: a7 4s REFINERY ENGINEERING a kk FANS FOR INDUSTRIAL BOILERS Fans used in industrial and waste heat boilers are mostly of radial type (Centrifugal) Fans. The following types of Centrifugal Fans are used in boiler applications. 1. Backward curved bladed fan 2. Forward curved bladed fan 3. Radial tip bladed fan 4, Paddle type fan Aerofoil bladed or backward curved bladed fans are used for forced draught or supply air applications due their high efficiencies and limit-load characteri- stics. Forward curved bladed fans are seldom used for draught applications because of their overloading characteristics. It is generally used in venti- lation applications since the unit sizes are smaller. The efficiency of the forward curved bladed fan is about 70%. The radial tip bladed ians and paddle type bladed fans are used for material handling applications. (Paddle bladed fans are used for mill exhauster appli cations). ‘These fans have good erosiow resistant characteristics though the efficiencies are very poor. FANS FOR INDUSTRIAL BOL L. Forced draught fan 2, Induced draught fan 3.Gas recirculation fan Forced draught fans supply air for combustion. This fan is used in both balanced draught and pressutised furnace applications. Induced draught fans handle the products of combustion and produces balan- ced draught. This fan is applicable only in balanced draught applications. Gas Recirculation fans may be used for steam temperature control purposes in some units. CONSTRUCTIONAL DETAILS: Radial fans have single inlet or double inlets. The following are the components of radial fan 1. Rotor assembly consisting of shaft, impeller, hub, keys 2. Bearing assemblies ‘3. Control devices - Inlet guide vane or damper control 4, Spiral casing 5. Inlet box wee Oeie a; REFINERY ENGINEERING Fans For Industrial 12s Boilers LaiL / scoot or taming Rotor_Assembly:-_ It consists of shaft, impeller. hub and keys. Shaft is manufactured from solid forging or it can be manufactured from hollow seamless pipes. Hollow shafts are preferred since high critical speed reserves can be achieved for the same weight. Also heating up and cooling down are uniform in hollow shafts. Minimum recommended margin between first bending critical speed and miaximum operating speed shall be minimum 30%. Forgings as per Indian Standards C-40 or 1875 class IV can be used for solid shafts. St 35 seamless pipes are used for hollow shafts. For appli- cations beyond 400 deg C but less than 500 deg C, 13CrMo¥4 material is used. Impelter: All-welded construction impellers are preferred to bolted or rivetted constru- ctions. The mechanical integrity of the latter is very poor. Modern manu- facturing technology permits the use of high or ultra-high strength materia for the manufacture of impellers. The materials are selected based on static and dynamic stresses. The mate- rials used for industrial fans have a minimum yield strength of 36 Kg/sq.mm. Material selection of impeller is very critical and the selection is based ‘on various operating conditions such as temperature, dust, presence of corro- sive chemicals etc. Bearings: Antifriction or sleeve bearings ate’ used for fan applications. Antifriction bearings: Double row spherical roller bearings can be used to take moderate radial and thrust loads. Grease lubrication or oil lubrication is used. For heavy loads, cylindrical roller bearings are used for radial loads and angular contact ball bearings are used for thrust loads. For over-hung design fans, tubular bearing housings or plummer blocks are used. Separate assisted lubrication is to be provided for fans handling gases at high temperature (eg. GR fan) and the hot lubricant is to be cooled in an expernal oil cooler. ‘When assisted lubrication is employed, the system should be made reliable with 2 x 100% duty pumps, coolers and filters with inter- connecting pipe lines and fittings. For Refinery service, API standards are to be followed for oil supply unit components and the lube oil pump motor shall be flame proof.industrial a j i : 7 f Oa REFINERY ENGINEERING ; Fan Wis ScHOOLOF TRAINING = * > * Boilers Sleeve Bearings:- Spherically seated ring oil lubricated water-cooled split bearings are pre- ferred for forced draught and induced draught applications. Though sleeve bearings are expensive, they have the following advantages over antifriction type. H I. Since the bearing assembly is horizontally split, replacement . of liners can be carried out by removing the top half of the bearing cap and liner cap (with jacking the shaft). 2. Since liner sets are interchangeable with housings, re-alignment is not required. 3. When properly lubricated, liners have indefinite life. ( 5 4. Vibration damping is very good. ee 5. Mostly the bearings are water-cooled and hence there is no need for assisted lubrication with LT motor driven pumps, coolers, filters and associated problems with those equipments. tee 6. In the event of bearing failure the babbit does noi damage the shaft. ee Inlet guide and damper _control- For foreed draught fans inlet-guide vane controls are used. It can also be us- ‘ed in the case of a oil or gas fired units. Inlet guide vane control is preferr- : ed because ol its low power requirement for control. ie, Inlet guide vane controlled fans have higher efficiency than damper controlled fans. Inlet guide vane controlled fans should have positive fink mechanism. Angu- lar joints or spherical plain bearings with hinge heads are to be used to achieve positive movement of all blades. The blade shaft of the vanes can be fitted in the housing through bush bearing or antifriction bearing. : Double side sealed grease-filled deep-groove antifriction ball bearing could q) be used. Damper control consists of multi-louvres. It is simple in construction and wee _ maintenance ‘epairs could be easily “carried out. It is generally preferred Because of its simplicity. It is used in fan applications where the fan has to handle dust-laden gases. Damper controlled fans have poor efficiencies at part loads. patie Spiral Casing f The spiral casing or scroll casing is the stator part of the fan in which a the pressure energy rise ‘takes place. It is of welded construction and fabri- ; cated from plain carbon steel plates. The casings are stiffened by rolled steel sections like flats, angles or channels. Sprial casings are split for easy mounting and dismounting of rotor. Flanges are provided in the parting plane. wee We}CHOOL OF TRAIN! Boilers ™ ne Au feos REFINERY ENGINEER Fans For Industrial Vas Depending on the magnitude of the fan, the casing splits are decided. Small fans have circumferential flange joints whereas large fans have radial splits. ‘Access doors or hand holes are a must in the spiral casing and must be located in convenient locations for observation. Direction of rotation of the radial fans are located by the casing only. For a backward curved bladed fan the impeller should be mounted in such a way that the blades are curved backward to the direction of rotation and the impeller rotates in the direction in which the spiral progresses. Inlet Boxes = Fans with duct systems in suction side or with silencers require inlet boxes. The inlet box should be aerodynamically shaped well in order to have uni- form flow and minimum losses. The construction of the inlet box is similar to spiral casing- ‘Fan supporting arrangements There are different methods of supporting of fan casings and shafts. Casings are either centrally supported or bottom supported. Central supporting is done on the fans handling hot gases. It allows the casings to expand uniformly on all directions. Spiral casing feet are located near the parting plane of the casing. The feet are supported either by steel or by concrete. This method of supporting is used for heavy duty fans. Light duty fans have bottom supports and generally these fans handle atmos- pheric air. The thermal expansion of the casing is in the upward direction and compensation is to be provided between the impeller and spiral casing inlet mouth while erecting the fan so that during steady state running, uniform gap is maintained. Supporting of fan shafts 1. Overhung design Simply supported design For supporting any rotor system,, minimum 2 supports are required. Fans are used with 2 bearing supports." These supports can be on one side (Over- hung) and they can be on either side of the impeller (simply supported). Light duty fans and forced draught fans can be with overhung arrangement. This arrangement is very economical but susceptibility for vibration problems is high. Simply supported designs are preferred: for fans of heavy duty applications. (eg: Induced draught fans) which are subjected to wear. and tear. Susceptibility for vibration problems is less. we SIHApplication FORCED, DRAUGHT FAN GAS RECIRCULATIO! FAN 5 7 EXHAUSTERS UBPHN rHO ‘Om DHS HOO Balanced draught I~Aerofoil « ~ guide Vane) I-Aerofoil TI-Backward curved (with dnlet vane control) I-Backward curved. with damper control TI-Aerdfoil with damper _ control ‘I-herofoil TI-Backward curved (with damper control - ‘I-Paddle type II-Radial tip Blade Fans For Industrial Boilers Boiler Furnace Type Pressurised furnace I-Aerofoil TI-Backward Ti-Backward curved, curved (with inlet (with inlet guide vane)= . a Oy, REFINERY ENGINEERING pe Fans For Industrial Lub fs {OOL OF TRAINING : Pete Preferred Operatiny ds to Forced draught, Induced draught fans are driven by constant speed squirrel cage induction motors. Motors below 160 KW are LT (415V, 3 phase) and above 160 KW are HT (either 3.3 KV or 6.6 KV). While selecting the fan, high operating speeds are preferred since it results in small unit size. Forced draught fans which handle clean air are selected at 1480 rpm or above. Preferred speeds for induced draught fan and gas recirculation 1s 990 or 740 rpm. Performance curves of fans ; Performance curves are set of curve which are drawn with volume in axis ‘and pressure in ordinate for different vane positions of control device or for different speeds. Iso-efficiency lines are also marked. For a given homo- logous series of fans the performance curves are identical. Boiler manufacturers specify the following duty conditions for fan selection. 1, Boiler Maximum Continuous Rating condition. - (MCR condition) 2. Fan Block or design point condition - (TB condition) The duty conditions of the fans corresponding to the maximum continuous rating of the boiler is known as MCR condition. argins are added to volume and pressure. 1. Uncertainities regarding fan performance 2. Variations in fue! fired 3. Combustion air and excess air requirements 4. Air heater leakage 5. Air infiltration 6. Inlet temperature and air moisture. Factors for adding margins on pressure :~ RECOMMENDED DESIGN MARGINS 7 ‘On Volume ‘On Pressure Forced draught Fan 50% Induced draught Fan 30% Guidelines for good aerodynamic selec 1, The operating point should lie in the peak efficiency zone at the highest possible vane opening. It ensures good controllability. 2. For fans handling clean air, the maximum operating speed should be chosen so that the unit size is small. 3, The operating parameters selected should not lic in the unstable zone or even close to the stall line. It should ensure that the system resis- tance curve does not cut the stall line. 4, The duty point should lie in the drooping characteristic portion. we Th= oF Oa REFINERY ENGINEERING ; Fans For Industrial Las SCHOOL OF TRAINING Boilers Fan_drive systems 1. Electric drive 2. Steam-turbine drive 3. Dual drive Electric drive or constant speed drive applications, squirrel cage induction motors are used When speed variation is required, slip-ring motors or pole-amplitude-modulated ener coer frequency-controlled motors are used. Also many a time, squirrel Cage induction motor with variable speed hydraulic couplings are used for speed cont team Tur! In industrial applications where steam is available, steam turbines are emplo~ yed as fan drives. These are single-stage overhung steam turbines. If foreign xteam is not available for start-up purposes, then, atleast one FD fan and ‘one ID fan shall have electric drive. Dual-drive: Dual-drive system will have two drives with one way clutches, One, side of the fan will have motor drive afd the other Side will have TUfbin® drive, Motor will be energised for the start-up of the plant. At that instant, turbine will be disengaged by means of one-way clutch. Once when the plant gene- Fates steam, them, turbine will be used to drive the fan. The motor side fone way clutch will disengage the motor and prevent it from idle rotation. One way clutches used for this purpose should be rated for continuous duty and should be self-supported type. Lubrication is possible without stopping the fan. There are clutches which rotate when the fan is in service. On maintenance point of view such clutches are not preferred. One has to stop the fan for lubricating the clutch. The ‘turbine drives for Refinery service shall correspond to API standards. Cou For capacities upto 100 KW tyre couplings (cushion couplings) can. be used. These couplings can take large misalignments and can be used for places where quick alignments are required with less alignment accuracy. Pin type flexible couplings are generally used between fan and drives, Bibby couplings or gear couplings are not generally preferred due to their high costs. MAINTENANCE ASPECTS OF FANS: -This portion does not deal with the routine maintenance prescribed by the manufacturers. General guidelines are discussed. Ble{_RESOT PB Fans For Industrial Boilers Supervision of fans:~ Temperature monitoring and vibration monitoring All fans are to be provided with thermometers for measuring and recording the beating temperatures. When antifriction bearings are used, the Alarm can be set at 95 deg. C and Trip can be set at 105 deg C. Gas filled ther- mometers can be used for local reading. Resistance thermometers or thermo- couples are used for remote indication. In addition, "Temp-plates" can be used to find out whether at any point of time the temperature has crossed the prescribed limit. Temp-plates can be stuck on the housing like a sticker and the colour change indicate the temperature cross over. Vibration measurement/monitorings +. Fan vibrations are to be continuously measured and recorded on all three direction (X Y Z direction) in both drive and Non-drive end of bearings. Velocity measurements can be adopted for vibration measurement, VDI standards are used for the acceptance criteria. VDI 2056 Machine group G for the fans mounted on concrete and group T for machines mounted on vibration isolators. Modern installations are provided with continuous monitoring of vibrations with facilities for recording and signature analysis. When vibration level value are beyond "good" level then vibration analysis is carried out by porta- ble vibration analysers. Enclosed chart indicates probable causes for vibration and the frequencies. . Dynamic balancing +- All the fan rotors should be statically and dynamically balanced. Quality grade for dynamic balancing shall be as per ISO 1940 quality grade 6.3 for fans operating at 740 rpm and 2.5 for fans operating at 990 rpm and above. The dynamic balancing should be done in works. However trim balancing, can be done at site. Field balancing can be performed with the aid of porta- ble vibration analysers. Noise reduction Occupational Safety and Health Association (OSHA) USA, have specified plant noise levels and permitted hours. For an 8-hour continuous sound exposure, the permitted level is 90 dBA. Hence, if the noise levels are more than’ 90 dBA, overall at a distance of 1m. from the profile of the machine at a height of 1.5 m, then attenuation is required. Different methods of attenuation: a) installing the fan in sould proof enclosures b) providing silencer at fan suction ) Acoustic insulation of the fan.RA REFINERY ENGINEERING 9! Fans For Industrial ‘ SCHOOL OF TRAINING Boilers. The silencers used for reducing the noise, work on the absorption principle. A rectangular casing (silencer) contains baffles or coulisses. These baffles have fibre glass or mineral wool filling. On both sides, perforated sheets are kept. The sound waves travel through the wool via perforated sheets. The sound energy is converted into heat energy and noise is absorbed. ‘These types of silencers are also known as ‘Absorption type'. Only absorption types are used for forced draught fans. Whenever the silencers are to be used to reduce the noise of induced draught fans, Reasonating Silencers are to be used. Special Precautions for trouble free operation:~ 1. Never by-pass any interlook logic. 2. Start the {an with no load (ie. the control device in min position). 3. Use the right impeller in the right casing. This problem will arise when there are clockwise fan and counter-clockwise fan in the same plant. ‘Clockwise impeller should be mounted in the clockwise casing. 4, Use proper lubricants. Do not mix lubricants of different grades. 5. When the fan is coupled with a turbine, never overspeed the turbine beyond the maximum speed of fan. If overspeed trip is to be checked for turbine, then, decouple the fan. 6. Use flexible hoses for water inlet and outlet of bearings. Flexible hoses do not strain the bearings. 7. Do not perform welding on the shaft or on the impeller without knowing their metallurgy. 8 Never operate a fan beyond its rated speed (name plate speed). 9. Maintain history of the fan for planning spares. wee 10 f=‘Sy REFINERY ENGINEERING : 10 Fans For SCHOOL OF TRAINING Industrial = Boilers, Fan Assembly : ; ‘ Single Width—Single Intet : Open Inlet FIG.NO.O1 mann notes pei REFERENCE: Alo se Section, Toning ~Seu_(SpIVaT Cash {10 tems 12 sld oan teri, 4 eset See Vane Cain App) ie fa ems HC Appt 7, Lin, a9 901 shown, (Ses Contract eae 21 Appt Drawing for apples (4) Rotor shown for earityonty = Nota pat of Tee Housing Anarbly. nyeSUCTION CHAHUER SCHOOL OF TRAINING * |! Fans For Industrial Boilers DAMPER ASSY, SPIRAL CASING IMPELLER, SINGLE SUCTION RADIAL FAN FIG.NO. 02 ae IRIEFO, periNERY ENGINEERING WwW SCHOOLOF TRAINING * 12 Fan Assembly Double Width—Double Inlet Open Inlet Fans For Industri; Boilers BLOF MeO Toaiy So nig ~ Sie Sa inte ise Sara notes REFERENCE: Alt a8 Section 5 (1) tems 16 2 soldat an ately can be purchased with Vans Control Housing Auambly. lemblad where apalicabe or both may be pu al 13 /-9h Sy, REFINERY ENGINEERING 2B Fans For SCHOOL OF TRAINING ? 3 Industrial Boilers. 5 DANPER ASSY: SUCTON CHAMBER : ire lh fan Harr SeIRAL CASING DOUBLE SUCTION RADIAL FAN- \FIGNO. 04 oonBO crn f oe ‘Sy, REFINERY ENGINEERING Mb/s scHooror traning $+ |? Components of Fan Fans For Industrial Boilers. |. Streamlined ——_-Radial inlet vane control inlet box Housing cover Impeller with Inlet cone Belt guard Motor support Bearing support a for fan for fan earing type RUM type RUR suppor for fan type AUK Figure -05 " Expanston joint (Fan housing with Inspection cover) Spleal_cosing . 13 fe= a RSS WwW REFINERY ENGINEERING co JOOL OF TRAINING Fans For Industrial Boilers. COUNTER-CLOCKWISE ghocewise me FIG.NO.U6 Wheel Blade Types and RotationG REFINERY ENGINEERING SCHOOL OF TRAINING 2 16 ' Fans For Industrial Boilers, Impeller Double Width-Double Inlet ROTATION Erosion Resistant Construction SECTION X + x SECTION Y ¥ ores REFERENCE: Alto 49 Se M7 [-ef c REFINERY ENGINEERING. Saat Fans For Las SCHOOL OF TRAINING Industrial Boilers, 4 (Overhang) Typical Bearing Arrangement FIG.NO, 08 vee 138 ]-< of 4s REFINERY ewGiNecRING’ Vas SCHOOL OF TRAINING * 18, Typical Bearing Arrangement (Simply Supported) + FIG.NO, 03 Fans For Industrial Boilers. ve ID JeTED, REFINERY ENGINEERIN: » @ TRAINING + 19 ¢ Fans For Las sicarmerrs Industrial Boilers. ‘ron courdine on stave + Type! Rotor Bagla Suation tou + FIG.NO. 10 -CENTENPLATE Lanes KEY AND KEVWAY. Fon courting 5108 PLAT; ROEPLATR pagan must ‘seaming eND ‘Loans on, Expansion BEARING ENO or ey anu Kermay JOURNAL: cautans foron Ler on, fae ‘ana FIG.NO. tt . _noron wrt on SINGING AREAS EXTENSION ‘Typical Rotor Double Sustion Fars 20 /-WW 2 97 ©,, REFINERY ENGINEERIN eeeage Fans for Industrial Vs SCHOOL OF TRAINING Boilers. | BACKWARD CURVED MAX EFFICIENCY: For Plate Blade = 85% Aerotoil = 90% VOLUME —— FIG.NOI2 FORWARD CURVED MAX EFFICIENCY =70% VOLUME FIG.NO.13 oe 21Pans For Industrial | Boilers. , : TURBINE one way euuicH DUAL DRIVE FAN Fig.No1s ONE Way CLUTCH MoToR- 123 [>4 ‘)y, REFINERY ENGINEERING Pans For Las SCHOOL OF TRAINING | 23° # Industrial 7 Boilers. 2s T 1 aH sataritny aiaus \ coe tt man prin \ \ Noo ou ~ i ST Wes 6 AS w 30 ot KO WS 160 900 0 DS 400 trtan rer me . VDI- 2056 FIG.NO.16 wee 2b fe2%, nesieny ENGINEERING x Pans For As SCHOOL OF TRAININ ae eee Industrial Boilers. lf \ AL RELATIVE POSITION OF IMPELLER AND SPIRAL CASING “FOR BACKWARD’ CURVED CENTRIFUGAL FAN 8 RELATIVE POSITION OF TANGENT ARB AT OUTLET OF CURVATURE OF BLADE WITH RESPECT 10 DIRECTION OF ROTATION OF BACKWARO CURVED CENTRIFUGAL FAN A.C. COMPONENTOFAB RESOLVED ALONG WITH PERIPHERY OF IMPELLER. ©. AXIAL FANS ROTATE IN ANTICLOCKWISE DIRECTION AS SEEN FROM ITS DRIVE END DIRECTION OF ROTATION OF IMPELLER ws 25 fe{EFINERY ENGINEERIN( 4 236, 23 AD HOOL OF TRAINING * @ Industrial Fans For Boilers, voxiwa9 awn a0in> sana wo Se2any0 30 DuIN390 49 YorLDauIG Gaaning no gama sv" wamaant ae NOW¥1N 40 NOULDIIG BAL MI S35m9. aA TORINOS Sava SIRS SI aR » 26 |- BaTI3EM 40 KOLVLOY 40 NoWZI¥IG BML MI SHae avs¢ 30, @ -EFINERY_ ENGINERRIN' \a/ SCHOOL OF TRAININ % Industrial Fans For Boilers. 26 spuqvosel Jo $9809 ur 1daax2 20} aigron jo anes eae wey Aauand2y snovonouAs x2 Le WHAT 2013 Wey “z ssevase9) jee sjaissod y wawernsenus ooh Aupoqen sn ~ Apeaizun, ‘vouriqia ews sou 10 295 veg pur buses jo seunewes vigy 9 Weesn Wa XL “uousenp jee wy 9619] sCujdnes jo iewuOrieni Aq puncy sag susreadde suonesqia $0 sinea vowwes soy ue aauasEa 20g ewe seueequn, sawed asvua Aonanoays sonny asavo “ATGVL NOILVSISILNIG! NOLLWUBIA we 27 [~| 2 SO. * 9, REFINERY ENGINEERING i Fans Fi - gL F sauso: or manus fee Industrial Boilers, or em, cy ‘centre of gravity displacement e in pm Acceptable residual unbalance pér unit of rotor mas i ee * _ 30 60 95 150 300 600 950 1600 3.000 15.000:30.000 95,000 rev/min pe 05 1 1625 6 10 16 25 60 100160 250 600 10U0 1600. ‘Maximum sevice speed of rotation FIGURE 4 — meSs, OY ft Od REFINERY ENGINEERING SCHOOL OF TRAINING Balances ng erjtertai<- 0 AE « Balancing: gual by edged ine ot “lf anpathoces in Service. AN cayses of vitora tion / “are not due to umbalance - other. causes of vibration . are. due to -misalrgnment . -, _ looseness, faa lty bearing ere. ( Refer “por LOSE “Group G-a ‘ 0% F Od REFINERY ENGINEERING ey: SCHOOL OF TRAINING os balaactag STATIS 8 Dynami nhalance.. :on As REFINERY ENGINEERING \a/ SCHOOL OF TRAINING "180-190 of ropey. ecceeentntity- mi kg : allowable un balancement. in 9 or- Cho Sep doo pm Fan Site Speeck “<950xpm: G63 ; > BSorpw + G25 “allowable unbalance ment ; _ Goeo0ox d per plane Serene Grodex Reber, +raf Ss OF Od REFINERY ENGINEERING ’, REFINERY ENGINE SCHOOL OF TRAINING PERFORMANCE TESTING COdES 4. BS. O48 - Part A 2. Amen = 210. ee Mor res | Vot CInlet) — 25% - 5% ~ 254 Fon Appicdeny | - 2% | -3% (| Power. input [ 47h +107 tl5K Tony lows. - eters Ok Spead . dia © dia™ Pre ss ure Speer Pewer oc Spaadi B dee : ie — expuk = VA ws x Pressure THM Yo- toa ieeeTETEMPwemMseou emngereduaz .°¢ fa yoRTL Qeer See at queusmseay orNssoag “Gg “ ueg ‘ Fezoucueu ued *7 Aezouoweuky uoysz01 PTRIOIUL °9 F030H OTIRDeTR- Zhay - : a Sy renery ENGINEERING oo CALCULATION : oS = “Cd : ; 2 Conf. of clisefunge of Oripface 1A + BP across Onipice ‘ Blak Pressure Static Preceure + Rynamie Pressure : 2 dynamic Pressure t Pe) xb x ae a 9% Input to for : Longue x hPM hw ol x Pressure Depa to fw ot. in wife. Shassure in fy/m° Epiciency of fam :