

Fan Selections

Static Pressure at Fan outlet

Operating & Design Temperatures

Nature of Application

Dust Concentration

Actual Density of Flue gas/ Air

Preferable fan speedPreferable fan speed

Frequency (Hz)

Drive Arrangement

Fan Arrangement

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FANS-TERMINOLOGY

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FAN TERMINOLOGY

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FAN –AERODYNAMIC CHARACTERISTIC CURVE

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1. Volume is directly proportional to fan speed

FAN LAWS- CHANGE IN SPEED

Q N2 2

2. Pressure is proportional to the

square of the velocity

Q N2

1

2

1=

T PT P

S PS P

V PV P

NN

2

1

2

1

2

1

2

1

2= = =

⎛⎝⎜

⎞⎠⎟

3. Power is the product of volume by energy

1 1 1 1

PP

NN

2

1

2

1

3=

⎛⎝⎜

⎞⎠⎟

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FAN LAWS- CHANGE IN IMPELLER DIAMETER

Changing the Impeller DiameterIf wheel velocity is constant a change in impeller diameter can simplify the affinityimpeller diameter can simplify the affinity laws to

Volume Capacityq1 / q2 = (d1 / d2)3 (1b)

Head or Pressuredp1 / dp2 = (d1 / d2)2 (2b)

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PowerP1 / P2 = (d1 / d2)5 (3b)


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FAN APPLICATION IN CEMENT PROCESS PLANTS

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Raw mill:

FAN APPLICATION IN CEMENT PROCESS

Packing Plant:Small size fans & BlowersRaw mill:

ID & ESP/ BH Fans

Coal Mill:Booster & Recirculation Fans

Pre Heater:Kiln, Pyro & Calciner String FansKiln ESP Fan

Small size fans & Blowers

** WHRS (Waste Heat Recovery Boiler System)ID Fan

Cooler:Cooler FD & Cooler Vent / ESP Fans

Cement mill:Cement Mill ID & BH FansSeparator Fans

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STEEL PROCESS FLOW CHART

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Sintering Plant (SP):

FANS APPLICATION IN STEEL PLANTS

Direct Reduced Iron (DRI): ID & FD Fans

Waste Gas FanCooling Air FanHot Air fan &Secondary Air FanCoke Oven Fans

Electric Arc Furnace (EAF):ID Fans

Mini Blast Furnace (MBF):High Pressure BlowersExhaust Fan

Pelletizing:gID/PA & SA Fans

Steel Melting System (SMS)ID Exhaust Fans

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FANS APPLICATIONS IN POWER PLANTS- BOILER

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1. ID Fans

THERMAL POWER STATION- BOILER APPLICATION

2. FD Fans

3. PA Fans4. SA Fans

5. Seal Air Fans6 C b ti Ai F6. Combustion Air Fan

7. Blowers like

scanner Air fan etc.

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REFORMER ID FAN

FAN APPLICATION IN REFINERIES

REFORMER ID FANCOMBUSTION AIR FANPRIMARY AIR FANSECONDARY AIR FAN FD FAN

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CRITICAL FAN PARTS - ROTOR

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FABRICATION FAN PARTS - STATOR

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ErosionBuild up / Coating

Major Problems

FAN TROUBLE SHOOTING

Build up / CoatingLack of capacityUnbalance in Impeller.VibrationsBearing FailureLeakagesL b i iLubricationSurgingMisalignmentImproper layout systemUn stability in Process

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IMPELLER WEAR PROBLEM DURING OPERATION

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IMPELLER WEAR PROBLEM DURING OPERATION

CorrosionFatguei

Build up & Vibrations

Lack of CapacityOver Consumption Extreme Temp Conditions Surging

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HARD FACING METAL DEPOSED BY WELDING

Wear plates with hard facing materialsIMPELLER WEAR PLATES WITH HARD FACING

BLADE

CARBON STEEL PLATE

Hard facing material is never welded directly on the blades toavoid metallurgical problem.

This protection can be easily replaced without modifyingthe mechanical structure of the impeller.

Even airfoil blades can be protected

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Fan Retrofit ?????

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Fans - Major power consumers

F b ffi i

OBJECTIVE:

Fans operate at best efficiency at original design point

Modernization / Up-gradation of plant changes system resistance

Hence fans operate less efficiently

Retrofit & upgrades (R&U) : provides solution

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System Resistance Change?

NEED FOR RETROFITTING

1. Retrofitting means upgrading the existing equipment to improve the efficiency and performance of the equipment. 2 Retrofitting is usually performed in large scale industries such as Cement2. Retrofitting is usually performed in large scale industries such as Cement Industry, Power plant industry where a complete new installation consumes huge amount of time and money.3. The basic need for retrofitting in industrial fans is to improve the performance of the existing fan.

Need for Retrofitting•Optimization of existing fans•Retrofitting of industrial fan involves adding or replacing a component to the•Retrofitting of industrial fan involves adding or replacing a component to the existing fan system in order to achieve increased performance.•Coming to the retrofitting of industrial fans, it will be something like change in system resistance either to increase or decrease depending on need. Industrial fans start to decrease its performance after some period of time. With retrofitting one can optimize the existing fan.

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Retrofitting is a better alternative to optimize fan performance. It also has many advantages and can be easily performed with less investment and Why

R t fit ?

FAN RETROFIT / ENHANCEMENT OPTIONS

y pin less time period.

A change to variable speed drive

Increasing the fan Capacity

Reducing the fan power consumption

Replacing the impeller (..in an existing casing

Retrofit ?

p g p ( g gwith another design impeller)

Adding erosion or corrosion protection

Improving inlet / discharge flow conditions( System Effects)

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RETROFIT –ALTERNATIVE SOLUTION

Retrofit uses maximum availability of existing equipment and which is a economic alternative than a complete new installation.

R t fit bi th d t f i ti i t dRetrofit combines the advantages of existing equipment and new equipment which is a cost saving option.

Retrofitting involves simple assembly which does not require a skilled labour who is expensive than a regular manpower.

If we take the case of installing a complete new system in the plant, we have to shut down the entire system for a longer period of time.

If we perform retrofitting, as it involves installation of parts, it will consume less time for installation and decreases the shut down period. This regulates the overall loss to the plant.

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FAN RETROFIT – KEY WAYS

When the flow of a fan is reduced, the rotor and inlet are replaced in orderto enhance the flow and pressure for the same input power of an industrial fan.

Industrial fan also consists of small parts which are to be changed to obtain anIndustrial fan also consists of small parts which are to be changed to obtain an increased efficiency. The parts which are involved are casing of fans, inlet boxes, dampers and silencers etc.

Bearings in fan are one of the most important parts; the life period of a fan depends on the working condition of a bearing. Changing bearings will ensure more life and lesser maintenance for an Industrial fan.

Industrial fan consists of rotating parts, which cause wear of the material. By ti i t t t i l t th l t f f ill lt icoating wear resistant material on rotor or any other plants of fan will result in

good wear life.Industrial fan also produces a lot of noise; the level of noise can be minimized

by retrofitting silencers or dampers to the fan.

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RETROFIT PERFORMANCE CASE STUDIES

CASE STUDY No. : 01 POWER SAVING & CAPACITY ENHANCEMENT

C t O i t F t HF4S TSR 360 3TS8Customer : Orissa cements Plant : Orissa , Rajgangpur. (3000 TPD)

Fan type : HF4S TSR 360 3TS8 Application : Pre heater fan

New Fan in the existing foundation and System replacing HUMBOLDT fan. Sl.No Parameters Unit Old Fan New Fan Change in %

Design Design 1 Inlet Flow m3/hr 396000.0 410000.0 3.5 2 Net Static Pressure mmwg 841.0 1000.0 18.9 3 Speed rpm 980 930 -

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4 Power consumption at fan shaft kW 1158 1267 9.4 5 Fan Efficiency % 78.3 88.1 12.5

Summary

A new fan is fitted in the existing foundation to enhance the capacity as well as efficiency.


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RETROFIT PERFORMANCE CASE STUDIES

Case study : 02Power saving & Capacity Enhancement

C t M/ G i I d t i Ltd R i E i ti F T HF5S TDR 315 3TD8A

Old Fan : Flakt New Fan- F18 TDR 368 3TD8A

Design Design1 Volume m3/hr 640000 700000 9%2 Net static pressure mmwg 1590 1480

Plant: Raipur, Chattisgarh Application: Raw Mill FanRetrofit Impeller,Hub in existing condition for power savings & capacity enhancement purpose

S no

Parameters Unit Capacity increase

Customer: M/sGrasim Industries Ltd,Raipur Existing Fan Type : HF5S TDR 315 3TD8A

2 Net static pressure mmwg 1590 14803 Speed rpm 930 9094 Fan shaft power Kw 3432 32725 Fan Efficiency % 80.75 86.2

Power savings Kw 160.5 202Note : Scope of Supply

Actual Power savings 202 KW. Performance proved at site Impeller, Hub &cones only

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KNOW ABOUT FANS & APPLICATION [Compatibility Mode]