' M

Chapter - 6

STUDY OF PERFORMANCES OF INDUCED

DRAUGHT (ID) FAN THROUGH DCS BASED
INSTRUMENTATION AND CONTROL
SYSTEM OF A HIGH CAPACITY BOILER AND
DESIGN OF NEW INDUCED DRAUGHT FAN
FOR THE EFFICIENCY IMPROVEMENT OF A
STEAM GENERATION PLANT

IEEE Region JO Colloquium and the Third ICIIS, Kharagpur, INDIA

December 8-10, PAPER NO: - 479, Article number 4798468.
http://www. ieeexplore. ieee. org,7

iffi. . . . . . . . .......... . . . . . . . . . . . . —m
Study of Performances of Induced Draught (ID) Fan through DCS Based Instrumentation and Control System of a High Capacity
Boiler and Design of New Induced Draught Fan for the Efficiency Improvement of a Steam Generation Plant_____ Chapter - 6

6.1 INTRODUCTION
The air/gas system can be considered to centre upon the furnace, in which combustion
of gas and /or pulverized fuel occurs, the products of which form the furnace gases.
Draft control system comprises with induced draft (ID) fan and forced draft (FD) fan
[16,17, and 73], The induced draft fans and forced draft fans provide control for draft
and forced air zoning of fuel burned furnaces of steam generation plant of a thermal
power plant The induced draft fan exhausts flue gases from the furnace and induces
combustion air into the furnace by having the furnace operated under negative
pressure. Forced draft fans are used for supplying the combustion air into the furnace
of a boiler. A good design of fan and its control system increases plant reliability by
improving furnace pressure control and airflow control, which is most critical control
part of combustion control system. The fans are designed to operate with balance draft
conditions, their throughput being controlled, respectively, by radial and differential
vane control mechanism. Balance draft furnaces are typically operated at slightly
negative pressure, but they can also operate at slightly positive pressure. The induced
draft fans are backward-curved laminar bladed type. The fans and their motors are
attached to foundations at datum level. Induced draft fans are used to control the
furnace pressure by extracting the flue gas through chimney of boiler. Many works
are still being reported on the performance and efficiency of a thermal power plant.
Beasley, 0. W., et al [21] have studied the ID and FD fans of cogeneration plant. A
first of its kind, induced draft (ID) heat recovery steam generators (HRSG) have been
in service at a cogeneration facility. The study indicated that the FD fan may require
the HRSG duct burner to be shut off following a CT trip and re-ignited after the FD
fan was in service. Although the induced draft HRSG design cost more than the FD
fan design, the induced draft design has improved the cogeneration facility's steam
generation reliability. Das, K. K., et al [58] have derived the optimal block
replacement policies for four different operating configurations of induced draft fans.
Under the usual assumption of higher cost of repair or replacement on failure
compared to preventive replacement, the optimal preventive replacement interval is
found by minimizing the total relevant cost per unit time. Owen, E. L., et al [161]
have described the use of an-ac adjustable-speed drive for induced draft fan. Some of
the early electronic power converters utilized mercury-arc rectifiers such as thyratrons
and ignitions. Their use in an-ac adjustable-speed drive began about 50 years ago.
Sheridan, S. E., et al [198] (1984) have described the basis and experience in
automating the control of a 1500- ton/day four-stage heater cement kiln. The control
substitutes the coordinative control actions formerly carried out by the kiln operators
by utilizing a minicomputer to implement fuzzy logic control strategies. Operating
decisions are made more consistent and quantitative and less subjective to human
operator control philosophy variations. Mukherjee, K. P., et al [154] have investigated
a serious case of damage of induced draft fan at the Bokaro Thermal Power Station.

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 Investigation on the Improvement of Steam Generation Plant through Imtrnmentation and Control Applications

The efficiency and economy of power generating plants depend largely on the
minimization of breakdown in various units. They have also described various tests
carried out to determine the causes of damage.

In the first part of the present work, the performance of the present induced
draft fans already installed in DCS based instrumentation system of a running steam
generation unit of captive power plant at RCF, Thai Unit has been studied and from
this study, the cause of low efficiency problems of the existing system has been
investigated. All experimental data are collected through DCS coming from different
field instrumentations for investigating the performance of ID fans. In the second part
of the work, the design of new induced draft fans has been proposed and in the last
part, the saving calculation due to this new design has been made. The report of all
these works is presented in this chapter.

6.2 CASE STUDY

The present study has been made in a typical steam generation plant of naphtha and
natural gas based fertilizer plant at the Thai unit of Rashtriya Chemicals and
Fertilizers during running condition of the plant The Steam Generation Plant consists
of three boilers, each having capacity of 275 MT/hr steam. Pressure and temperature
are maintained at 100 kg/cm2 and 510°C in high-pressure steam header, respectively.
Out of the three boilers, two boilers are kept in service and third boiler is kept as
standby. These boilers were designed for coal and natural gas as fuel. In year 1997, all
the burners were retrofitted to use naphtha & natural gas as fuel. There are two
induced draft fans and two forced draft fans present to maintain the balanced draught
at furnace in each boiler. All control loops are handled by DCS based instrumentation
system. All required parameters are like steam flow measured by flow nozzle through
smart differential pressure (DP) transmitter, fuel flow measured by Micro-motion
(Coriolis based) mass flow meter, flue gas oxygen measured by zirconia based
oxygen analyzers, other flow measured by orifice flow meter through smart
differential pressure (DP) transmitter, different pressure measured by smart pressure
transmitter and all temperature measured by K-type thermo-couple with MTL
converters.

The induced draft fan, each of 2661mm diameter, backward curved laminar
bladed, single inlet fan type B.B.65/2 manufactured by Davidson and Company Ltd,
Sirocco Engineering Works, is designed to deliver 75 m3/sec of flue gas with a
density of 0.8168 Kg/m3, at a pressure of 382 mmWC and at a temperature of 150 °C.
The fan is operated at a constant speed of 740 rpm by a 430 KW electric motor
(supply - 3.3 kV, 3 phase, 50 Hz) manufactured by Laurence Scott, and

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Study of Performances of Induced Draught (ID) Fan through DCS Based Instrumentation and Control System of a High Capacity
Boiler and Design of New Induced Draught Fan for the Efficiency Improvement of a Steam Generation Plant_____ Chapter - 6

Electromotors. A Wellman Bibby resilient grid spring coupling of size 5429,

interposes driver and driver shafts.

6.2.1 Study of the Existing Fan Performances and draft losses in the Boiler:
; i »>*

(a) Power input to the motor (kW)

p _ V3Wco«&
1000

Where, V, I and 0 are the input voltage, current and phase angle respectively,

(b) Fan Efficiency (E,) %

Volumb fa-Sac.
Ef = 3.02 XPawer Input to ShaftikVTj (2)

(c) Fan Shaft Power P,

^Volume i^)XTotal
P,= 102
(3)

Design Data of Induced Draft Fans:

Volume- 75 M3/Sec.
Pressure - 382 mmWC
Temperature-150 °C,
Characteristics - Centrifugal backward curved type
Fan Manufacturer - Davidson & Co. Ltd., Sirocco Engineering Works.

Table 6.1: Design Data of Flue Gas Draft Losses

Fuel Natural Gas (NG) Coal Firing

Firing
Load Condition MCR 75% MCR 75%
Furnace section (mm WC) 3 3 3 3
Secondary Super Heater (mm WC) 3 2 3 2
Rear Enclosure (Screen) (mm WC) 2 1 2 1

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 Inve»tlgation on the Improvement of Stem Generation Plant throngh Initrumentadon and Control Application!

Primary Super Heater (mm WC) 11 6 13 7

H.T. Economiser (mm WC) 28 15 33 19
Mill Air Heater (mm WC) 5 3 5 3
L.T. Economiser (mm WC) 15 8 23 11
Main Air Heater (mm WC) 78 46 94 55
Precipitator (mm WC) 12 7 14 8
Ducting & Dampers (mm WC) 80 46 80 47
Total Draught Losses (mm WC) 237 137 270 156

6.2.2 Performance Calculation:

From equation (3), Shaft Power rating of induced draft fan at full load is given by,

75X382
= 280.9 KWH (4)
102

Full load induced draft motor current at 100% damper opening =82 Amp.
From equation (1), Full load power of induced draft fan motor is given by,

1/3X3300X82X019 ,
421.8 KWH (5)
1000

From equation (2), induced draft fan Efficiency is given by,

2B0.9X100
66.6 96 (6)
421,8

Normal induced draft fan motor current = 72 Amp.

From equation (1), Normal induced draft fan motor Load is given by,

73X3300X72X0,9
3703 KWH (7)
1000

At that condition induced draft fan load is given by,

370.4 X — = 246.7 KWH (8)

100

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Study of Performances of Induced Draught (ID) Fan through DCS Based Instrumentation and Control System of a High Capacity
Boiler and Design of New Induced Draught Fan for the Efficiency Improvement of a Steam Generation Plant_____ Chapter-6

Table 6.2: Online Running Plant Data of Flue Gas Draft at Different Locations

Date: 1/15/2007
Flue Gas side Boiler2
Differential
No. Location mm ofWG
Pressure
1 Primary SH outlet -20.32
2 HT Eco. Outlet -20.32
LT eco
mill air heater
press drop at mill air heater=2-3 48.28
3 R. A. Heater A flue gas inlet -68.60
4 R.A. Heater A flue gas outlet -182.88
Across flue gas RA heater-A=3-4 114.28
5 R.A. Heater B flue gas inlet -73.66
6 R.A. Heater B flue gas outlet -190.50
Across RAH-B=5-6 116.84
nt ESP inlet common duct pressure -162.50
8 ESP-A outlet duct pressure -226.06
ESP-A=4-8 43.18
9 ESP-B outlet duct pressure -226.06
ESP-B=6-9 35.56
10 ESP outlet common duct pressure -190.50
Across ESP common ducts=7-10 28.00
11 Induced draft fan-A outlet -12.70
12 Induced draft fan-B outlet -5.08
Air Sic e
Differential
No. Location mm of WG
Pressure
1 R.A. Heater A air inlet 177.80
2 R.A. Heater A air outlet 88.90
Across RAH-A 88.90
3 R.A. Heater B air inlet 190.50
4 R.A. Heater B air outlet 93.98
Across RAH-B 96.52
Other Parameters
1 Steam flow 234.83 T/H
2 FW flow 237.42 T/H
3 Spray Water flow 0.12 T/H
4 Gas Flow 0 NmJ/H
5 Naphtha Flow 13180 Kg/H

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 Invert!gation on the Improvement of Steam Generation Plant through Initnurientation and Control Applications

6 Forced draft A air flow 131.96 T/H

7 Forced draft B air flow 151.8 T/H
8 Furnace Pr -4.57 mmWC
9 Flue Gas O2 3.0 %
10 Drum Pr 113.85 . Kg/cm2
11 Steam Pr 103.98 Kg/cm2
12 Windbox Pr 85.9 mmWC
13 Windbox Temp 202.8 UC
14 Platen SH outlet Temp 441 °c
15 Final Steam temp 501.7 °c
16 RA heater A flue gas inlet 254.77 uc
17 RA heater B flue gas inlet 250.04 uc
18 RA heater A flue gas outlet 120.58 uc
19 RA heater B flue gas outlet 117.58 °c

6.3 DESIGN DATA FOR NEW INDUCED DRAFT FANS AND

MOTORS:

Design Consideration for induced draft fans:

At normal load, in Boiler-2 induced draft suction pressure -226 to -240mmWC,

Where
• Pressure drop across RA Heater in 12 % air leakage is 114 to 116 mmWC (but
for 25% air leakage is 140 mmWC in extreme case)
• Pressure Drop across ESP is 10 to 35 mmWC due to ESP duct leakage which
was designed for coal firing.
• Pressure Drop inside the Boiler across the flue gas path is 75 to 80 mmWC.

After ESP removed and new ducting induced draft suction pressure will be less by 15
to 30 mmWC and after attending seal leakage in RA heater, there will be almost 25 to
30 mmWC pressure drop improvement observed (according from the online data).
Then induced draft suction pressure will be in the range of 185 to 200 (max.) mmWC
at the normal load.
For full load suppose induced draft suction pressure will be in the range 250-275
mmWC and taking 10 % excess suction design pressure will be maximum 300
mmWC.
Study of Performances of Induced Draught (ID) Fan through DCS Based Instrumentation and Control System of a High Capacity
Boiler and Design of New Induced Draught Fan for the Efficiency Improvement of a Steam Generation Plant_____ Chapter-6

Table 63: Design data of Boilers for Flue Gas

Fuel Natural Gas (NG) Naphtha

Load Condition MCR 75% MCR 75%
Evaporation rate (T/H) 275.00 : ' 206.50 275.00 206.50
Fuel Consumption (T/H) 16.454 12.350 17.20 12.90
Air to fuel ratio (T/T) 17.35 17.35 15.2 15.2
Excess air in Furnace (%) 8.0 8.0 10.0 10.0
Excess air in RA heater Inlet (%) 10.0 10.0 12.0 12.0
Excess air in RA heater Outlet (%) 20.0 20.0 22.00 22.00
Total Combustion air (T/H) 285.5 214.3 261.4 196.1
Air to forced draft Fan (T/H) 308.3 231.4 287.5 215.7
RA heater Inlet air (T/H) 314.1 237.7 292.8 219.6
RA heater Outlet air (T/H) 342.6 257.2 318.9 239.2
Leakage air in RA heater (T/H) 28.5 19.5 26.1 19.6
Total air flow from forced draft fan 336.8 250.9 313.6 215.7
(T/H)
Hot air to wind box Temperature 200 168 200 168
(°C)
RA heater Inlet Temperature (°C) 272 251 272 251
RA heater Outlet Temperature (UC) 135 135 135 135
Flue gas at induced draft fan & 130 130 130 130
Stack Temperature (°C)
Ambient Temperature (°C) 40.0 40.0 40.0 40.0

From the design data we have found that maximum air flow required for NG firing, so
we can design the induced draft fan with this data.

Table 6.4: Online Results for Fine Gas

Evaporation rate (T/H) 275.00

Fuel Consumption (T/H) 16.454
Air to fuel ratio (T/T) 17.35
Excess air in Furnace (%) (taking) 10.0
Excess air in RA heater Inlet (%) 12.0
Excess air in RA heater Outlet 37.0
(%)(maximum 25% leakage)
Total Combustion air (T/H) 285.5
Air to forced draft fan (T/H) 314.1

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 Invettigation on the Improvement of Steam Generation Plant through Instrumentation and Control Application*

RA heater Inlet air (T/H) 320.0

RA heater Outlet air (T/H) 391.0
Leakage air In RA heater (T/H) 71

Taking with some excess capacity, total maximum flue gas flow will be 420 T/H.
Density of flue gas at 140 °C is approximately 0.89 Kg/ NM3.
Therefore required induced draft fan capacity is given by in place of 75 M3/ S.

420000
2X0.89X3600
65.5 M3/S (9)

Therefore, we consider for new induced draft fan capacity is 66 M3/ S. (10)

6.4 SAVING CALCULATION FOR INCORPORATING OF

NEW DESIGN INDUCED DRAFT FANS IN PLACE OF
EXISTING FANS

6.4.1 Power Saving Calculation:

Power rating of new induced draft fan at full load from equation (3) is given by,

=194.1 KWH (11)

102 v '

We are using backward curved type centrifugal fans for induced draft fans, which
have peak efficiency range of 79 - 83%. We consider the new induced draft fans
efficiency be 79%.
Therefore motor input power for full load condition is given by,

===
0.T9
= 245.6 KWH (v 12)1

Taking 10 % extra rating, 270 KWH motor will be sufficient for induced draft fans,
which is the same rating of forced draft fans.
Now for the normal load condition, induced draft suction pressure will be 200
mmWC.
And from Table 6,2 online Data,
Steam flow -234.8 T/H
Naphtha flow —13.18 T/H + 1.304 T/H (Corresponding to NG flow for two burners
1600 NM3/H)= 14.484 T/H.

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Study of Performances of Induced Draught (ID) Fan through DCS Based Instrumentation and Control System of a High Capacity
Boiler and Design of New Induced Draught Fan for the Efficiency Improvement of a Steam Generation Plant_____ Chapter-6

Air to fuel ratio for naphtha = 15.2 T/T of Naphtha

Actual Excess air for naphtha = 17 %.
Total combustion air to furnace = (15.2 X 14.484) X ^1 + = 2575 T/H

Total flue gas flow in induced draft fans (taking 12 % air leakage) = (257.5 +
26.4)
= 283.9-284 T/H.

Therefore normal induced draft fan flow is given by,

284300
44.3 M*/S (13)
2X0.83X3600

Power in fan side is given by equation (3),

200 X44-3
= 86.9 KWH (14)
302

Motor input power is given by,

—
0.79
= 110 KWH (15)'
v

Therefore total power saving per Boiler due to in new induced draft fan design taking
12 % air leakage in RA heaters is given by,

2 X (370,3 - 110.0) = 520.6 KWH (16)

Taking total 240 days boiler running and power generation cost Rs. 8.40/KWH, total
monitory saving is given by,

520.6 X 8,4 X 24 X 240 = Rs. 2.52 Crores/Annum (17)

6.4.2 Steam Saving in Turbo Generator (TG):

There are two turbo-generator sets for captive power to meet the required power for
the whole plant. These turbo-generators are synchronized with the grid of MSEB
(Maharashtra State Electricity Board) and import/ export controller is used to control
the load demand in such a way that set point is setted at zero position.

Data of 15th January’2007:

1. TG total steam inlet flow rate - (73.6 + 74.0) = 147.6 MT/H.

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 Invcrtlgatlon on the Improvement of Steam Generation Plant through Instrumentation and Control Applications

2. TG total Ext-1 flow rate - (25.3 + 36.6) = 61.9 MT/H

3. TG total Ext-2 flow rate - (16.6 + 6.6) = 23.2 MT/H
4. TG total Condensate flow rate -(31.8 + 30.9) = 62.7 MT/H
5. Total MW Generation-(12.63+ 11.74) = 24.37 MWH
6. Specific Consumption - 2.97 T/MWH (TG-1) & 3.05 T/MWH (TG-2).
7. Average Specific Consumption -3.01 T/MWH
8. Enthalpy: -
a) TG inlet steam - 807 Kcal/Kg
b) TG Ext-1 steam - 725 Kcal/Kg
c) TG Ext-2 steam - 680 Kcal/Kg
d) TG Condensate steam to condenser - 575 Kcal/Kg

Taking actual TG generating load calculation of utilization of heat to generate

2437 MW captive powers:

Utilized heat in turbine is by,

JUTWCnl
147.6 X 807 - 61.9 X 725 - 23.2 X 680 - 62.7 X 575 = 22.407===i =
m
26.05 MWH

Therefore thermal efficiency which is converted into power generation is given by,

^•X 100 = 93.6% (18)

Calculation of TG Specific consumption after installation of NEW Design

Induced Draft fans in two boilers:

Load decreases due to new induced draft fans in two boilers =

2 X 520.6 = 10402 KWH
Then TG generation load will be (24.37-1.04) = 23.33 MWH
Require heat to generate 23.33 MWH in turbine = 23.33 X = 21.435 MWH
0.936
As the Ext-1 and Ext-2 will almost remain constant, which totally depend on the
boiler load (although some amount steam inlet to TG will be decreased due to
decrease in generation, we take it constant for making easy calculation), only
condensate flow will be decreased with the decrement of generation.
Let the Condensate flow be X T/H to generate 23.33 MWH for above conditions.
Therefore, from energy balance equations,

21435 = (61.9 + 23.2 + X)B07 - (61.9 X 725) - (23.2 X 680) - (X X 575)

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Study of Performances of Induced Draught (ID) Fan through DCS Baaed Instrumentation and Control System of a High Capacity
Boiler and Design of New Induced Draught Fan for the Efficiency Improvement of a Steam Generation Plant Chapter - 6

Or, X = 57.8 T/H

Therefore Steam flow for turbo-generators = 61.9+23.2+ 57.8 = 142.9 T/H.

Average turbo-generator specific consumption = 2.94 T/MWH (theoretically)

Therefore specific consumption improve due to tv/o boiler modification =0.07

T/MWH.
Total steam saving due to the above improvement (taking only 0.05 T/MWH
improvements) is given by

2333 X (K05 = UL7 T/H

Therefore monitory saving per annum for two boilers (taking steam specific
consumption 0.864 MKCal/MT) =
1.17 X 0.964 X 24 X 360 X 2692 = Rs.2.35 Crores/Anmim

Therefore total saving for the installation of new design induced draft fans in
three boilers = Rs. 9.91 Crores/Annum.

6.5 SOME COMMENTS FROM THE COMPARISON OF OLD

FANS AND PROPOSED NEW DESIGN FANS
According to Above Design M/S. HOWDEN, UK supplied the Data of New Induced Draft
Fans as

Old Fan New Fan

Volume Flow 75.0 m3/s 65.0 m3/s
Static Pressure Rise 38.20 mbar 30.0mbar
Inlet Temperature 150 deg C 140 deg C
Fan Type /Size BCB 65/2 S.I. (2661mm dia) Z9B 1796.02 S.I. (1832mm
dia)
Running Speed 740 rpm 985 rpm
Absorbed Power 365 kW 244 kW

The new fan, which has been specifically selected for the stated volume, pressure &
temperature, is a smaller, high efficiency, aerofoil bladed fan. We have reduced the
fan size by increasing the running speed, which gives the benefits of improving access
around the fan casing, reducing absorbed power by over 30%, and offers the potential
to reduce the motor rating capacity.

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 Invertlgadon on the Improvement of Steam Generation Plant through Inrtrnmentation and Control Applications

6.6 DISCUSSIONS:

From the online data of Table 6.2, it is observed that losses in draft in old ESP duct
which are not required for the present scenario. From the design data and actual data,
it is also observed that fan is very much over designed than the actual requirement and
from fan performance calculation shows that fan efficiency is approximately 66%
which is very low due to 25 years old design compare with the latest market available
design. So this type of new induced draft fan design required for improve the plant
efficiency, better control and save the fuel for the global interest
Also from the above email from the manufacturer, this type of design is
recommended by which power saving above 30% will be observed.

This work is based on the real application in the industry. From the online data of
Table 6.2, it is observed that losses in draft occur in old ESP duct which are not
required for the present scenario. From the design data and actual data, it is also
observed that fan is very much over designed than the actual requirement and from
fan performance calculation it is found that fan efficiency is approximately 66%
which is very low due to 25 years old design compared with the latest market
available design. So this type of new induced draft fan design is required to improve
the plant efficiency, better control and save the fuel for the global interest.
Also from M/S. HOWDEN, UK the fan manufacturer, this type of design is
recommended by which power saving above 30% will be possible. Here it is to be
mentioned that the proposed design has to be used in a power plant where over
designed fans are used to get the optimum efficiency.

176