HRL Technology Group Pty Ltd ABN 89 609 887 327 [email protected] hrl.com.au
Melbourne Level One Unit 4 677 Springvale Road Mulgrave VIC 3170 Phone +61 3 9565 9888 Fax +61 3 9565 9879
Morwell Tramway Road Morwell VIC 3840
Phone +61 3 5132 1500 Fax +61 3 5132 1580
Queensland Unit 2 33-37 Rosedale Street Coopers Plains QLD 4108 Phone +61 7 3423 4300 Fax +61 7 3345 5937
1
IDFan
Cap
ability
hrl:
IDFanCapabilityOptimisinginduceddraftfanperformanceandreliability
ChallengesSub-optimalinduceddraft(ID)fanperformancecanleadtoshort-andlong-termissuessuchas:• prematurecrackingoffanimpellers• increasedpowerconsumptionandhenceauxiliaryload• damagetofanimpellersthrougherosion.
Solutionshrl:canhelpplantoperatorsmeetthesechallengesby:• providingindependentIDfanperformance/acceptance
testingtorelevantcodessuchasASMEPTC11-Fans• auditingfandesignusingstressandmodalanalysis
(finiteelementmethods),impulsetesting,fatigueassessmentsandstraingaugesurveys
• undertakingprocessmodellingandcomputationalfluiddynamics(CFD)modellingofthefansandsurroundingductworkunderexistingandpotentialoperatingconditions.
Benefitshrl:servicesandexpertiseprovideplantoperatorswithnumerousbenefits,including:• independentacceptancetestingtoensureoriginal
equipmentsuppliersperformanceguaranteesaremet• performancetestingandprocessmodellingproviding
insightintohowplantoperatingconditionsareimpactingonIDfanperformanceandefficiency
• auditingfandesignstodeterminethesteadystate,staticanddynamicstressesexperiencedduringoperation;andthemodefrequenciesandshapes,tohelpdeterminethecauseandriskofprematurecracking
• auditingthatcanalsodetermineexpectedfanlifeandassistindevelopingweld-repairprocedures
• usingcomputationalfluiddynamicsmodellingtorevealtheunderlyingflowstructureswithinthefanandsurroundingductworktodiagnoseperformanceissuessuchasvibrationcausedbythefanoritsinteractionwithsurroundingductwork
• usingCFDmodellingtopredicterosionpatternscausedbyparticle-ladenflowstohelpplanmaintenanceandcomparescenariostominimisesucherosion.
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Case Study Investigating premature cracking in an ID fan AnAustralianpowerstationfoundsignificantcrackingwithintheimpellerononeoftheirinduceddraftfans.Theimpellerhadbeenreplacedthreeyearsearlierandhadbeensubjectedtoseveraldesignchanges,suchthatthereplacementimpellercouldbeconsideredasadifferentstructuretotheoriginal.hrl:wasengagedbythepowerstationoperatorstoinvestigatetherootcauseofprematurecrackinginthenewimpeller.hrl:investigatedthecrackingby:• installing(wireless)straingaugesontothenewimpeller
tosurveystrainduringstart-upandnormaloperation• undertakingafiniteelementanalysis(FEA)ofthefanto
determinetheresonantfrequencyoftheimpellerandmodeshapeofthenaturalfrequencies
• undertakingsteady-stateanalysistocomparetheoperatingmeanstressofthenewimpellertotheoriginal
• performingastiffenedmodalanalysistodeterminethesystem’snaturalfrequenciesandmodalshapes
• performinganunstiffenedmodalanalysistodeterminestaticnaturalfrequenciesforvalidationagainstimpacttestingresults
• performancetestingofthefanduringoperationtodetermineitsefficiencyunderdifferentoperatingconditions.
hrl:establishedthemostprobablecauseofthecrackingtobevibration,possiblylinkedtothechangedimpellerdesign.hrl:providedthepowerstationoperatorswithoptionstopreventfurthercrackingoftheirIDfans.hrl:recommended:• thefanmanufacturerreviewthefanflow-design
characteristicsbasedontheperformancetestdatahrl:collectedunderplantoperatingconditions–nearstallatlowload
• tomitigatetheflow-inducedvibration,thestationtoconsiderasmallerfan,orinstallingavariablespeedfanorbypassductsystem
• installingflue-gasflowmeasurementdevicesonbothfanstoeliminatebiastoonefan
• specificoperatinginstructionstoavoidrunningthefanatnear-stallcondition.
Contact JamesTaylor
Contact DaoNguyen
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Ó2016HRLTechnologyGroupPtyLtd
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