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Tanjung Jati B Training

PA-FD-ID Fans
Tanjung Jati B Training
Boiler Precipitator
FGD Absorber
2 x 660MW (net)
P.T. Central Java Power
Tanjung Jati B Units 1 & 2
Tanjung Jati B Training
OPERATIONS
PA-FD-ID FANS
Tanjung Jati B Training
PA-FD-ID Fans
Location
PA FANS ID FANS FD FANS
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PA-FD-ID Fans
Function
The fans serve to provide the following regarding
The operations of the Boiler, ESP & FGD Systems
FD FANS: Combustion Air for the Burners
ID FANS: Remove Flue Gas from the Boiler & ESP
and force the flue gas through the
FGD System to the Stack
PA FANS: Provide air for the operation of the
Pulverizers and transport of pulverized
coal to the Burners
Tanjung Jati B Training
PA-FD-ID Fans
Forced Draft (FD)
Induced Draft (ID)
Primary Air (PA)
FD Fans
Each FD Fan has a single inlet and provide
50% of the total air requirement at Boiler
Maximum Continuous Rating firing Bengalon
Coal at 1% sulfur.
The FD Fans are the Axial type versus the
Centrifugal type PA and ID Fans.
Air flow through the fan is controlled by the
Variable Pitch Blades.
Tanjung Jati B Training
FD Fans
Axial Design
MOTOR
INLET BOX
AIR FLOW BLADES
DIFFUSER
LUBE AND/OR
HYDRAULIC UNIT
STRAIGHTENING
VANES
OUTLET AIR
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FD Fans
Secondary Air System
FD Fan
FD Fan
SCAH
SCAH
Air Heater
Air Heater
Air Foil B
Air Foil A
Burner Level
Windbox
(typical)
Inlet
Silencer
Screen
N
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Hot Crossover
Duct
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ID Fans
Fan Bearings
The ID Fans have sleeve-type bearings which
require continuous water flow for cooling.
Water is supplied by the Closed Circuit Cooling
Water (CCCW) system.
The bearing are also equipped with a oil level
site gauge. If the oil appears cloudy or frothy,
most likely cooling water has entered the oil
cavity and has contaminated.
FD Fans
Some Components and Terms to remember
Variable Pitch Blades
Hydraulic-Lube Unit
Fan Stall
Tanjung Jati B Training
Tanjung Jati B Training
FD Fans
Variable Pitch Blades
Variable Pitch Blades, internal to the Fan
Housing are used to control air flow through
the fan.
A stand alone Hydraulic Oil Unit provides the
necessary oil pressure to adjust the pitch of
the Blades.
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FD Fans
Hydraulic Unit
The Hydraulic Unit serves two functions
Adjust the pitch of the Blades
Provide Lube Oil for the Fan Bearings
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FD Fans
Hydraulic Unit
The Hydraulic Oil Unit consists of the following
Local Control Cabinet
Two (2) motor-driven oil pumps
Oil Heater
Oil Cooler
Oil Sump
Filters
Instrumentation (Flow switch, Level switch)
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FD Fans
Hydraulic Unit
The Control Cabinet has the following features
Indication Lamps
Oil Pump Status
Oil Heater Status
High/Low Oil Temperature
Low Oil Level
Low Oil Flow
Low Oil Pressure
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FD Fans
Hydraulic Unit
The Control Cabinet has the following features
Buttons & Switches
Oil Pump Select
Oil Pump Start
Oil Pump Stop
Oil Pump Hand/Off/Auto (x2)
Alarm Reset
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FD Fans
Hydraulic Unit
The Oil Pumps are interlocked such that a
significant drop in oil pressure from the
operating pump will start the stand-by
pump.
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FD Fans
Hydraulic Unit
CONTROL PANEL
OIL SUMP
OIL PUMPS
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FD Fans
Start-Up
Prior to starting an FD Fan, the Hydraulic Unit
must be available and operating. If the Hydraulic
Unit panel indicates any alarms, these should be
investigated and cleared prior to starting the Fan.
An Induced Draft Fan must be in service prior to
starting an FD Fan.
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FD Fans
Automatic Operation
During automatic operation the FD Fan Inlet
Vanes will control air pressure in the Secondary Hot
Crossover Duct to the desired set point.
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FD Fans
Trip Interlocks
Fans will trip under the following conditions
Secondary Air Duct Pressure High-High
High Fan Bearing Vibration
High Fan Bearing Oil Temperature
Furnace Pressure High-High
Loss of Flow Path
Loss of Breaker (power failure)
High Motor Amps (time delay)
Hydraulic Oil Unit Failure
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FD Fans
Shutdown
Prior to stopping the FD Fan, the fans loading
should be reduced manually and slowly. This
will allow the other operating FD Fan to maintain
control of the Secondary Air Duct pressure.
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FD Fans
Stall
Fan stall is a condition where there is a
sudden and significant drop in the differential
pressure (air flow) between the fan inlet and outlet.
A differential pressure transmitter is provided to
monitor air flow conditions.
Tanjung Jati B Training
FD Fans
Stall
Fan stall is a serious and potentially danger situation
which is usually accompanied by vibration and
increased noise. Fan blade failure can occur.
When fan stall is suspected, the fan should be
SHUT DOWN immediately.
Tanjung Jati B Training
PA-FD-ID Fans
Forced Draft (FD)
Induced Draft (ID)
Primary Air (PA)
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ID Fans
Description
The Induced Draft (ID) Fans are single-speed,
double-inlet, centrifugal-type fans.
The ID Fans operate at a relatively low speed
compared to the FD Fans and Primary Air Fans.
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ID Fans
Function
The ID Fans remove flue gas from the Boiler and the
Precipitator and force those flue gasses through the
FGD System to the stack.
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PA-FD-ID Fans
Location
PA FANS ID FANS FD FANS
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ID Fans
Operation
ID Fans, serve to control Furnace Draft Pressure
during Unit operation. During start-up of the Boiler,
the ID Fan Inlet vanes and Start-Up Damper work in
unison to control the flow through the ID Fan.
ID Fans
Flue Gas System
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Man-Safe
Double Dampers
with Seal Air
Tri-Sector
Air Heaters
Precipitators
Boiler
ID Fans
Start-Up
Control Damper
Guillotine Isolation
Damper with Seal Air
To FGD
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ID Fans
Fan Bearings
The ID Fan have sleeve-type bearings which
require continuous water flow for cooling.
Water is supplied by the Closed Circuit Cooling
Water (CCCW) system.
The bearing are also equipped with a oil level
site gauge. If the oil appears cloudy or frothy,
most likely cooling water has entered the oil
cavity and has contaminated.
Tanjung Jati B Training
ID Fans
Start-Up
Prior to starting an ID Fan, an operator should
check the oil level in the bearing and be sure
that the CCCW isolation valves are open.
Be sure all housing doors are closed and an
operator should be present when the fan is started.
Tanjung Jati B Training
ID Fans
Start-Up
When the ID Fan is commanded to start, the
fans Outlet Isolation Guillotine Damper will
close. Once the dampers close limit switch
is activated the fan will start. The isolation
damper will open after a time delay.
After the ID Fan is started, the operator will
manually modulate both the FD & ID Fans to
achieve the desired air flow and furnace
pressure prior to putting control in automatic.
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ID Fans
Automatic Operation
The ID Fans inlet vanes modulate to control
Furnace Pressure only.
If two fans are running and one trips, the
remaining ID fan will control Furnace Draft
while the unit runs back or reduces load
towards 50%.
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ID Fans
Automatic Operation
How does an operator know both fans are
operating at the same load?...
The motor running amps will be the same!
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ID Fans
Trip Interlocks
Fans will trip under the following conditions
High Fan Bearing Vibration
High Fan Bearing Oil Temperature
Furnace Pressure High-High
Loss of Flow Path
Loss of Breaker (power failure)
High Motor Amps (time delay)
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ID Fans
Shutdown
Similar to the FD Fan, the inlet vane controls
should be put into manual and the Inlet Vanes
should be closed slowly. When the fan is at
minimum loading, the fan can be stopped.
Tanjung Jati B Training
PA-FD-ID Fans
Forced Draft (FD)
Induced Draft (ID)
Primary Air (PA)
Tanjung Jati B Training
PA-FD-ID Fans
Location
PA FANS ID FANS FD FANS
Primary Air (PA) Fans
Function
Two (2) 60% capacity, single-speed,
centrifugal-type primary air fans are needed
for the following
Circulation of coal in the pulverizers
Hot air to dry the coal
Transport pulverized coal to the burners
Primary air accounts for approximately 25%
of the air flow required for combustions
Tanjung Jati B Training
Primary Air
Tanjung Jati B Training
MILL A
MILL B
MILL C
MILL D
MILL E
MILL F
PA Fans
Inlet Screen
and Silencer
Isolation
Dampers
Cold Air Duct
Hot Air
Duct
Tri-Sector
Air Heater
Control Dampers
Guillotine
Isolation Damper
To Seal
Air Fans
Air Measurement
Tanjung Jati B Training
PA Fans
Fan Bearings
The PA Fans have sleeve-type bearings which
require continuous water flow for cooling.
Water is supplied by the Closed Circuit Cooling
Water (CCCW) system.
The bearing are also equipped with a oil level
site gauge. If the oil appears cloudy or frothy,
most likely cooling water has entered the oil
cavity and has contaminated.
Tanjung Jati B Training
PA Fans
Fan Motors
The PA Fan Motors have oil-lubricated bearings
which requires a stand alone lube oil skid. One
lube oil skid supplies oil to both motors.
Tanjung Jati B Training
PA Fans
Fan Motor Lube Oil Skid
The lube skid has very similar components
to the FD Fan oil skid
Two (2) Oil Pumps
Oil Sump
Filters
Air Cooler
Oil Pressure & Temperature Switches
Gauges
Junction Box
Tanjung Jati B Training
PA Fans
Start-Up
Prior to starting an PA Fan, an operator should
check the oil level in the bearing and be sure
that the CCCW isolation valves are open.
Be sure all housing doors are closed and an
operator should be present when the fan is started.
Tanjung Jati B Training
PA Fans
Start-Up
Prior to starting an PA Fan, an operator should
also check to be sure that the Motor Lube Oil
Skid is started and functioning properly (no alarms).
Tanjung Jati B Training
PA Fans
Start-Up
Prior to starting a pulverizer, a PA must be started
first. When the fan is commanded to start, the fans
Outlet Isolations Damper will be commanded to close.
once the Dampers closed limit switch is activated,
the PA Fan starts. After a specified time delay, the
Outlet Isolation Damper opens.
Tanjung Jati B Training
PA Fans
Automatic Operation
The loading of the PA Fans is controlled by variable
Inlet Vanes. This is determined by the Primary Air
Hot Crossover Duct Pressure Set Point.
If two fans are in service and one trips, the Boiler
load will runback to approximately 60% load.
Tanjung Jati B Training
PA Fans
Trip Interlocks
Fans will trip under the following conditions
Boiler MFT (pulverizers tripped)
High Fan Bearing Vibration
High Fan Bearing Oil Temperature
Loss of Flow Path
Loss of Breaker (power failure)
High Motor Amps (time delay)
PA Fans
Shutdown
Tanjung Jati B Training
Similar to the other fans, the inlet vane controls
should be put into manual and the Inlet Vanes
should be closed slowly. When the fan is at
minimum loading, the fan can be stopped.
PA Fans
Shutdown
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Once the last pulverizer has been shutdown,
the Primary Air Fans can be stopped.
PA-FD-ID Fans
General Start-Up Sequence
Tanjung Jati B Training
The start-up sequence for the fans is as follows.
This assumes all fans are available
ID Fan A or ID Fan B
FD Fan A FD Fan B
ID Fan B ID Fan A
FD Fan B FD Fan A
PA Fans A/B (prior to starting a pulverizer)
Tanjung Jati B Training
OPERATIONS
PA-FD-ID FANS
(END)