Boiler Draft System

 Induction of sufficient quantity of air for Stack

complete combustion &
 Removal of the product of combustion Fan

 Product of Combustion to be taken through a tortuous path

 It is to be dispersed in atmosphere according to the prevailing
environmental regulations

Draft (Draught):
Difference between the atmospheric pressure and the static
pressure of combustion gases in a furnace, gas passage, flue or stack.
Driving force for the gas movement.
 Boiler Draft System
Draft System
Natural Draft
Mechanical Draft
Forced Draft
Induced Draft
Balanced Draft

Natural Draft: No power needed, lesser control, for smaller system

Forced Draft: Leakage of gas through the system, less volume

(mass) flow rate

Induced Draft: Infiltration of air, larger volume (mass) flow rate

 Natural Draft
Hot air or gas having lower density than the cold air exhibits the natural tendency
of moving upwards.
Stack effect is defined as the pressure difference between two points in a boiler
due to elevation difference. The stack effect as such either aids the flow of hot
fluid or resists the flow depending upon direction of flow in the boiler setting

A typical stack or chimney

Conical Shape to increase

velocity

Better structural stability

Stack alone is not sufficient

to create draft. Fans are
needed
 Natural Draft
DESIGN OF STACK

• STACK EFFECT:- difference in pressure caused by difference in

elevation between two locations in a vertical ducts or passages
conveying heated gases at zero gas flow.

g  1 1
g 
PSE  z a   g  
z   PSE stack draft effect driving pressure, N/m 2
gc  va vg
gc
 
g acceleration of gravity, 9.8 m/s 2 g c 1 kgm/Ns 2
z elevation between point 1 and 2 (m)
 a density of air at atmospheric pr. (kg/m 3 )
 g average density of flue gas (kg/m 3 )
va specific volume of air at atmospheric pr. (m3 / kg )
vg average specific volume of flue gas (m 3 / kg )
 Stack Design
The height and diameter of stacks for Natural Draft units depend on:-
1. Draft loss through the boiler from the point of balanced draft to the
stack entrance
2. Average temperature of the gases passing up the stack and the
temperature of the surrounding air
3. Required gas flow from the stack
4. Barometric pressure
• Important points to be considered to determine stack height and
diameters:-
1. Temperature of surrounding air and gases entering the stack
2. Drop in temperature of the gases within the stack due to heat loss to
atmosphere and air infiltration.
3. Stack draft loss associated with the gas flow rate.
5
 Stack Design
• Stack flow loss
L G2 G2
P  f v v
l D 2 gc 2 gc
Pl stack flow loss, lb/ft 2 (N/m 2 )
f = friction factor
L = length of stack, ft (m)
D = stack diameter, ft (m)
G= mass flux = m/A, lb/[Link] 2 (kg/m 2 s)
A=stack cross sectional area, ft 2 ( m 2 )
g c 32.17 lbm ft/lbf s 2 (1 kgm/Ns 2 )
For natural draft units stack flow losses are typically less than 5%

6
 Natural Draft - Stack maintenance

Stack operation and maintenance:

Leak tight connections- Cold air leak increases flow friction,

reduces stack effect, erosion potential of the stack

Erosion due to particulate matter, acid corrosion

Effect of erosion and corrosion is more at the entrance and

where the gas has to take a sharp turn

Abrasion resistant material and corrosion shields at those

locations is a good maintenance practice
 Balanced Draft System
Both forced draft and induced draft when exclusively adopted in boilers
have their own demerits. With the forced draft the possibility of flame/hot
flue gases coming out of the boiler persists and due to heavy ingress in
induced draft system, it is difficult to maintain the optimum airflow for
combustion. The balanced draft system overcomes these difficulties. In this
system both forced draft and induced draft fans are used. In forced draft
fan is utilized to draw the controlled quantity of air from atmosphere and
force the same into the furnace. The induced draft fan sucks the products
of combustion from the furnace and discharges into the chimney. The
point where the draft is zero, is known as balancing point. This balancing
point is normally maintained at the tip of the burners/nozzles where the
air enters the furnace. Thereby a very small negative pressure is
maintained at the furnace and other downstream paths of the boiler to
prevent the hot flame / gases coming out of the boiler.
Components of the Boiler Draft System : The boiler draft system consists
of
[Link], 2. Air heaters, 3. Ducts and flues, and 4. Stack/Chimney.
 Balanced Draft System

Schematic representation of a balanced draft system

 A B ID FAN C D

ESP

PA 5A A FD FAN B PA 5B

RAPH-5A RAPH-5B

GR 5A GR 5B
 Thermal Power Plant Fans
Forced Draft Fan, Induced Draft Fan, Primary air fan, Gas recirculation
fan, Seal Air fans, Scanner Air fan, Igniter air fan.
Types of fan
Centrifugal Fan ( forward Curved, backward curved, radial, aerofoil
shaped)
Axial Fan –Axial reaction and axial impulse.
Fans provided in 500 MW Trombay unit 5 (Typical example)
· FD Fans :2 axial reactive single stage Variable pitch with 6.6 KV, 990
RPM. 2700 KW motors
· PA Fans :2 axial reactive double stage Variable pitch with 6.6 KV, 1480
RPM. 2750 KW motors
· ID Fans: 4 radial with 6.6 KV, 740 RPM, 2050 KW motors
 What are Fans For?
A fan is typically a mechanical device that causes a movement
of air, vapor & other gases in a given system. Fans are widely
used for circulating air in rooms & buildings for cooling/heating
people, for cooling motors, materials & products, for exhausting
dust & noxious fumes, for conveying light materials, for forced
draft in steam boilers and in heating, ventilating & air-
conditioning systems.
For effecting the air flow, the fan develops a total pressure
difference over the inlet & outlet air streams; the total pressure
rise comprises two components viz., i) static pressure which
depends on the blade profile, number of blades, pitch, hub
shape etc. i.e. aerodynamic characteristics of the fan impeller
and ii) dynamic pressure which develops due to velocity or
kinetic energy imparted to the air stream.
 What are Fans For?
A fan is an apparatus that converts electric energy into aerodynamic
energy. Some of this energy is useful, other output energy is wasted
energy like the air swirl at the fan's exit. We can get only two types
of useful aerodynamic energies out of a fan, and these are:
Static Pressure (Considered a form of energy.)
Kinetic Energy (Energy due to the velocity of the air particles.)
Static Pressure:
This is the energy that will make the air flow through the ducts.
Static pressure is a very powerful tool for "long distance cooling“ or
‘’supplying air at a distance” (for example boiler furnace). This
energy does not dissipate easily (unless the fan stops working ).We
measure static pressure in inches of column of water. To give us an
idea, the static pressure that the atmosphere exerts upon us due to
its weight is equal to approximately 407 inches of water.
 Fans

Kinetic Energy:
The fan not only increases the air pressure behind it but also
blows air. The kinetic energy is measured usually in cubic feet
per minute (CFM) and is called a volumetric flow rate (not mass
flow rate) which, by the way, does not change with altitude. To
measure the energy output of a fan, we want to find out how
much static pressure alone can the fan exert upon the air (shut-
off condition) and how much kinetic energy alone can the air
through the fan develop (free-delivery condition). These two
pieces of information can be found in the extreme regions of the
so called characteristic curve. See figure next slide.
 Types of Fans

Fans may be classified as centrifugal fans or axial-flow fans. In

centrifugal fans, air is led through an inlet pipe to the centre or
eye of the impeller, which forces it radially outward into the
volute or spiral casing from which it flows to a discharge pipe. In
an axial-flow fan, with the runner & guide vanes in a cylindrical
housing, air passes through the runner without changing its
distance from the axis of [Link] would be no centrifugal
effect on the airflow generated. Guides or stator vanes serve to
smoothen/straighten the airflow and improve efficiency. In
general, an axial-flow fan is suitable for a larger flow rate with a
relatively small pressure gain and a centrifugal fan for
comparatively smaller flow rate and a large pressure rise.
 Types of Fans – Axial fans
Axial flow fans are further classified as axial reaction and axial
impulse fans based on how the energy is imparted to the medium
when it flows across the fan.
Degree of Reaction in axial fan is defined as the ratio of the head
developed across the impeller to the head developed across the fan.
In case of axial impulse fan the degree of reaction will be less than
0.2 where as in axial reaction fan it will be around 0.8.
This variation is due to the blade configuration in the different type
of fans. The reaction fans are provided with profile blades wherein
the blade cross-section varies continuously from root to tip. The
impulse fans have non profile blades wherein the blade profile is
uniform. As such the axial reaction fans are called as Axial profile
Bladed fans(AP fans) and impulse fans as Axial Non profile bladed
fans (AN fans).
Axial Reaction fans are further classified as single stage (AP1) and
two stage (AP2) fans
Aerofoil :
Airfoil also spelled as aerofoil, is a shaped surface, such as an airplane
wing, tail, or propeller blade that produces lift and drag when moved
through the air. An aerofoil produces a lifting force that acts at right
angles to the air stream and a dragging force that acts in the same
direction as the air stream.
If an aerofoil is to fulfill the desired function, it must experience a lift
force, as well as a drag force when in motion. The lift force arises
because the speed at which the displaced air moves over the top of the
airfoil (and over the top of the attached boundary layer) is greater than
the speed at which it moves over the bottom.
The pressure acting on the airfoil from below is therefore greater than
the pressure from above. The design of the airfoil, nevertheless, has a
critical effect on the magnitude of the lift force. Drag
A fluid stream exerts a drag force (FD) on any obstacle placed in its path,
and the same force arises if the object (aerofoil) moves and the fluid is
stationary.
 The fan efficiency
The fan efficiency is defined as the ratio of air power (output)
to shaft power requirement (input). An optimally designed
fan impeller with improved aerodynamics requires less shaft
input power for desired delivery of air volume with total
pressure rise as per the system requirement. With reduced
shaft power requirement, there is a commensurate reduction
in energy consumption.

Thus the fan efficiency is directly contingent upon selection of

fan and the operating point relevant to the system resistance
 Axial Fan Characteristic

------ BldAngle60deg ------BldAngle65deg ------BldAngle70deg

------ BldAngle45deg ------BldAngle50deg% ------BldAngle55deg

Centrifugal Fan Characteristic
 Centrifugal Fans

Components of a centrifugal fan

Centrifugal Fans

Fig 2a , b, c
 Centrifugal Fans
Forward-curved blades
Forward-curved blades, as in Figure 2(a), use blades that curve in the
direction of the fan wheel's rotation. These are especially sensitive to
particulates. Forward-curved blades are for high flow, low pressure
applications.
Backward-curved blades
Backward-curved blades, as in Figure 2(b), use blades that curve
against the direction of the fan wheel's rotation. The backward
curvature mimics that of an airfoil cross section and provides good
operating efficiency with relatively economical construction
techniques. These types of fan wheels are used in fans designed to
handle gas streams with low to moderate particulate loadings. They
can be easily fitted with wear protection but certain blade curvatures
can be prone to solids build-up.
 Centrifugal Fans
Backward curved fans can have a high range of specific speeds
but are most often used for medium specific speed
applications-- high pressure, medium flow applications.
Backward-curved fans are much more energy efficient than
radial blade fans and so, for high power applications may be a
suitable alternative to the lower cost radial bladed fan.
Straight radial blades
Radial fan blades, as in Figure 2(c), extend straight out from the
hub. A radial blade fan wheel is often used on particulate-laden
gas streams because it is the least sensitive to solids build-up on
the blades, but it is often characterized by greater noise output.
High speeds, low volumes, and high pressures are common with
radial fans, and are often used in vacuum cleaner, pneumatic
material conveying systems, and similar processes.
 Fans and Blowers
Fans and blowers provide air for ventilation and industrial process
requirements. Fans generate a pressure to move air (or gases)
against a resistance caused by ducts, dampers, or other
components in a fan system. The fan rotor receives energy from a
rotating shaft and transmits it to the air
Fans, blowers and compressors are differentiated by the method
used to move the air, and by the system pressure they must
operate against. As per American Society of Mechanical
Engineers (ASME)the specific ratio - the ratio of the discharge
pressure over the suction pressure - is used for defining the fans,
blowers and compressors Fan and blower selection depends on
the volume flow rate, pressure, type of material handled, space
limitations, and efficiency. Fan efficiencies differ from design to
design and also by types
Fans, Blowers & Compressor

Fans
Centrifugal Fan:
The major types of centrifugal fan are :
radial, forward curved and backward curved
Radial fans
These fans are industrial workhorses because of their high static pressures (up
to 1400mm WC) and ability to handle heavily contaminated airstreams.
Because of their simple design, radial fans are well suited for high
temperatures and medium blade tip speeds.
Forward-curved fans
These fans are used in clean environments and operate at lower temperatures.
They are well suited for low tip speed and high-airflow work - they are best
suited for moving large volumes of air against relatively low pressures.
Backward-inclined fans
These fans are more efficient than forward-curved fans. Backward-inclined fans
reach their peak power consumption and then power demand drops off well
within their useable airflow range. Backward-inclined fans are known as "non-
overloading" because changes in static pressure do not overload the motor.
Centrifugal Fans
Axial Fans
Axial Fans
Axial Fans
 Axial Fans
• Blades – Wear & damage
• Pressure testing of blade
bearing assemblies for oil
leakage
• Slide pads- Wear & bearing
Impeller Assembly damage
• Connecting lever for Cracks
or damage
 Fans
The fans are called Primary Air(PA), Secondary Air(SA), Induced
Draft(ID) fans , Gas Recirculation (GR) fans, Seal Air fans, Scanner Air
fans and Igniter fans depending on the application of their use. FGD
units are provided with booster fans to boost up the pressure.
• Fan control : To meet varying requirements of the system, common
methods of fan output control are damper control, variable-speed
control and blade pitch control in case of axial flow fans. Variable speed
control is the most efficient method of controlling fan output since it
also reduces power consumption. From the relationships of speed to
capacity, pressure and power it follows that by reducing speed by one
half, fan output will drop one half, pressure one fourth, and horsepower
one eighth.
Different options of
Vane control
 Fan Performance Curves
Fan performance curves and data show how much pressure and airflow a given fan
can produce at a given speed. This data is based on the system resistance (pressure)
occurring away from the fan. Fan performance curves are developed by fan
manufacturers based on the testing of a prototype fan fabricated based on the
theoretical design.
Fan performance is best expressed in graphical form. These functional relations are
the fan characteristic curves. In these curves capacity in cfm is shown horizontally as
the independent variable and head (static pressure), shaft horse power and static
efficiency are dependent variables plotted vertically. Fan speed is constant. Since fan
operation for a given capacity must match single values of head and horsepower on
the characteristic curves, a balance between fan static pressure and system resistance
is required. If the system resistance for a given capacity is less than the head
indicated on the fan characteristic curve, additional variable flow resistance, such
control damper, must be added to the system. Varying the operating speed to yield a
family of curves, will change the numerical performance values of the characteristics.
However, the nature of the curves remains substantially unaltered. Performance at
different speeds for the same efficiency can be related by the following :
1. Capacity is directly proportional to speed.
2. Head is directly proportional to speed squared.
Fan Performance Curves
Centrifugal Fans
Fan Performance Curves
Axial Fans
 System characteristic curve
The system resistance is the sum of static
pressure losses in the system

It is a function of the configuration of ducts,

pickups, elbows and the pressure drops across
equipment

The system resistance varies with the square

of the volume of air flowing through the
system

system resistance increases substantially as

the volume of air flowing through the system
increases; square of air flow, resistance
decreases as flow decreases
 System characteristic curve
System Resistance Change
The system resistance has a major role in determining the
performance and efficiency of a fan. The system resistance
also changes depending on the process. For example, the
formation of the coatings / erosion of the lining in the ducts,
changes the system resistance marginally. In some cases, the
change of equipment (e.g. Replacement of Multi-cyclones
with ESP / Installation of low pressure drop cyclones in
cement industry) duct modifications, drastically shift the
operating point, resulting in lower efficiency. In such cases, to
maintain the efficiency as before, the fan has to be changed.
Hence, the system resistance has to be periodically checked,
more so when modifications are introduced and action taken
accordingly, for efficient operation of the fan.
 System characteristic curve
The resistance to air flow (pressure) increases when the flow of air is
increased and varies as the square of the flow.
The pressure required by a system over a range of flows can be
determined and a "system performance curve" can be developed.
This system curve can then be plotted on the fan curve to show the fan's
actual operating point at "A" where the two curves (N1 and SC1)
intersect. At fan speed N1, the fan will operate along the N1
performance curve, flow (Q1) against pressure (P1) at operating point A
From the two methods, first method is to restrict the air flow by
partially closing a damper, causes a new system performance curve
(SC2) where the required pressure is greater for any given air flow.
The fan will now operate at "B" to provide the reduced air flow Q2
against higher pressure P2
Second method to reduce air flow is by reducing the speed from N1 to
N2, keeping the damper fully open. The fan would operate at "C" to
provide the same Q2 air flow, but at a lower pressure P3
Reducing the fan speed is a much more efficient method to
decrease airflow since less power is required and less energy
is consumed
 Fan Laws
Flow ? Speed Pressure ? (Speed)2 Power ? (Speed)3

Q1 N 1 SP1  N 1 
2
kW 1  N 1 
3
    
Q2 N 2 SP 2  N 2  kW 2  N 2 
Varying the RPM by 10% Varying the RPM by 10% Varying the RPM by 10%
decreases or increases air decreases or increases the decreases or increases the
delivery by 10%. static pressure by 19%. power requirement by
27%.
Where Q – flow, SP – Static Pressure, kW – Power and N – speed (RPM)
Impact of speed reduction

% %
Speed Power
100 100
90 73
80 51
70 34
60 22
50 13
 Fan Performance
System resistance along with the fan static pressure characteristics
at various speeds, both as function of volumetric flow rate are plotted. If
the fan operates at constant speed, any output less than that shown at
the intersection of the system resistance and specified rpm curves must
be obtained by throttling the excess fan head. This results in wastage in
power that can be avoided by using a variable speed drive.
Backwardly curved blade wheels are generally selected for forced draft
service because the high speed is suitable for standard motor drive. The
power demand is self limiting, and the static efficiency is high. These
fans may be satisfactorily operated in parallel.
Induced draft fans operate in gas of much higher temperature and may
handle gases laden with dust. Forwardly curved blade wheels run at the
lowest speed to develop a given pressure, hence are frequently chosen
for induced draft service so that the centrifugal stresses in the wheels
will be least. The forward curvature reduces the blade depth, but gives a
large inlet opening for the gas. conditions.
 Fan Performance

Fan Safety Factors : To make sure that the fans will not limit a boiler’s
performance, margins of safety are added to the calculated or net fan
requirements to arrive at satisfactory test block specification. These
margins are intended to cover conditions encountered in operation that
can be specifically evaluated. For example, variation in fuel ash
characteristics or unusual operating conditions may foul heating
surfaces. The unit then requires additional draft. A need for rapid load
increase or a short emergency overload often calls for overcapacity of
the fans. The customary margins to allow for such conditions are 15 to
20 % increase in the net weight flow of air or gas, 15to 20% increase in
net head, and 25F increase in the air or gas temperature at the fan inlet.
 Fan Performance
General performance requirements for force draft fans.
Reliability : Modern boilers must operate continuously for long periods
(up to 18 months) without shut down for repairs or maintenance. The
fan must be well balanced, and the blades so shaped that they will not
collect dirt and disturb this balance.
Efficiency : High efficiency over a wide range of output is necessary
because boilers operate under varying load conditions.
Pressure : Fan pressure should vary uniformly with output over the
capacity range. This facilitates damper control and assures minimum
disturbance of air flow when minor adjustments to the fuel burning
equipment change the system resistance.
 Fan Performance
Capacity : When two or more fans operate in parallel, the pressure
out-put curves should have characteristics similar to the straight blade
or backward curve blade fans in order to share the load equally near the
shut off point.
Horsepower : Motor driven fans require self limiting horse power
characteristics, so that driving motor cannot overload. This means that
the horsepower should reach a peak and drop off near the full load fan
output.
ID fans : Induced draft fans has the same basic requirements as forced
draft fan except that it handles high temperature gas which may contain
erosive ash. Flat, forward curved and occasionally backward curved
blades with less curvature are used. Excessive maintenance from
erosion is sometimes avoided by protecting casing and blades with
replaceable wear strips. Bearings, usually water cooled have radiation
shields on the shaft between rotor and bearings to avoid overheating.
 Operating Efficiency of Fan
Operating efficiency and performance evaluation of fans : All fans
need to be studied for their operating efficiency(as per performance
test) with the help of energy instruments in addition to online valid
calibrated instruments to identify energy saving measures. The
parameters to be studied in detail are :
• Air/gas rates of fan / ducts
•Static pressure, dynamic pressure and total pressure
•Power consumption of the fan ( for estimating the operating
efficiency of the fan)
•Monitor present flow control system and the frequency of flow
variations (for exploring application of variable frequency drive)
 Operating Efficiency of Fan
Compare the actual values with the design / performance test values, if
any deviation is found, list the factors with the details and suggestions
to overcome.
•Enlist scope of improvement with extensive physical checks /
observations
•Based on actual operating parameters, enlist recommendations for
action to be taken for improvement, if applicable such as
•Replacement of fan
•Impeller replacement
•Variable speed drive application
•Cost analysis with saving potential for taking improvement measure
 Fan Application and Matching

Application and matching of Fans : The installed fan has to be

thoroughly verified for its application, whether the fan is best
suited for its application, duty, load variation etc. The variation
options to be considered for improving energy efficiency are :
• Replacement of fan with the best suited energy efficient fan
• Replace/trim the impeller, if the fan is throttled to reduce flow by
10-20%.(if smaller impellers are not available).
•Retrofit with variable speed drive fans if the fans are serving
variable loads
 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.
 Fan pressures
Static pressure
Static pressure is the potential energy
put into the system by the fan.
Velocity pressure
Velocity pressure is the pressure along
the line of the flow that results from
the air flowing through the duct, used
to calculate air velocity
Total pressure
Total pressure is the sum of the static and
velocity pressure.
The fan flow is measured using pitot tube
manometer combination, or a flow
sensor (differential pressure instrument)
or an accurate anemometer
Measurement of Pressures
Measurement by Pitot tube
Total pressure is measured
using the inner tube of pitot
tube and static pressure is
measured using the outer
tube of pitot tube.

When the inner and outer

tube ends are connected to a
manometer, we get the
velocity pressure.
TRAVERSE POINTS FOR VELOCITY MEASUREMENT
The velocity pressure varies across the
duct.
Friction slows the air near the duct walls,
so the velocity is greater in the center of
the duct.
The velocity is affected by changes in the
ducting configuration such as bends and
curves.
The best place to take measurements is in
a section of duct that is straight for at least
3–5 diameters after any elbows, branch
entries or duct size changes
The velocity should be calculated for each velocity pressure
reading, and the average of the velocities should be used.
Typical Fan Characteristic Curves
 Operation of Fans in parallel and series
The performance of two fans in parallel will result in doubling the
volume flow, but only at free delivery. As Figure shows, when a
system curve is overlaid on the parallel performance curves, the
higher the system resistance, the less increase in flow results with
parallel fan operation. Thus, this type of application should only be
used when the fans can operate in a low resistance almost in a free
delivery condition. By staging two fans in series, the static pressure
capability at given airflow can be increased, but again, not to double
at every flow point, as the above Figure displays. In series operation,
the best results are achieved in systems with high resistances.
In both series and parallel operation, particularly with multiple fans
certain areas of the combined performance curve will be unstable
and should be avoided. This instability is unpredictable and is a
function of the fan and motor construction and the operating point
 Operation of Fans in parallel and series
An additional fan in parallel to the first increases airflow in a low static pressure
situation. An additional fan in series increases the airflow in a high static-pressure
enclosure."
Operation of Fans in parallel and series
 Fan Operating Point
The figure below show the relationship between airflow and
static pressure for a typical fan. The performance of a fan in a
specific application is determined by the intersection of the
System Resistance/Impedance Curve and the Fan Characteristic
Curve. The System Impedance Curve is a property inherent to an
individual enclosure/system.
Typical Fan Characteristic Curves
Effect of Speed
 Fan Flow Control
Flow Control Strategies
Typically, once a fan system is designed and installed, the fan operates
at a constant speed. There may be occasions when a speed change is
desirable, i.e., when adding a new run of duct that requires an
increase in air flow (volume) through the fan. There are also instances
when the fan is oversized and flow reductions are required. Various
ways to achieve change in flow are: pulley change, damper control,
inlet guide vane control, variable speed drive and series and parallel
operation of fan
Damper Controls
Some fans are designed with damper controls. Dampers can be
located at inlet or outlet. Dampers provide a means of changing air
volume by adding or removing system resistance. This resistance
forces the fan to move up or down along its characteristic curve,
generating more or less air without changing fan speed. However,
dampers provide a limited amount of adjustment, and they are
not particularly energy efficient.
 Fan Flow Control
Inlet Guide Vanes
Inlet guide vanes are another mechanism that can be used to meet
variable air demand. Guide vanes are curved sections that lay against
the inlet of the fan when they are open. When they are closed, they
extend out into the air stream. As they are closed, guide vanes pre-swirl
the air entering the fan housing. This changes the angle at which the air
is presented to the fan blades, which, in turn, changes the
characteristics of the fan curve. Guide vanes are energy efficient for
modest flow reductions – from 100 percent flow to about 80 percent.
Below 80 percent flow, energy efficiency drops sharply.
Variable Blade Pitch
Axial-flow fans can be equipped with variable pitch blades, which can be
hydraulically or pneumatically controlled to change blade pitch, while
the fan is at stationary. Variable-pitch blades modify the fan
characteristics substantially and thereby provide dramatically higher
energy efficiency than the other options discussed thus far.
 Fan Flow Control
Variable Speed Drive
Although, variable speed drives are expensive, they provide
almost infinite variability in speed control. Variable speed
operation involves reducing the speed of the fan to meet
reduced flow requirements. Fan performance can be predicted
at different speeds using the fan laws. Since power input to the
fan changes as the cube of the flow, this will usually be the
most efficient form of capacity control. However, variable
speed control may not be economical for systems, which have
infrequent flow variations. When considering variable speed
drive, the efficiency of the control system (fluid coupling, eddy-
current, VFD, etc.) should be accounted for, in the analysis of
power consumption
 Fan Flow Control
Factors to be considered in the selection of flow control methods
Comparison on of various volume control methods with respect to
power consumption(%) required power is shown in Figure .All
methods of capacity control mentioned above have turn-down ratios
(ratio of maximum–to–minimum flow rate) determined by the
amount of leakage (slip) through the control elements. For example,
even with dampers fully closed, the flow may not be zero due to
leakage through the damper. In the case of variable-speed drives the
turn-down ratio is limited by the control system. In many cases, the
minimum possible flow will be determined by the characteristics of
the fan itself. Stable operation of a fan requires that it operate in a
region where the system curve has a positive slope and the fan curve
has a negative slope. The range of operation and the time duration at
each operating point also serves as a guide to selection of the most
suitable capacity control system.
 Fan Flow Control
Outlet damper control due to its simplicity, ease of operation, and
low investment cost, is the most prevalent form of capacity
control. However, it is the most inefficient of all methods and is
best suited for situations where only small, infrequent changes are
required (for example, minor process variations due to seasonal
changes.
The economic advantage of one method over the other is
determined by the time duration over which the fan operates at
different operating points. The frequency of flow change is
another important determinant. For systems requiring frequent
flow control, damper adjustment may not be convenient. Indeed,
in many plants, dampers are not easily accessible and are left at
some intermediate position to avoid frequent control
Control options for centrifugal
fans
Damper control
•Lowest capital cost
•Ease of operation-automatic
control
•List expensive fan drive
•Continuous, not step
operation

Wastage of power
 Axial fans
Axial fan-Fixed pitch, adjustable pitch, variable pitch
Performance control characteristics
•Areas of constant efficiencies run parallel to the boiler resistance line-
high efficiency over a wide boiler load range
•Control range is very large both above and below the maximum
efficiency
•The lines of constant blade angle are actually individual fan curves-as
the curves are very steep, change in resistance produces very little
volume change.
•As the blade angle can be adjusted from minimum to maximum flow
change is nearly linear
 Axial Fans
Stall Condition.

The angular relationship between the air flow impinging

on the blade of a fan and the blade itself is known as
“the angle of attack”. In axial flow fan, when this angel
exceeds a certain limit, the air flow over the blade
separates from the surface and centrifugal force then
throws the air outwards, towards the rim of blades. This
action causes a build up of pressure at the blade tip,
and this pressure increases until it can be relived at the
clearance between the tip and the casing. Under this
condition the operation of the fan becomes unstable,
vibration sets in and the flow starts to oscillate. The risk
of stall increases if a fan is oversized or if the system
resistance increase excessively.
 Stalling of Axial Fans

Stall is aerodynamic phenomenon which occurs when a

fan operates beyond its performance limits and flow
separation occurs around the blade.
Axial Fan Stalling
Stall prevention
When axial fans are sized properly and the resistance curve is
parabolic chances of stall is less
Possibility of stall increases when the fan is over sized compare to
volume capacity, System resistances increases significantly or fans
are operated improperly

Noise in a Fan
Single tone noise is generated when the concentrated flow
encounters a stationary object after leaving the rotating blade
passage.
The distance between the blades and the stationary objects affects
the sound
The blade passing frequency and its first harmonic is most dominant.
Broad band noise is produced by the fluid passing through the fan
housing, contains a range of frequencies
Noise in a Fan
Single tone noise is generated when the concentrated flow encounters a stationary object after
leaving the rotating blade passage.
The distance between the blades and the stationary objects affects the sound
The blade passing frequency and its first harmonic is most dominant.
Broad band noise is produced by the fluid passing through the fan housing, contains a range of
frequencies
•Sound radiates from the inlet opening, the discharge duct and the fan housing. All three areas
should be analyzed separately and treated in appropriate manner. Inlet sound level from the
primary air fans and forced draft fans can
be reduced by absorption silencer
•Fan casing noise can be minimized by mineral wool insulation and
acoustic lagging
•Fan discharge noise needs more detail analysis to have
cost effective solutions
•For forced draft fans and primary air fans, absorption discharge silencer is sufficient
•For induced draft fans additionally thermal insulation
and lagging are needed.
•Stack outlet noise can be reduced by discharge silencer.
•However, it is not suitable for coal fired units
as the panels gets plugged by fly ash
Noise Control
Fan Selection
 PA fan construction
Primary Air fan : The fan consist of the following components:
a) Suction bend, with an inlet and an outlet side pipe for volume
measurements
b)Fan housing with guide vanes (stage 1)
c) Main bearings (anti-friction bearings)
d) Rotor consisting of shaft, two impellers with adjustable blades and
pitch control mechanism.
e) Guide vane housing with guide vanes (stage 2)
f) Diffuser with an outlet-side pipe for pressure measurements.
Suction bend, fan housing and diffuser are welded structural steel
fabrications, reinforced by flanges and gusets, resting on foundation on
supporting feet. On its impeller side, the suction bend is designed as an
inlet nozzle. Guide vanes of axial flow type are installed in the fan and
guide vane housings, in order to guide the flow.
Suction bend and diffuser are flexibly connected to the fan housing via
Axial Fans FD / PA Application
 PA Fan
Fan and guide vane housing are horizontally split, so that the rotor can
be removed without having to dismount the servomotor. The fan is
driven from the inlet side. The main bearings are accommodated in the
core of the fan housing. The impellers are fitted to the shaft in overhung
position. The centrifugal and axial forces of the impeller blades are
absorbed by the blade bearings. For this purpose the blade shaft is held
in a combination, of radial and axial antifriction bearings. Each blade
bearing is sealed off by means of seals.
Blade pitch control unit : An oil hydraulic servomotor flanged to the
impeller and rotating with it adjusts the blades during operation. The
servomotor consists of piston, cylinder and control parts.
At pitch control, the translational movement of the servomotor piston is
converted into rotational movement of the blade shafts via adjusting
levers, so that the blade angles are variable.
 Fans
Oil System : The main bearings and hydraulic servomotor are supplied
with oil from a common oil tank. Two oil pumps are mounted on the
tank. One is operated as a main pump, whereas the other one is used as
standby pump. The latter is started via the pressure switch, in the event
of control oil pressure declines.
FD fans construction is similar to that of PA fan. But FD fan is a single
stage fan.
Induced draft fans : There are four ID fans provided per boiler, 3
operating and one standby. (some 500 MW boiler are provided with 3 ID
fans, two operating and one standby). These fans are single stage
double inlet centrifugal fans.
The principal elements of the fan are :
Housing, inlet dampers, rotor with bearings and shaft seal.
Regulation : The capacity of ID is changed by varying the speed(either by
VFD or hydraulic coupling) and also by adjustable inlet dampers
arranged in front of impeller.
 Fans
Scanner Air Fan : The function of scanner air fan is to provide a
continuous supply of clean air to purge and cool the flame scanners. Air
for the system is drawn from the FD fan discharge ducts through a filter
by one the two scanner fans then discharged through distribution pipe
work to each flame scanner. One of the fans is provided with DC supply.
In case of AC failure DC scanner fan gets started. An emergency damper
is provided in the suction duct to facilitate suction from atmosphere.
The discharge from each fan includes a pneumatically operated isolating
damper which will open and close in response to signals from FSSS. A
pressure switch is provided to initiate the automatic start up of the
standby fan if scanner duct to furnace differential becomes less than 6
inches.
Seal Air Fans : These fans take suction from cold PA header and boost up
pressure for providing sealing air to coal mills/feeders.
Igniter Air Fans : These fans take suction from FD fan discharge duct and
provide air for igniters.
 A B ID FAN C D

ESP

PA 5A A FD FAN B PA 5B

RAPH-5A RAPH-5B

GR 5A GR 5B
 SECONDARY AIR CIRCUIT
350 DEG
S 35 degR
C SD SD
A
AIR FROM ATMOS SD- 2 A
P
P 8.1 10.1
H
H 8.2 10.2
B
B
FD B

SD-6

FROM GRF - B

-10 mm

• FURNACE
FROM GRF - A

SD-5

S SD R
SD-1
C
7.1 A SD9
A P .1
P 7.2 H 9.2
AIR FROM ATMOS
H A
FD A A 35 DEG C 350 DEG

IGNITOR AIR FAN

 Flue gas system
ESP GD GD-19
GD- GD- GD-7 GD-15 GD-23
R 3.1 11A
5A ID A
3.2 11B
A
GD 29.1 29.2
P
H 20
A 8 12A 16 24
5B ID B GD
12B
27.1
27.2

Stack
GD 30.1 30.2 GD
GD 5.1 5.2
28.1
28.2
9
13A
R 5C 13B 17
ID C 25
A 21
P GD 31.1 31.2
GD
H GD-
B 4.1 14A
5D ID D
4.2 14B
GD- GD-10 GD-18
GD-26
GD-22
 Primary Air System
PA 5A PA 5B

RAPH-5A RAPH-5B
FD Fans
 Operating Efficiency of Fan
Operating efficiency and performance evaluation of fans : All fans
need to be studied for their operating efficiency(as per performance
test) with the help of energy instruments in addition to online valid
calibrated instruments to identify energy saving measures. The
parameters to be studied in detail are :
• Air/gas rates of fan / ducts
•Static pressure, dynamic pressure and total pressure
•Power consumption of the fan ( for estimating the operating
efficiency of the fan)
•Monitor present flow control system and the frequency of flow
variations (for exploring application of variable frequency drive)
SPECIFICATIONS OF ID FAN
SPECIFICATIONS OF F.D FANS
SPECIFICATIONS OF F.D FANS
 PA FANS

Primary air fans are second high power consuming fans

in a thermal power plant.
Specifications of PA fans
Specifications of PA fans
 FANS PERFORMANCE ASSESSMENT

 Static Pressure

Potential energy put into the system by the fan

 Velocity pressure

Pressure arising from air flowing through the duct. This is used to
calculate velocity
 Total pressure

Static pressure + velocity pressure

Total pressure remains constant unlike static and velocity

pressure
 The fan efficiency
The fan efficiency is defined as the ratio of air power (output)
to shaft power requirement (input). An optimally designed
fan impeller with improved aerodynamics requires less shaft
input power for desired delivery of air volume with total
pressure rise as per the system requirement. With reduced
shaft power requirement, there is a commensurate reduction
in energy consumption.

Thus the fan efficiency is directly contingent upon selection of

fan and the operating point relevant to the system resistance
 FAN OPERATING EFFICIENCY EVALUATION

Fan static kW = Q in m 3
/ s x static pr. developed by fan in mmwc
102

Fan static efficiency % Fan static kW x 100

=
Input kW to
Q in m3/ s xmotor mdeveloped by fan in mmwc
total pr.
Fan total kW =
102
Fan mechanical Efficiency = Fan total kW x 100
Input kW to motor x m
Parameter Details Unit

Q Air flow rate m3 / s

Static pressure Difference between discharge & suction pressure mmwc

Fan static/ total kW Static / total power consumption of the fan kW

Input kW to motor Measured power consumption of the motor kW

m Efficiency of the motor at operating load

Total pressure Difference between discharge & suction pressure mmwc

 FAN OPERATING EFFICIENCY EVALUATION
273 X 1.293
Corrected air density,  =
273 + Air temperature in 0 C

Cp x 2 x 9.81 x Diff. velocity pr. in mmwc x 

Velocity in m / s =

Parameter Details Unit
Cp Pitot tube constant 0.85 or as given
by manufacturer
 Density of air or gas at test condition Kg / m3

Volumetric flow (Q), m3/s = Velocity, m/s x Area, m2

 FAN OPERATING EFFICIENCY EVALUATION

In case of gas flow measurement of ID fans,

Where it is not possible to measure the gas flow, Then the mass flow
method can be adopted, Provided the oxygen content and actual coal
flow measurements are available.
 FAN OPERATING EFFICIENCY EVALUATION

For flow estimation through this method, the following are required:
 Stoichiometric air requirement (work out based on the coal
composition)
 Oxygen content at ID fan inlet (measured)
 Excess air (estimate)
% Excess air = (%O2 in flue gas x 100) / (21 – O2 in flue gas)
 Coal flow (based on actual measurement or on average basis)
 Fly ash content (assumed based on past data)
 FAN PERFORMANCE ANALYSIS
While in case air flow measurement for FD and PA fans the following
instruments (which ever are suitable) can be used
 Thermal anemometer
 Vane type anemometer
 Pitot tube along with micro manometer can be used
 Online measuring instrument
If the fans are operating in parallel, it is advised to measure all above
parameter for every fan separately to evaluate the individual
performance. However combined parameters of flow and head need to
be verified with Performance curve for parallel operation
 FAN PERFORMANCE ANALYSIS

• If the fans are operating in parallel, it is advised to measure all

above parameter for every fan separately to evaluate the individual
performance.

• However combined parameters of flow and head need to be

verified with Performance curve for parallel operation

•Compare the actual values with the design / performance test values
if any deviation is found, list the factors with the details and
suggestions to over come.
 FAN PERFORMANCE ANALYSIS
The investigations for abnormality are to be carried out for
problems.
 Enlist scope of improvement with extensive physical checks /
observations.
 Based on the actual operating parameters, enlist
recommendations for action to be taken for improvement, if
applicable such as- Replacement of fans, Impeller replacement,
VFD application.
Cost analysis with savings potential for taking improvement
measures.
 FAN PERFORMANCE ANALYSIS
Visual survey of insulation & the ducting system:
 Insulation status (measure the surface temperature with the aid
of surface thermocouple / infrared pyrometer or by using thermal
imaging cameras)
 Bends and ducting status
 Physical condition of insulation
 Identification of locations where action is required to improve the
insulation (provide with detailed techno-economics)
 Improvement options for ducting systems if any
 Sources of air ingress
 FAN PERFORMANCE ANALYSIS

Study of air ingress in to the system:

 Before and after air pre-heater
 Before and after ESP
 Before and after ID fan
The difference in the oxygen gives the extent of air ingress in
to the system.
Measurements of oxygen content across all units in flue gas
path, indicates the locations where ingress is occurring.
 FAN PERFORMANCE ANALYSIS

Reduction in air ingress will result in

•Reduction in power consumption if ID fans
•Reduced boiler losses
•Improvement in boiler loading
•Increased unit load
•Increased margin on ID fans
Minimizing air in leaks in hot flue gas path will reduce ID fan load as
cold air in leaks increase ID fan loading tremendously due to density
increase of flue gases and choke up capacity of fan resulting in
bottleneck.
FAN PERFORMANCE ANALYSIS
 Energy Savings Opportunities
Minimizing demand on the fan
1. Minimizing excess air level in combustion systems to reduce
FD fan and ID fan load.
2. Minimizing air in-leaks in hot flue gas path to reduce ID fan
load, especially in case of kilns, boiler plants, furnaces, etc.
Cold air in-leaks increase ID fan load tremendously, due to
density increase of flue gases and in-fact choke up the
capacity of fan, resulting as a bottleneck for boiler / furnace
itself.
3. In-leaks / out-leaks in air conditioning systems also have a
major impact on energy efficiency and fan power
consumption and need to be minimized.
The findings of performance assessment trials will automatically
indicate potential areas for improvement, which could be one or a more
of the following .
1. Change of impeller by a high efficiency impeller along with cone.
2. Change of fan assembly as a whole, by a higher efficiency fan
3. Impeller derating (by a smaller dia impeller)
4. Change of metallic / Glass reinforced Plastic (GRP) impeller by the
more energy efficient hollow FRP impeller with aerofoil design, in
case of axial flow fans, where significant savings have been reported
5. Fan speed reduction by pulley dia modifications for derating
6. Option of two speed motors or variable speed drives for variable
duty conditions
7. Option of energy efficient flat belts, or, cogged raw edged V belts, in
place of conventional V belt systems, for reducing transmission
losses.
8. Adopting inlet guide vanes in place of discharge damper control
9. Minimizing system resistance and pressure drops by improvements
in duct system
 Gas Recirculation - GR Fan
One of the most attractive methods of controlling superheat or reheat,
both from economic and operational viewpoint, is gas recirculation. Gas
from the boiler ,economizer or air heater outlet is reintroduced to the
furnace by means of a suitable fan and ducts. If the recirculated gas is
introduced in the immediate vicinity of the initial burning zone of the
furnace and used for steam temperature control is called gas
“recirculation”, and recirculated near the furnace outlet and used for
control of temperature is called "gas tempering”. An important feature
of recirculated gas is that it changes only the pattern of heat absorbing
through the boiler and has negligible effect on the total boiler heat
absorption, the gas weight up the stack, and the boiler efficiency.
The thermal effect of recirculated gas depends on the on the amount of
gas recirculated, the location of the gas introduction, and furnace rating.
Introduction of gas at furnace bottom hopper produces a marked
reduction in furnace absorption and increases the absorption of the
convection section. The total heat absorption remains unchanged.
 Air / draft system Operation (typical)
System operation(start up of unit) : During unit start up all air and flue
gas duct dampers should in start up position.
1. ID fan outlet shut off dampers open, inlet control dampers closed.
2. FD Fan outlet shutoff dampers and blade pitch open ( FD fan blade
pitch should be closed before the fan is started).
3. Primary air outlet shutoff dampers and blade closed.
4. Gas recirculation fan outlet shut off and control dampers closed.
5. Air heater gas inlet and outlet, air inlet and outlet dampers should
be open.
6. Over fire dampers closed.
7. Windbox (secondary) auxiliary air dampers open or modulating.
8. One set of pulveriser seal air filter and booster fan shut off dampers
open.
9. One igniter fan shut off damper open.
 Air / draft system Operation (typical)
It is assumed that the unit will be started two ID, two FD fans, both
airpreheaters and both PA fans in service. In case only one set of
above equipment is available dampers associated with the idle
equipment should be closed.
Caution : The ID fans may be capable of developing drafts in excess of
furnace design pressure (Implosion). Therefore the operator must take
care to establish and maintain air flow path through the unit, prior to
starting ID fan and prior to opening the ID fan inlet control dampers by
insuring that the other dampers in the system are in the start up positions.
ID fan inlet control dampers must be kept closed until after the fan is
started. In case of variable speed operation the speed is kept at minimum.
This procedure will minimize the possibility of developing excessive
negative pressure in the unit during starting procedure.
Implosion : Condition of very high negative pressure arising during
operation of the unit due to various reasons, such as loss of fuel,
malfunction of draft and or fan controls, ash build up in boiler path etc.
 Permissive for Starting Fan
6.6 KV Breaker racked in.
Breaker in remote not on local.
Fan Lube oil / control oil pr. ok
ACW flow through LO cooler not low.
LO tank Level not low.
A Clear Path Logic satisfied.
Outlet Damper close
Inlet Damper Open
IGV / Blade pitch in minimum position.
Any bearing temp. not hi
 Line up for Starting of Fans
Line up of Flue and Air path :
1. Check that RAPH is in service.
2. Line up lube oil system of ID fans to be take in service
3. Line up flue gas path :
a) Open at least one set of RAPH gas inlet / out let dampers
b) Open RAPH gas outlet interconnection dampers
c) Open at least one set of ESP inlet/outlet dampers
d) Open ID fans inlet header interconnection dampers
e) Open ID fan inlet dampers depending on whichever ID fans are
available.
f) Open ID fans to stack isolation dampers
g) Check that ID fan outlet dampers are closed and on manual mode.
h) Check that control dampers are in minimum position and on
manual mode. ( The ID fan outlet dampers open after a time delay of
 Line up for Starting of Fans
Line Up Secondary Air Path :
Air path from FD inlet to stack should be through to prevent furnace
facing ID fan shut off head.
1. Ensure that both FD fans are available for starting lube oil system
and opening the dampers and blade pitch.(Both FD fans required to
maintain path from FD inlet to stack through, when starting the first
FD fan)
2. Line up both FD fans lube oil system
3. Line up secondary air path :
a) Open at least one set of RAPH inlet/outlet dampers
b) Open the cold secondary air interconnection dampers
c) Open discharge dampers of the stand by fan
d) Open FD fans blade pitch control of the standby fan
e) Check that fan discharge dampers are closed and on manual mode
for the fan to be taken in service.
 Taking Fans in service
The discharge dampers open after a time delay of 60 seconds.
f) Check that blade pitch control is on manual mode and in minimum
position for the fan to be taken in service.
Check that auxiliary dampers are open 20-40 %.
Rack in 6.6KV breaker of ID fan to be taken in service.
1. Start ID fan and observe that fan current is ok
2. Check that ID fan discharge damper go open after 60 seconds (check that
ID fan control dampers are on manual mode and in minimum position)
3. Rack in 6.6 KV breaker of FD fan
4. Start FD fan and its current is ok (area person to ensure this)
5. Check that FD fan discharge dampers go open after a time delay of
60seconds
6. Set the draft set point to 5 mm wc and transfer the ID fan damper
control on auto mode.
7. Establish 30% air flow through the furnace by increasing the FD fan blade
pitch control. (transfer auxiliary air damper control to auto mode)