AIR PREHEATERS

LJUNGSTROM REGENERATIVE AIR PREHEATERS

INTRODUCTION:
A high level of efciency of steam generators depends on how
efectively the input energy is recovered for utilization. To recover a
part of the heat energy in the exit fue gases for pre-heating of
combustion air in air heaters located in the outgoing fue gas path is
one such activity aimed at improving the efciency of the boiler. The
advantages of such preheating of air are as under.
. !ot air is used for drying coal as well as transporting pulverized
coal to burner.
". #ven poor $uality fuel can be efciently burn with less unburnt
particles.
%. &ue to hot air admission into the furnace' combustion is more
stable and intensi(ed.
). !igh heat transfer rates are obtained in furnace and faster load
variation is possible.
*. #fciency of boiler increase due to reduction in outgoing fue gas
losses.
TYPES OF AIR HEATERS:
+ased on their operating principle air heaters are broadly
classi(cations'
. ,ecuperative air heaters
". ,egenerative air heaters
,ecuperative air heaters are of static construction. The heating
medium will be fowing on one side and the air in other side of tubes
or plates. Air heaters of this type are further classi(ed as plate type
air heaters and tubular type air heaters.
,egenerative air heaters are of rotating type and the wise
called as rotary air preheaters. The heating medium fows through
closely pac-ed heating elements to raise its temperature and then air
is passed through the same elements to pic-up heat. Air heaters of this
type are further classi(ed as l.ungstrom air heaters and rothemunle air
heaters. /n l.ungstrom type air heaters closely pac-ed heating
elements rotate while in ,0T!#12!3# type air heaters' the elements
are stationary where as the air hoods rotate at about rpm.
SELECTION OF AIR HEATERS:
The following factors are to be considered for selection of air heaters.
. Type of fuel'
". 4uantity of fue gas to air heaters'
%. 4uantity of air from air heaters'
). Available temperature of fue gas at air heater' inlet and desired
temperature of gas at air heater outlet'
*. 5pace re$uirement'
6. &raught loss'
7. &rop in air pressure'
8. #conomy in construction'
9. #ase of maintenance to ensure surface cleanliness.
ADVANTAGES OF REGENERATIVE AIR HEATERS:
The regenerative air heaters have the following
advantages over recuperative type.
: They occupy less space.
": !eat transfer rate is high
%: ;eight of material used per s$uare meter of heating surface is
les.
): 5urface area for heat insulation becomes less due to the reduced
volume of the air heaters.
*: &raught loss is less.
6: 5ustained high efciency of air heaters during operation
7: #ase of maintenance.
!ence in power station practice regenerative air
preheaters are widely employed. /n tune with this trend two
3.ungstrom type air pre heaters are provided for each +oiler in
power station-. The regenerative air preheaters <,A=!: are
located in between the furnace and electro static precipitators.
>lue gases pass vertically downwards whilst the fow of air is
directed upwards through specially built ducting. ") segments of
closely spaced corrugated plates are (xed to a rotor and
arranged to revolve at a slow speed inside the casing in the air
heater.

GENERAL DESCRIPTION OF LJUNGSTROM AIR PREHEATERS:
The main components of rotary air heaters are'
: ?asing
": ,otor
%: ,otating gear
): &rive unit
*: 5ealing
6: 3ubrication and cooling system of bearings
7: 5oot blowers
8: ;ater washing system
9: >ire extinguishing system
CASING:
The casing is octangular in shape and is made of welded
carbon steel plates and rolled bars. The body of casing is provided
with stifening ribs and frames. >langes are provided for
accommodating for sealing. The upper and lower bridges of the
casing' which houses the bearings' support the internals.
The four supporting legs at the bottom of the casing are
secured to the buc- stray construction. >langes are provided to
connect the fue gas inlet duct and air outlet duct at the top of the air
heater and to connect the fue gas outlet duct and air inlet duct at the
bottom of the air heater. >our short interconnecting ducts of circular
shape at one end and s$uare shape at the other end' connect the air
heater to the air and gas ducts.
0n the upper side of the air duct' manhole is provided for
changing the heat elements. The upper and lower ends of air and gas
passages are providing with manholes and observing windows.
ROTORS:
The rotor assembly with its vertical shaft is housed inside the
casing. /t is divided in to ") sectors by means of radially located
partition wall plates. ?orrugated heating elements are (xed between
these wall plates. The rotor assembly consists of two sections the top
section of @@ mm height -nown as A hot side rotor sectorB or Ahot
end bas-etsB and the bottom section of )@@ mm height -nown as
Acold side rotor sectorB or Acold end bas-etsB. /n between these
sections there is a clearance of 6*@mm. The rotor revolves at " ,=1
and the heating bas-ets absorb the heat from the gas and transfer it
to the incoming air.
ROTATING GEAR:
A slow speed of " rpm for the rotor is obtained through a
pin-toothed wheel mounted on the circumference of the rotor. This
wheel is in mesh with a toothed pinion' which is driven by an electrical
motor through a coupling and reduction gear.
DRIVE UNIT:
There are two drive motors. 0ne is to be normal service and
other serves as stand by. A common reduction gearbox is provided
with clutch arrangements for securing drive transmission from either
one of the motors. The gearbox has a reduction ratio of "C. The drive
gear <** teeth: after speed reduction meshes with the crown gear
placed on the mantle of the rotor. The crown gear has )*6 pins <9
teeth per segment:. The ultimate reduction ratio thus achieved by the
above arrangement to turn the air heater rotor at " rpm is %6".*C.
;hile one motor is driving the ,A=!' the other motor connected to the
same gearbox is to be -ept with out rotating. This is achieved by
connecting the ,A=! motor to the gearbox through a magnetic clutch.
The magnetic clutch is supplied with ") volts supply and gets
energized whenever connecting it to the gearbox starts the drive
motor there. At the same time the magnetic clutch of the reserved
motor will be in deenergised condition thus -eeping the reserve motor
decoupled from the gearbox. /f there is any failure on the part of the
magnetic clutch' it can be assembled as the mechanical coupling.
SEALINGS:
The gas side of air heaters is under vacuum and the airside
is under pressure. !ence prevention of air lea- of to the gas duct is to
be ensured at the all points. This is achieved by radial sealing'
circumferencial sealing and axial or shell sealing arrangements. ,adial
and axial seals are of counter weight type and the circumference seal
is of s-irt plate type.
LUBRICATION AND COOLING SYSTEM OF BEARINGS:
The vertical rotor shaft has two bearing and is supported by
the bottom bearing. The separate oil pump supplies lubrication oil for
the bearing. Two pumps are provided for this purpose' one to be in
service and the other for being -ept as stand by. The lubrication oil
pump is a gear pump driven by a @.@9-w motor. /t ta-es the oil from
the lube oil storage tan- and supplies the oil through a (lter and oil
cooler to the bearings. The oil returns bac- through two return lines
one from each bearing to the oil tan- itself. Auxiliary cooling waters is
used for oil cooler. The lube oil tan- is also provided with a vapour
extractor.
SOOT BLOWERS:
To remove the soot and dirt from the heating plates soot
blowers and water spray nozzles are provided in the air heaters. Two
swiveling electric steam soot blowers are installed in each ,A=!' one
operating in the gas-discharging region. 5team is ta-en is from ,!
inlet header or from auxiliary steam header.
RAPH WATER-WASHING SYSTEM:
/n spite of soot blowing with steam' some difcult to
dislodge deposits will be still there in ,A=!. 5uch adhering ash
deposits in ,A=! elements cause partial cho-ing in ,A=! indicated by
an increase in diferential pressure across ,A=! such deposits are
removed by water-washing of ,A=!. ;ater washing is an of-load
cleaning operation. /t is to be done while the corresponding /& D >&
fan is stopped.
The water used for water washing is service water. 5ervice
water pressure is boosted up a centrifugal pump located in between
>& fan AD+ of unit %. The discharge from the pump is fed to a bus
from where one tapping for each boiler is ta-en.
/n each ,A=! there are two water line connections one to
each soot blower. The soot blower nozzle can be used for water
washing. Apart from the above' another water washing tapping is also
provided in each ,A=!. There are number of nozzles in this line which
is (xed to middle frame. The ,A=! is to be continuously rotated at "
rpm itself while water washing.
FIRE FIGHTING SYSTEM:
/n case of any (re in ,A=!' to put out the (re' the number
of water nozzles is provided on top of each ,A=!. Their nozzles are
provided both in airside and gas side of ,A=!. ;ater for (re (ghting is
tapped from (re (ghting waterbus at 7-meter elevation. The (re line
tapping is divided in to two' one to each ,A=!. #ach line to a ,A=!
again sub-divides into two' one entering the sir side and another gas
side duct of ,A=!.
/n boiler " area <near >& fan "A: there are two (rewater
boaster pumps provided to boost up the (re (ghting water pressure.
This water supply lines are available at higher elevations of boiler to
supply (re (ghting water at locations in higher elevations of boiler in
case of any event utilizes.

RAPH CLEANING SYSTEMS
INTRODUCTION:
Air pre heaters have been in general use for many years for
reclaiming heat from fue gases at lower temperature levels than is
possible with economizers. +y using air pre heaters' much lower gas
temperatures can be achieved with conse$uent improved boiler
efciencies due to the reduction in heat re.ected to the chimney. 5uch
improved boiler efciency will be achieved only if satisfactory
performance of air pre heaters is maintained continuously. The
satisfactory and successful performance of air pre heaters not only
depends on adopting due care in selecting air pre heaters' but also
-eeping air pre heaters heat transfer areas clean. 5oot blowing with
steam is widely adopted to ensure cleanliness of air heater elements.
This helps to maintaining a low draught loss across air heater and
optimizes >& and /& fans loading. 5winging lance type soot blowers are
employed in ,egenerative air pre heaters of T=5-//E stage F/ steam
generators. /f and when steam soot blowing proves to be inefective
indicated by a large pressure drop across air pre heaters' water
washing of ,A=! is to be resorted to.
RAPH SOOT BLOWERS:
#ach ,A=! is provided with two numbers of soot blowers. The
blowers are located in the fue gas duct. 0ne above the ,A=! and the
other below the ,A=!. 5team at 6-bar pressure is the medium used
for blowing and the source is either from re heater inlet header or
auxiliary steam header.
The ,A=! soot blower consists of steam blowing as well as water
fushing lances (xed to a common frame. The water lance is above and
steam lance is below' the water lance protruding a little bit farther than
the steam lance. A moor through reduction gear drives the lances and
the rotary movement of the motor is converted to a slow swinging
action of ,A=! lances. The ,A=! lances are arranged to swing
horizontally through *@G thus covering the ,A=! elements radially. This
coupled with the rotary movement of the ,A=! ensures cleaning of all
,A=! elements in one cycle of operation. The driving gear' steam and
water line connections and the stufng boxes are located in the outside
of the plate wall of the 3.ungstorm air pre heater. The pipes of fushing
water and steam are connected to the stufng box housing by means
of fanged .unctions.
The lances are arranged such that they can swing by about *@G
in ** minutes thereby cleaning all the ,A=! elements while the ,A=!
in rotates. The steam blowing nozzles will be used during normal
operation while the water fushing nozzles are used for cleaning ,A=!
elements when ,A=! fouling is high.
RAPH BLOWER DRIVE:
The drive motor is connected through a coupling to a double
worm gear. The output shaft of the double worm gear is connected
through a coupling to a single worm gear. A lever mechanism
connected to the outlet shaft of the latter gear transforms the rotation
so that the lance will do a swinging through a soot blowing cycle.
1otor C %HI )*vI . J;I 9)@ rpm
&ouble worm gear C /nput speed 9)@ rpm
0ut put speed o.989)
rpm
Kear ratio C9*@
5ingle worm gear C /nput speed @.989) rpm
0ut put speed o.@8% rpm
Kear ratio C*)
5winging speed of the soot blower C @.@8% rev.
5winging time for one swing C ** minutes
5winging angle C *@G
OPERATION OF RAPH SOOT BLOWERS:
The ,A=! soot blowing is to be carried out at suitable intervals
so as to avoid excess fouling of ,A=! elements indicated by an
increase in pressure drop. The normal pressure drop across ,A=! will
be about @@ to "@ mm wcl in the gas side and about "@ to "* mm
wcl in the airside. /f the pressure drop exceeds by about %@ to )@ mm
wcl from the above value on the gas side' ,A=! steam soot blowers
should be operated. ;henever there is only oil (ring for more than an
hour' ,A=! soot blowing should be carried out.
The ,A=! soot blowing should be done with super heated steam
with a super heat of at least "@ to %@ Gc. #nsuring that can minimize
the fouling problems'
a: The average cold end temperature is maintained at @@Gc.
b: Lormal 5?A=! level is maintained.
c: ,A=! soot blowers arm movement is proper.
PREPAROTORY WORKS:
The following preparatory wor-s are to be done before operating
,A=! soot blowers.
. /t is to be chec-ed whether all the gas dampers in the fue gas
way up to chimney are opened. The particular air pre heater and
the /& fan should be in service.
". The blowers should be visually being chec-ed.
%. The hand operated valves in the drain lines of ,A=! steam lines
are to be opened.
). 5upply availability to ,A=! soot blower drive motor and the
motors of the valves in the system is to be ensured.
*. 5team supply from ,! inlet header' or auxiliary steam header is
to be ensured.
6. /n case steam is ta-en fro ,! inlet header' the drain M-!->-5 66
is to be opened and by opening valves "98'"99' the line is to be
charged and warmed up to valve *8<i.e.: the motor operated
valve through which ?,! steam is admitted to ,A=!.
7. 0n completion of warming up the valve M!>5 66 should be
closed. The pressure reducer valve %66 in the ,! steam line will
now open to maintain a pressure of 6 -sc in the system.
8. After chec-ing the pressure' the valve *8 is to be opened and
steam can be admitted to ,A=! soot blower lines. Jeeping the
,A=! steam drains on both sides open until the temperature
rises to about "@@Gc should warm up the lines.
9. /f steam is ta-en from auxiliary steam header' valve *79 is to be
opened and the lines are to be warmed up by -eeping open the
drains on both sides. <M!>56)AD6)+:.
@. After warming up of the lines ,A=! soot blower line' the
drains M!>5 6)A D6)+ is to be closed and the system pressure is
to be chec-ed. <5hould be 6 -sc:Low the soot blowers can be
operated.
. ?hec- for the availability of A1Ms below the air pre
heaters.
RAPH SOOT BLOWER OPERATING INSTRUCTIONS:
,A=! soot blowers operation can be carried out either with ?,!
steam or auxiliary steam. The mode of operation can be manual or
partially automatic or fully automatic.
MANUAL OPERATION WITH AUXILIARY STEAM
>or the operation of ,A=! blower' Asteam releaseB is necessary.
5cheme preparation to obtain Asteam releaseB can be carried out
either by automatic programmed or completely manually.
/n the manual mode with auxiliary steam' the following
se$uence of operations should be carried out.
. 5elect ,A=! manual mode by pressing ,A=! 1AL2A3 push
button.
". 0pen the ,A=! steam drain valves left and right <M!>5 6) A
D6) +:.
%. 0pen the auxiliary steam-isolating valve <*79:.
). After the temperature release is obtained in left side' close the
left side drain valve. 5imilarly after the temperature release is
obtained in right side' close the right side drain valve.
*. After pressure release and temperature release for left and
right is attained. Auxiliary steam release lamp will glow.
6. Low (rst switching on the drive and then opening the
corresponding blower valve M.!.>.5 "8 by pressing the open
push button can operate the ,A=! blower. >irst operate the
bottom blower in the left side.
7. After running for the re$uired time of operation <** minutes:
close the valve and then switch of the drive with the 0>>
push button.
8. 5imilarly the next blower <left Ftop: can is put into operation
by switching on the drive (rst and then opening the valve.
9. 5imilar procedure is to be adopted for the operation of right
side blowers.
@. After completing the operation of all the four blowers the
isolating valve *79 should be closed and the drain valves
<M!>5 6) A D6)+: should be opened.
MANUAL OPERATION WITH CRH STEAM:
/n the manual mode with ?,! steam' the following se$uence of
operations should be carried out.
. 5elect ,A=! manual mode by pressing ,A=! 1AL2A3 push
button.
". 0pen the cold re heat drain valve M.!.>.5 66.
%. 0pen the hand operated valve "98.
). 0pen the cold re heat line steam isolating valve "99.
*. After the temperature release is obtained in ?,! system <this
can be seen in steam soot blower panel:' close the drain valve
M.!.>.5 66.
6. 0pen the ,A=! steam drain valves M.!.>.5 6)AD6)+.
7. 0pen the ?,3 isolating valve *8.
8. After the temperature release left and right are attained' close
the respective drain valves.
9. ;hen the pressure release and temperature release for left
and right is attained' ?,! steam release lamp will glow. Low the
,A=! blower can be operated manually.
@. 0perate the blowers one by one as already described.
. After completing the operation of all the four blowers the
isolating valve *8 should be closed and the drain valves
<M!>5 6) A D6)+: should be opened.
". ?lose the ?,3 steam isolating valve "99.
%. 0pen the ?,3 drain valve M.!.>.5 66.
NOTE:
. The running blower cannot be stopped unless the blower valve is
closed fully.
". &uring the blower operation if the temperature release left or
right goes of' the valve closes and then the drive switches of.
<Temperature switch setting is "@@Gc:.
%. &uring the blower operation' if the pressure release goes of' the
running drive switches of automatically. <=ressure setting is "
-sc:.
). Auxiliary steam isolating valve <*78: and ?,! steam isolating
valve <*8: are interloc-ed. #ither of these can be opened' only if
the other is fully closed.
*. ;hen ,A=! manual push button is pressed' ,A=! manual lamp
will glow only when the ,A=! NA2T0 =,0K ,2LO' N+,#AJO' NA2T0
=,0K 0>>O lamps are not glowing.
6. The release lamp A5T or ?,! will be 0L even if the temperature
release on one side <left or right: is obtained. +ut the blowers on
that side alone can be operated.
7. /n manual mode any number of blowers can be put into
operation. !owever it is preferable to operate only one blower at
a time.
PARTIALLY AUTOMATIC OPERATION OF RAPH BLOWERS
PARTIALLY AUTOMATIC OPERATION WITH AUXILIARY STEAM.
. 5elect ,A=! manual mode.
". =re select auxiliary steam by pressing pre select push button of
auxiliary steam.
%. 5witch on the (lling programmed by pressing AA2P/3/A,Q 5T#A1
>/33/LK =,0K,A11#B 0L push button.
>rom this moment onwards' the valves concerned cannot be operated
manually. The following se$uence of operations ta-es place
automatically.
a: ?,! isolating valve <*8: closes if not already closed.
b: ,A=! steam drain valves left and right <M.!.>.5 6) AD6)+:
open.
c: Auxiliary steam isolating valve 9*79: opens.
d: ;hen left side temperature release is attained' left side
drain valve closes and when right side temperature release
is attained right side drain valve close
;hen the pressure release and temperature release left and
right side are attained' auxiliary steam release lamp glows.
). Low switch on the drive of a bottom blower and then open the
corresponding valve.
*. After running for the re$uired time of operation' close the valve
and switch of the drive.
6. =roceed in the same manner for the remaining blowers.
7. After completing the operation of all four blowers switch of the
(lling programmed by pressing the AA2P/3/A,Q 5T#A1 >/33/LK
=,0K,A11#B 0>> push button. The following se$uence of
operations ta-es place.
a: Auxiliary steam isolating valve <*79: closes.
b: ,A=! steam drain valves <M.!.>.5 6)AD6)+: open.
/f the above se$uence of operations does not ta-e place' a forced
cancellation of the automatic (lling programmed can be done by
pressing NA2P/3/A,Q5T#A1 >/33/LK =,0K,A11#O0>> push button (rst
and then 0L push button. The NA2P/3/A,Q 5T#A1 >/33/LK
=,0K,A11#O 0>> lamp will glow. Low the valves can be operated by
openEclose push buttons.
PARTIALLY AUTOMATIC OPERATION WITH COLD RE HEAT STEAM.
. 5elect ,A=! manual mode.
". =re select ?,! steam.
%. 5witch on the cold re heat (lling programmed by pressing ?,!
>/33/LK =,0K,A11# 0L push button. The following se$uence of
operations ta-es place automatically.
a: ?,! drain valve <M.!.>.5 66: opens. </f not open already.:
b: ?,! isolating valve "99 opens.
;hen there is no ?,3 pressure release within monitoring
time' the alarm AL0 ?,3 =,#552,#B appears.
c: After the temperature release is attained' ?,3 drain valve
<M.!.>.5 66: closes.
d: ,A=! steam drain valves <M.!.>.5 6)AD6)+: open.
e: ?,! isolating valve *8 opens.
f: After the left side temperature is attained' the left sides
drain valve closes. 5imilarly after the right side temperature
release is attained' the right side drain valve closes. /f the
temperature release is not attained within the monitoring
time' N,#3#A5# >A23TI alarm appears.
g: After the pressure release and temperature release left and
right are attained' ?,! steam release lamp glows.
). 0perate the re$uired blowers as described earlier.
*. After completing the operation of all blowers' switch of the ?,!
(lling programmed by pressing N?,! >/33/LK =,0K,A11#B 0>> push
button.
The following se$uence of operations ta-es place.
a: ?,! isolating valves <*8: closes.
b: ,A=! steam drain valves M.!.>.5 6)AD6)+ open.
c: ?,! isolating valve "99 closes.
d: ?,3 drain valve M.!.>.5 66 opens.
NOTE:
a: ?,! pressure setting " -sc.
b: Temperature setting "@@Gc
;hen there is a temperature decrease on right or left side' the
annunciation ,#3#A5# AE+E>A23T appears. The blower running on that
side switches of. <!owever the blowers on the other side may still be
operated.: =ost drain ta-es place in the side on which there was a fault.
<i.e.: drain valve on the leftEright side opens automatically. 0nce the
temperature release is attained' the valve closes automatically and the
release lamp will be on. The drives on that side can be operated now.
%. &uring blower operation if there is pressure decrease' steam
release lamp goes of. The alarm , =,#552,# &,0= appears.
AUTOMATIC OPERATION OF BLOWERS:
AUTOMATIC OPERATION WITH AUXILIARY STEAM:
: 5elect ,A=! auto mode by pressing ,A=! A2T0 push button.
": =re select auxiliary steam (lling programmed.
%: 5witch on the automatic programmed by pressing the A2T0
5TA,T push button.
): A2T0 =,0K,A11# ,2L lamp glows.
*: Auxiliary steam (lling programmed switches on automatically
and the following se$uence ta-es place automatically.
a: ,A=! steam drain valves <M.!.>.5 6)A D6) +: open.
b: ,A=! steam isolating valve <*79: opens.
c: After the temperature release left and right are attained'
,A=! steam drain valves close accordingly. /f the
temperature release is not attained within speci(ed time'
the alarm ,#3#A5# &#3AQ appears.
d: /f the pressure release is not attained within speci(ed time'
the alarm ,#3#A5# &#3AQ appears.
;hen both the temperature release <i.e. left and right@and
pressure release are attained' auxiliary steam release lamp
glows.
e: The (rst blower A switches on and the blower valve
M.!.>.5 "8 A opens.
f: After the running time <6@ minutes: the valve closes and
the drive switches of.
g: After the waiting time is over' the next blowerA" switches
on and the valve opens. After the running time is over' the
valve closes and the drive switches of.
h: +y the time of completion of the operation of blowerA"' it
can be expected that the temperature in the parallel line <+
side: has sun- below the limit value of "@@ Gc.
i: ;hen the temperature on +-side has sun- below "@@ Gc' an
automatic drainage ta-es place. The right side drain valve
M.!.>.5 6)+ opens. This drain valve closes after the
temperature release is attained.
.: ;ith temperature release and pressure release available
,A=! blower + switches on and its valve <M.!.>.5 "8 +:
opens. After the running time is over' the valve closes and
the blower switches of.
-: After the waiting time is over' blower +" switches on and
its valve <M.!.>.5 "8+": opens. After the running time is
over' the valve closes and the blower switches of.
l: Auxiliary steam (lling programmed switches of. The
following se$uence of operations ta-es place.
. Auxiliary steam isolating valve *79 closes.
". ,A=! steam drain valves M.!.>.5 6)AD6)+ open.
%. After this NA2T0 =,0K,A11# ,2LO lamp goes of.
AUTOMATIC OPERATION WITH COLD RE HEAT STEAM:
. 5elect ,A=! auto mode by pressing A2T0 push button.
". =re select ?,! steam (lling programmed.
%. 5tart the auto programmed by pressing NA2T0 5TA,TO push
button. A2T0 =,0K ,2L lamp glows. The following se$uence of
operations ta-es place automatically.
a: ?,3 drain valve M.!.>.5 66 opens.
b: After ?,3 drain valve is opened' ?,3 isolating valve "99
opens. /f there is no pressure release within speci(ed time'
the alarm L0 ?,3 =,#552,# appears.
c: After the temperature release is attained' the ?,3 drain
valve closes.
/f the temperature release is not attained within the
speci(ed time' the alarm A,#3#A5# &#3AQB appears. /f the
temperature release is not attained after a further speci(ed
time' the alarm N5T#A1 =,0K ,2LL/LK T/1#O fault
appears.
d: After the drain valve M.!.>.5 66 is closed' the ,A=! steam
drain valves <M.!.>.5 6)A D6)+: open. </f not open already:.
e: After the drain valves are opened' the isolating valve <*8:
opens.
/f the temperature releases left and right are not attained
within the speci(ed time' the alarm ,#3#A5# &#3AQ
appears.
f: After the left side temperature release is attained' the left
side drains valve closes and when the right side
temperature release is attained' the right side drain valve
closes.
;hen the both temperature and pressure release are
attained' ?,! steam release lamp glows.
Note: /f any alarm appears' it is to be ac-nowledged so
that further processing of the se$uence proceeds.
g: The blowers are put into operation automatically one by
one in the order A' A"' +' and +" as already described
under A2T01AT/? 0=#,AT/0L 0> +30;#,5
;/T!A2P/3/A,Q 5T#A1 NeOto N-O
h: After the operation of the blower +"' ?,! steam (lling
programmed switches of. The following se$uence of
operations ta-es place.
a. ?,! isolating valve <*8: closes.
b. After *8 are closed' ,A=! steam drain valves
M.!.>.5 6)A D 6)+ open.
c. ?,! isolating valve "99 closes.
d. ?,3 drain valve M.!.>.5 66 opens.
e. After that NA2T0 =,0K ,2L Nlamp is of.
NOTE: GENERAL
: A running auto programmed can be stopped at any time with
the 5T0= push button. Low the NA2T0 =,0K ,2LO lamp goes
of and N+,#AJO lamp fic-ers. The running drive switches of
after the valve closes automatically and the +,#AJ lamp
becomes steady. /n order to identify which blower has been
interrupted' the drive 0>> lamp for the interrupted blower
fashes rapidly until the automatic programmed is started
again with auto programmed 5TA,T =25! +2TT0L. After the
restart' blower operation continues for the remaining time.
": The programmed is put into N+,#AJO state by an alarmed
fault. The drive switches of and the drive of lamp fashes
rapidly' NA2T0 =,0K ,2LO lamp goes of and the N+,#AJO
lamp glows steady after the valve is closed.
%: The automatic programmed can be fully interrupted with the
brea- push button. A2T0 =,0K ,2L lamp goes of and A2T0
=,0K 0> lamp glows. The drive switches of after the valve
closing' ?,! release lamp goes of. The ?,3 isolating valve
<*8: closes. The drain valve M.!.>.5 6)A76)+ open. The ?,3
isolating valve "99 closes after the ?,3 drain valve opens.
): /f during the running time of a blower. Temperature decrease
on one side for example on right side occursI N,#3#A5# +
>A23TO alarm appears. ,A=! blower switches of. The
corresponding valve closes. 5team release is present on the
other side. &rive of lamp fashes rapidly. Accept the alarm.
Low a post drain is initiated automatically. The right side drain
opens. 0nce the temperature release is attained' the drain
valve closes automatically. Low re starting of the programmed
is possible by pressing the 5TA,T push button.
*: A pressure decrease during the auto programmed results in
alarmOs =,#552,# &,0=O. The blower running at this time
switches of. The drive of lamp fashes. A2T0 =,0K ,2L
lamp goes of. +,#AJ lamp glows steady after the valve is
closed. ?,! steam release lamp goes of. 0nce the pressure is
attained' the steam release lamp glows. Auto programmed
can be started again. The se$uence will continue and the
stopped blower will run for the remaining time.
6: /f steam soot blowing operation with ?,! steam is running'
?,3 isolating valve "99 and ?,3 drain valve M.!.>.5 66 will not
get afected when ,A=! auto programmed is over or when
+,#AJ button is pressed.
7: /f local operation is selected when ,A=! automatic
programmed is running' the running drive will be of after the
valve closes automatically. The +,#AJ lamp will fic-er and
after the drive is of' the lamp becomes steady. The automatic
programmed will come to a stop. =ressing the 5TA,T push
button after local operation is cancelled can re start the
programmed.
8: The automatic programmed start is prevented if there is a
fault on any ,A=! drive or blower valve at the time of start.
NOTE FOR RAPH DRIVES:
: The running drive will stop immediately on pressing the local 0>>
push button or on changing the local emergency switch to /
position irrespective of whether the operation is carried out in
local or manual or auto mode.
": /n auto mode' the drive cannot be switched on or of with 0L or
0>> push buttons at the control panel.
%: 0n giving the drive 0L command manually or locally or
automatically' if the 0L feed bac- from 1?? is not received
within seconds' alarm ,#M#,T/M# 5/KLA3 appears. ?ommand will
be reset and the fault lamp in the drive will fic-er.
): /f the drive gets overloaded' #3#?T,/? >A23T alarm appears and
the drive will be 0>> and the fault lamp of the drive will fic-er.
The alarm has to be accepted and reset in the 1?? module.
*: To operate from the local' local operation is to be selected with
-ey switch in the control panel and the local emergency switch
should be -ept in N@O position and the local 0L push button
should be pressed.
NOTE FOR VALVES:
: 0n giving the open or close command' if the valve stem does not
leave the end position' alarm 3/1/T 5;/T?! will appear.
": /f both the open and close limit switches have acted <e.g. due to
shorting: the alarm 3/1/T 5;/T?! will appear.
%: /f the valve motor gets overloaded or the local push button is
latched' the alarm #3#?T,/? >A23T will appear.
): /f the valve stops in intermediate position or the limit switch does
not act' alarm 3/1/T 5;/T?! will appears.
*: The valves can be operated from control panel even if 30?A3
operation is selected since there is no local open or close push
button.
6: /f local operation is selected' the valve cannot be opened or
closed automatically by (lling programmed.
7: 0n receiving openEclose command' if the valve stem leaves the
end position but does not reach the other end within the
speci(ed time' alarm ,2LL/LK T/1# appears.
ROUTINE CHECKS:
&uring operation of ,A=! soot blowers' the following are to be
chec-ed.
: a: 0il level and lubrication of the soot blower drives.
b: ?leanliness of the drive' motor etc.
": The soot blowing periodicity can be decided by observing the
pressure drop across the air heaters.
%: &uring shut down' inspection is to be carried out to chec-
whether cleaning of plates is uniform.
): /f the drive stops during operation due to tightness of the stufng
boxes' then steam is to be isolated and stufng boxes are to be
loosened.
*: /f the soot blower does not stop' after the scheduled ** minutes'
the timing device to be chec-ed.
ANNUNCIATIONS:
;hen any one of the following annunciations appears' accept the
alarm. The alarm will get cancelled.
! RELEASE DELAY FAULT
This fault appears when ,A=! left or right side temperature
drops' but does not come bac- within 6@ seconds after the
respective drain valve is opened.
"! RELEASE FAULT A
/f during operation of ,A=! blowers' T!# T#1=#,AT2,# ,#3#A5#
0L 3#>T side is 0>>' <drops below "@@Gc: this annunciation
appears.
#! RELEASE FAULT B
/f during operation of ,A=! blowers' T!# T#1=#,AT2,# ,#3#A5#
0L ,/K!T side is 0>>' <drops below "@@Gc: this annunciation
appears.
$! R. PRESSURE DROP
/f during operation of ,A=! blowers' the ,A=! steam <?,!EA5T:
pressure drops below" J5?' this annunciation appears.
%! STEAM PROGRAMME TIME FAULT
This annunciation appears due to any one of the following
reasons.
a. &uring ,A=! steam (lling programmed with ?,! in auto or
partially auto mode' if ,A=! temperature release 0L in left
side and right sides do not appear within 9@ seconds after
?,! (lling programmed is 0L.
b. /f ,A=! ?,! (lling programmed is not completed within 7*
seconds after initiation.
c. /f ,A=! steam (lling programmed with auxiliary steam in
auto and partial auto modes if temperature release on in
left and right sides do not come within 6@ seconds after
auxiliary steam (lling programmed is 0L.
/f ,A=! auxiliary steam (lling programmed is not
completed within *@ seconds after initiation.
FD AND FANS
FORCED DRAUGHT AND INDUCED DRAUGHT FANS
INDRODUCTION:
The volumetric machines' which impart energy on air or gas' are
fans' blowers and compressors. Those devices developing a pressure
ratio <outlet to inlet pressure: up to .* is classi(ed as fans whereas
devices that could develop higher pressure ratios i.e. R .* is -nown
as blowers and compressors. ?ompressors are generally water cooled'
where as blowers do not have any arti(cial cooling arrangement.
>ans are generally classi(ed as centrifugal fans <radial fow fans:
and axial fow fans. ?entrifugal fans are subdivided as (xed blading
types and rotatable blading types. The following laws govern the
functioning of all the above types of fans however.
. ?apacity of a fan / s directly proportional to speed.
". !ead is directly proportional to the s$uare of the speed.
%. =ower is directly proportional to the cube of the speed.
THE AXIAL FLOW FANS IN TPS II:
The forced draught fans and induced draught fans for T=5//' stage
/ boilers were manufacturing and supplied by mEs -uhnle' -opp D
-ausch' west Kermany <--- of west Kermany:' who have developed
the (rst successful axial fow fans. They have (rst developed a type
fans and subse$uently introduced type A= since 96@.
GENERAL ARRANGEMENT OF AP FAN:
The A= type fan consits of the following components.
. 5uction chamber
". /mpeller housing
%. 1ain bearings
). ,otor with ad.ustable blades
*. =itch control units
6. Kuide wheel housing with guide vanes and
7. &ifuser
SUCTION CHAMBER:
The fan suction is made of fabricated walls' reinforced with
stifeners and its inlet is provided with wire mesh coverings. /t is
rectangular in cross section at the entry point and circular when it gets
connected to the impeller housing. An expansion .oint connects both
circular and rectangular shaped ducts. A manhole is provided to
facilitate easy access to remove intermediate shaft without disturbing
the motor. The suction chamber is provided with fanges for mounting
the shaft protecting tube and the coupling guard. The suction chamber
is the foundation through the directly transmitted to the foundation
through the supporting feet. 1oreover the inlet duct is of N3O shape and
also converged to fan impeller housing so that it can act as an in.ector.
IMPELLER HOUSING:
The casing is horizontally split to provide easy inspection and
maintenance for the rotor. An inspection door is provided assembling
and dismantling of blades without removal of impeller casing pro(led
hollow stifness are provided for routing oil pipe' cable for
instrumentation ect. The casing is supported on foundation through
support feet. The sliding supports at the feet of the inlet duct and of
impeller housing can slide free from clearances of the foundation. The
hub of the inlet housing can slide free from clearances of the
foundation. The hub of the inlet housing' core if the fan housing and of
the guide wheel housing' the pitch control mechanism in the difuser
core and the shaft protecting tube are insulated within to protect the
main bearings' pitch control mechanism ect. >rom high temperature
gases.
MAIN BEARINGS:
The rotor is supported by cylindrical roller bearings. An angular
contact ball bearing assembled along with cylindrical roller bearings on
the drive side absorbs axial thrust. The mono bloc- bearing housing is
bolted to the beating supports in the fan housing assembly. These
bearings are lubricated and cooled by a circulating oil lubricating
system. The shaft passages in the bearing housing are sealed of by
radial sealing rings with a labyrinth seal. An oil splash ring is provided
inside.
The centrifugal forces of the rotor blades and the forces released
by the pitch control are absorbed in antifriction bearings. >or this
purpose' the blade shafts are placed in the combined radial and axial
antifriction bearings' which are sealed of on both sides. Temperature
transmitters and vibration pic--ups are provided in the bearing
housing.
ROTOR WITH ADJUSTABLE BLADES:
%*%*%*%*%*ain shaft is a forged piece with a tapered end for
accommodating hub disc. 0ne end of fan shaft is connected to the
intermediate shaft and the other endI the impeller is mounted in an
overhung position. The hub has "% blade assemblies' which are (xed'
on its periphery. #ach blade assembly consists of a blade' blade shaft'
blade shaft bearing and a cran-ing lever. #ach blade assembly is
rotated freely on its shaft bearing. All the blades assemblies are
connected to a slide pad <ad.usting disc:. /t is a disc with a groove in
its periphery. 5uitable rotating units are (xed to these grooves on the
periphery where cran-ing levers of all blade shafts get connected.
;hen slide pad moves horizontally' than this horizontal movement is
converted into rotary movement of blades simultaneously.
PITCH CONTROL UNIT:
The pitch control system comprises of a hydraulic servomotor
and an external actuator connected to hydraulic servomotor. The
hydraulic servomotor consists of a cylinder assembly and piston
assembly. The cylinder assembly' which houses piston assembly' is
mounted on the fan impeller hub. ;henever fan rotates' the cylinder
assembly also rotates.
The piston assembly consists of a control rod' a control slide on a
piston integrated with slide pad. The control rod is of stepped shaft
with three drilled holes in its axis. 0ut of three holes' own to supply oil'
other is to return the oil and the third is to collect lea-age oil. This
control rod is -ept on bearings' which are housed inside the control
slide so that it can slide inside the control slide freely. This control rod
can be actuated axially from outside through suitable mechanical
lin-ages by an #lectrical actuator <motor:. /t can also be operated
manually at local. The oil lines' i.e. supply oil return oil and lea-age oil
to control rod are made through fexible hoses. The control slide is a
hollow shaft with internal steps so that oil can be admitted and
returned from any side of the piston chambers. The control slide is an
internal part of piston assembly.
OPERATION OF PITCH CONTROL UNIT:
The hydraulic servomotor fanged to the impeller hub and
rotating with it ad.usts the blades during operation. This results in a
closed fux of force between ad.usting force and oil pressure so that no
forces are released to the outside components bearings' housing'
foundation etc. &uring ad.ustment of blades' the translation movement
of servomotor piston is converted into rotation of blades shaft through
the cran-ing levers in order to enable to set blades at various angles.
The restoring moment of the blades results from the rotating
blades. The oil pressure in the servomotor counters them. ;eights at
the blade shafts partly compensate the restoring moments. The
movement of non-rotating control rod in the control slide to initiate the
blade ad.ustment re$uires only small $uality of forces.
The moment of blades otherwise varying the pitch of the blades
is efected in accordance with follow up principle. ;hen the electric
actuator causes the movement of non-rotating control rod in any
direction horizontally' then movement of the control rod is followed up
by the piston cum control slide and slide pad in same direction
resulting rotation of blades.
?ontrol oil conveyed by the oil system reaches the control rod
through a fexible hose at a pressure of @-" ata. ;hen the control
rod is moved towards left axially' the right side control edges admit oil
to the right side of the piston. 5imultaneously control oil in the left
side chamber <ad.acent to the impeller end: fows via the control rod
into the return lines to the oil reservoir. Low oil enters the right
chamber further and moves the ad.usting piston to the left until the
control edges of the control slide and control rod comes to original
position again so that no pressure oil is admitted to the right side
piston chamber and no pressure oil is drained from the left side piston
chamber.
5imilarly if the control rod is moved towards right' to left control
edges of the control rod will admit oil to the left chamber <ad.acent to
the impeller: and ad.usting piston moves towards right until a state of
e$uilibrium prevails again. The ad.usting slide pad (rmly connected to
the ad.usting piston transfers its to and fro motion as rotary motion to
the blade shafts.
The hydraulic ad.usting device and the oil unit from one system
pitch control cannot be efected either in automatic operation or
manually without control oil pressure. /f oil supply is interrupted' then
blade position will be retained. +lade positions are shown on the
graduated plate outside the fan. The angle of incidence of air to the
blades can be varied from F)@S to T"S
OUTLET GUIDE VANE UNIT:
/t is a fabricated and machine casing with guide vanes.
This unit is also (xed along the axis and connected to the impeller
casing as well as difuser assembly through fexible .oints. This unit
prevents damages to the fan that may arise when the fan is operated
in the stalling zone.
DIFFUSER:
This is also a fabricated assembly with ribs and fanges. /t is
supported on the foundation plates through welded feet. /t consists of
a casing and core. This assembly is isolated from the ducting by
means of fexible .oints. &oors are provided in the core for inspection
of servomotor' lin-age assembly and oil pipes etc.
RIGIFLEX COUPLING:
The fan shaft is coupled to motor shaft by rig fex coupling. This
is of an all steel coupling designed for in accuracies in assembly or
during operation li-e shaft misalignment thermal expansion' this type
of coupling enables easy alignment during installation. =arts that wear
out are not there and no lubrication is warranted. !ence little
maintenance is needed. 1oreover it is capable of withstanding
temperatures up to "7@S?.
/nduced draught fans handle ash laden fue gases and ash
erosion increases with fue gas velocity. 5o' /.&. >ans are generally run
at a lower speed compare to >.&. >ans and an erosion resistance
material is chosen for /.&. >an blades. 5tresses acting on the /.&. >an
rotor become more with high ash concentration and there is a
possibility of /.&. >an blades being sub.ected to sulphur*ic acid
corrosion. !ence the blade material for these fans should have the
property to resist corrosion as well as erosion and the material chosen
is Lodular /ron KKK )@ or Klobular graphitic cast iron' the corrosion
resistance of which is higher than that of steel.
1oreover' this is more easily cast able than steel and mould
(lling properties are decisively better. &ensity of this material is lower
than that of steel' which results in the rotor being sub.ected to lower
loads. This factor contributes to increased life of blade bearings' which
have to absorb axial thrust resulting from centrifugal forces. /t has also
been found that this material is better than steel for ta-ing up vibration
loads.
LUBRICATION AND CONTROL OIL SYSTEM:
The hydraulic servomotor and the fan bearings are supplied with
oil at diferent pressures from a common oil reservoir. #ach oil system
is provided with two gear pumps of which one will be in services and
the other will be standby. These pumps deliver oil at a pressure of
"@-gEcmU". /n the discharge line of each pump' a pressure relief line
<valve: is provided and this is .oined and this is .oined bac- to the oil
reservoir.
5ince the response time of this pressure relief valve is high' it
will not be able to absorb the pressure pea-s during initial starting of
the pump or the operation of pitch control unit. !ence to serve as a
vibration dampener in such circumstances' the system is additionally
e$uipped with a pressure reservoir' which is mounted in the oil system
before the coolers.
=umped oil is now diverted to oil coolers. Two oil coolers are
provided in each oil systemI one in services and the other reserve.
The oil cooler is of two-pass design in which auxiliary cooling water
fows through tubes and oil fows through shell side. Three way valves
provided at the inlet and outlet of the cooler and operated by a
common lever diverts oil to any of the cooler. Auxiliary cooling water is
tapped from the main bus through a hand operated valve and is
divided into two' and is connected to the cooler with inlet valve. The
outlet from cooler through a valve is ta-en and two outlets combine to
form a common line. A fow meter cum fow switch with isolation valves
are provided in the outlet line before it .oins the auxiliary cooling water
return bus.
0il from cooler is then diverted to thin (lter arrangement. The
(lter has a diferential pressure indicator' which will slowly change
from blue to red with increase in contamination. The display will slowly
change from blue to red with increase in contamination. ?hange over
of (lter can be efected with the help of a lever and the position of the
lever tells which (lter chamber is in use.
After the (lter' the oil fows in two channels' one to the control
oil system and the other for lubrication of bearings. A throttle valve
controls the pressure and oil fow in the lubricating oil system.
3ubricating oil supplied to the bearings returns through a reservoir
through a return line provided with a sight glass. The control oil
supplied to =?2 returns through a return line and through lea-age oil
returns line. Miew glasses are provided in these lines. An ori(ce is
provided in the control oil return line to restrict return oil fow thus
reducing pressure fuctuations in the system.
COOLING AIR FANS:
5ince induced draught fans handle hot gases' i.e. at *@ deg.c.
/& fan bearing housing' oil servomotor are exposed to high
temperature. /n order to provide ade$uate cooling' two cooling air fans
are provided for /& fan of the two' one in service and another is in
service and the other stand by draws an atmospheric air and supply
cooling air to bearing housing as well as to oil servo motor unit.
SILENCERS:
Loise is also a form of pollution. ?ontinuous exposure to high
noise levels may afect the hearing ability of operating personnel.
Therefore to muVe the noise levels' silencers are provided in suction
and discharge ducts of >& fan and in discharge duct of the /& fans.
The silencer for the /& fan is constructed in 6 parts each of
width %@@mm standing vertically li-e walls. #ach part is constructed
with three pieces. The construction of each part is as under.
0n one side of the partition plate' nine inclined plates are
provided pac-ed with glass wool and covered by a perforated plates
and six inclined plates are provided li-e wise in the other side.
The six parts of the silencer are arranged at 7@8mm pitch'
which allows sufcient glass fow. /n the entry point of the silencer a
semi circular plate is provided and a trapezoidal plate is provided in
the exit side. The silencer is positioned in the horizontal portion of the
/& fan discharge duct after the discharge damper. The height and width
of gas duct at this section is )8*@mm to )%*@mm respectively. The
a$uatics property of the glass wool helps to bring down the noise level
to minimum.
The silencer in the suction duct of >& fan is of eight parts and
that in the discharge duct is of four parts. #ach part is of a single piece
in the case of >& fan and the general pattern of construction is similar
in other respects to the silencer provided for /& fan.
OPERATION OF FANS:
The following chec-s are to be carried out before starting the fan
after shutdown.
PRECHECKS
#nsure that no line clear is pending on the fan and its
concerned e$uipments.
. >an housing and in the suction duct. Ascertain that no tools and
foreign materials have been left around the
". ,elease local latches for fan lubricating oil pumps and for cooling
air fan and main fan.
%. Ascertain the availability of local emergency trip switch.
). Merify the direction of rotation of fans' pumps' and blowers if any
defect is attended in the cables.
*. ?hec- the rigidity of all ducts and tightness of fanges.
6. #nsure proper coupling between motor and fan' motor and
pumps.
7. #nsure proper lin-ages between the actuator and pitch control
device.
8. ?hec- the availability of auxiliary cooling water' its pressure and
temperature.
9. ?hec- the lubricating oil colors in the tan- for any contamination.
@. ?hec- the 3ub oil tan- level and top up if necessary.
. ?harge the oil coolers and -eep them ready for operation.
". ?hec- the availability of all instruments for its contact
settings and their cold state values.
%. #nsure smooth operation of all dampers from 2?+ and also
at local.
). Avail power supply to fan drive' 3op drive and cooling air
fan drive.
*. 5tart any one cooling air fan and chec- for its smooth
operation.
6. 5elect and start one lubricating oil pump.
7. ?hec- the lubricating oil pump motor for any spar-'
vibration' noise etc.'
8. ?hec- the pump discharge pressure' charge oil in coolers
and (lters.
9. Merify diferential pressure of oil across oil (lters.
"@. ?hec- for any oil lea-age in the 3ub and control oil pilings.
". ?hec-s are to be done for correctness in
"". ,adial blade gap between blades and rotor hub.
"%. Kap between blades and rotor housing.
"). Axial gap between rotor and hub.
"*. Kap between impeller and difuser core.
"6. ?hec- the control oil pressure and 3ub oil pressure. /t
should not be " bars and "-".* bars respectively.
STARTING OF FAN:
The start up procedure for >.&. fan and /.&. fan is very similar.
The following is the se$uence that may be followed in starting the fan.
. The discharge damper of the fan <A& or K&": is to be
closed.
". The fan blades should be -ept in minimum position.
%. Any one cooling air fan is to be started for /& fans only.
). Any one lubricating oil pump is to be started and chec- for
*. 3ub oil pressure R.* bar
6. ?ontrol oil pressureR 8 bar.
7. &iferential pressure across (lterR." -sc.
8. The 3ub oil temperature before and after the cooler is to be
chec-ed.
9. /t should be ascertained that 3ub oil tan- level is R
minimum.
@. The damper A&%E" in case of >& fan and K& in
case of /& fan should be opened.
. ,elease the bra-e manually.
". 5tart the main fan.
%. The damper A& or K&" must be opened within %@
seconds after the fan has reached full speed
). Then the fan blades are to open according to the
re$uirements.
CHECKS DURING OPERATION:
,egular and systematic chec-s during operation of a fan ensure
smooth and efcient operation of fans.
. ?hec- the fan motor and fan for any undue noise' vibration.
". ?hec- the oil level in the lubricating oil tan-.
%. ?hec- the oil system for any oil lea-ages.
). ?hec- the lubricating oil pressure after the pump' after (lters' in
lub and control oil lines.
*. ?hec- the lubricating oil temperatures in the reservoir' before
the cooler' after the cooler.
6. ?hec- the diferential pressure across oil (lters.
7. ?hec- the oil for any contamination.
8. ;atch the bearing temperature at motor and fans.
9. ?hec- for e$ual loading of both the fans.
@. ?hec- the fan for loading corresponding to its blade
position.
. ?hec- the auxiliary cooling water fow of the oil coolers its
pressure and temperatures.
SHUT DOWN OF FAN:
The fan may be stopped only after gradual unloading. The following
se$uence of operation are to be carried out incase of stopping a fan.
. +ring the fan blades to minimum position gradually in manual
mode.
". 5top the fan.
%. Apply bra-e when speed drops below *@ rpm.
). ?lose the discharge damper of the fan.
*. 5top the lubrication oil pump when all three bearing temperature
reaches less than *@G?.
6. 5top the cooling air fan when all bearing temperature drops to
less than **G?.
7. /solate auxiliary cooling water supply to oil coolers.
PRECAUTIONS DUERING OPERATION OF AP FANS:
The inlet volume capacity <volume of gas or air handled by the
fan: is too low' stalling will ta-e place. 0peration on such condition
loads to increased loads acting upon the blades. /f the inlet volume
capacity is too little' the fed in power may result in non-permissible
heating of the fans. 5o' we should not operate the fans with too little
air or gas inta-e. /t is also not advisable to operate /.&. fans and >.&.
fans with the twisted blades in closed position.
The fans can be started with closed dampers. +ut continuous
operation with closed dampers is not permissible since with tight close
dampers' the inlet volume capacity becomes zero. !ence after
starting the fan' the dampers should be opened as soon as the fan
attains the operating speed. The rotor blades are to be opened to the
desired extent. 0pening of the dampers should be timed in such a way
that they are opened fully not later than one minute after the fan has
reached full speed.
PARALLEL OPERATION OF THE FANS:
. 5tarting the second fan and paralleling it with the running fan.
". ,unning fan should be brought to manual control.
%. +lade angle of running fan should be chosen in such a way that it
develops a leader pressure that that of the incoming fan.
). /ncoming fans should also be set under manual control.
*. ;ith closed blades' incoming fan should be started.
6. After reaching the full speed' discharge damper of incoming fan
is opened.
7. +lade angle in both the fans are manually ad.usted to share the
load.
8. After the above operations' both the fans can be put in automatic
operation.
STOPPING ONE OF THE TWO RUNNING FANS:
.+oth the fans are to be set to manual operation.
".0utgoing fanOs blades are closed gradually.
%.discharge damper of outgoing fan is closed.
).0utgoing fan can then be stopped.
*./f necessary the running fan can be put in automatic operation.
F.D.FAN&S OPERATING CONDITIONS:
0=#,AT/LK =0/LT W
5.L
0
&#5?,/=T/0L 2L/T @*T"
*
@@T
"*
@* @@ 8@ 6@ 6@
. >anOs in
operation
Los. " " " " " "
". ?apacity 1XEsec *9.7* *@.
6)
"6.
%
9.
@
9*.8
88
78.8
*
6).9
%. /nlet =ressure
<Absolute:
+ar .99)% .
99)%
.997 .
998%
.@@

.@@
"
.997
). /nlet
Temperature
G? )".% )"." %9.) %9.) %9.) %9.) %9.)
*. 5peci(c
;eightE&ensit
y
JgEmX .@@7 .@@
7
.@9 .@9 .@9
%
.@9
*
.@8)
6. Total =ressure 1ill 66.8 6".% )). ).* %).8 %@.* *9.9
,ise bar * " 7 9
7. &elivery
!eadE/sentropi
c !ead
LmEJg 6@@) *66" %98% %7*7 %)) "79 *)@
8. =ower
absorbed at
fan shaft
J; "6* @9@ 6%6 *7@ )@@ %@% )7
COMMON OPERATING CONDITIONS:
.1edium !andled -Air
".0perating 5peed -)8@ ,=1
%.,e$uired driving =ower -)@@ J;
).?ontrol 0il =ressure -@ to " bar
*.3ub 0il =ressure -".* +ar
6.3ub 0il Temp at ?ooler outlet -)@ to )*X? <1ax.7@X?:
7.0il ?harge -6%@ 3iters
8.&irection of rotation
as seen towards the inlet -?ounter ?loc-wise.
I.D.FAN&S OPERATING CONDITIONS:
0=#,AT/LK =0/LT W
5.L
0
&#5?,/=T/0L 2L/T @*T"
*
@@T
"*
@* @@ 8@ 6@ 6@
. >anOs in
operation
Los. " " " " " "
". ?apacity 1XEsec "99.7* "8).
9*
"%8.
6
""7.
*
8*.
8
8.
*
%@7
%. /nlet =ressure +ar .968 .97 .978 .98 .998 .99% .97
<Absolute:
). /nlet
Temperature
G? 6) 6) )9 )9 )6 ) %7
*. 5peci(c
;eightE&ensit
y
JgEmX .7)% .7)* .778 .779 .79 .8@6 .79*
6. Total =ressure
,ise
1illiba
r
)7.@6 )%.%
%
%".7
*
%@. ".9
6
6.@
8
)%.7%
7. &elivery
!eadE/sentropi
c !ead
LmEJg 6""6 *7"9 )*9 %8"" "7*% 98% *)%
8. =ower
absorbed at
fan shaft
J; *9) )@% 9%% 8%6 *8) ))6 **"
COMMON OPERATING CONDITIONS:
.1edium !andled ->lue Kas
".0perating 5peed -99@ ,=1
%.,e$uired driving =ower -7*@ J;
).?ontrol 0il =ressure -@ to " bar
*.3ub 0il =ressure -".* +ar
6.3ub 0il Temp at oil ?ooler inlet -)@ to )*X? <1ax.7@X?:
7.0il ?harge -@@@ 3iters.
8.&irection of rotation
as seen towards the inlet -?ounter ?loc-wise.
FANS-TROUBLE' CAUSE AND REPAIR
,02+3#
?A25#

,#=A/,
.5in-ing 0il
=ressure
.>ilter dirty
".3ea-ages in 0il system
%.Too high oil
temperature
).Lo oil in return line
*.&amaged pressure
?hange 0ver (lter ?lean
(lter
5eal lea- areas' replace
sealing elements.
Tighten duct screwings.
?onnect ?ooler. chec-
the cooling efect of
coolers.
?hec- the oil level in the
reservoir. Add more oil'
chec- that there are no
lea-s.
?hange over and clean
(lter.
?hec- the suction efect
of the pump.
#xchange and reset the
relief valve valve.
>ully open the valveI
slowly tighten the
setting screw until the
original oil pressure has
been set.
". !igh bearing
temperature
oil temperature in
reservoir too high
". 0il too viscous
%.?oolant temperature
extremely high
?onnect cooler
?hange oil' 2se
speci(ed oil
/ncrease cooling water
%. 2n$uiet
running
.2nbalance due to
deposits at rotor
". 2nbalance due to wear
on one side of blades
%. /ncreased bearing
wear.
). Alignment not correct
foundation yields.
,emove deposits
,eplace blades.
?hec- bearings' ,eplace
bearings if necessary.
,e-align
). Temporary +earing clearance too ,eplace bearings
un$uiet ness large
*.Mibrations Ascertain from
fre$uency
?larify whether it is
a case of forced
vibrations or of
resonanceOs with the
foundation.
+lade ad.ustment
.ammed.
).connection
between blades and
servomotor
interrupted.
?hec- blade bearings
,eplace defective
parts.
&ismount servomotor
chec- ad.usting disc
and lever.
6.2n$uiet running +earing ?learance too
large.
?hec- +earings.
,eplace bearings.
?hec- motor bearings
also.
7.3ub 0il =ressure Lo ori(ce in the
control oil returns
line.
=ressure reservoir no
longer operable
1ount ori(ce in the
control oil return line.
?hec- Litrogen charge'
if re$uired add Litrogen
or replace charge.
8.!igh =ressure hoses
at servomotor torn.
.?ontrol slide .ams. &ismount control bush
and control slide'
replace them. chec-
control bush' control
slide' piston rod with
piston for truth of
rotation.
9.0il losses seal at servomotor
defective front seal
inner seal.
5haft seals at main
bearings untight.
3ea-s in the oil
system.
,eplace seal &ismount
servomotor replace
seal' clean impeller.
1ount spare seals
5eal the lea- areas'
tighten
screwings'replace
sealing rings if
necessary.
@.;ater in the oil .0il cooler untight #xamine cooler'replace
cooler tubes or cooler if
necessary.
REGULAR MAINTENANCE OF THE FAN:
. After *@@ operating hours or at least once in every three months.
". ?lean oil (lters and chec- oil. /f water is found in the oil' separate
it' (nd its cause and eliminate it. ?hange the oil (lter when
dirtiness is indicated. ?lean the oil (lter part concerned.
%. After "@@@ operating hours or at least once in every six months.
Tightening of all (xing bolts.
). After )@@@ operating hours or at least once in a year. ?hec-
entire all charge' re(ll if re$uired.
*. After @@@@ operating hours.
6. ?hec- the rotor.
7. ?hec- servomotor and blade actuator.
8. ?hec- the coupling.
9. ?hec- alignment and tolerance' (rst without dismantling the fan.
@. /f there are no problems' continue the operation. 2nder
normal operating conditions' overhaul the fan between @'@@@
and 8'@@@ hours.
Note:
>ixed intervals for chec-ing the vanes' blades cannot be given'
as their wear mainly depends on the solid matter contents of air or
gas. /t is recommended to chec- vanes and blades for wear at
occasional operation standstills.
The two pillow bearings at the ad.usting shaft are to be regressed
during the inspection by means of a grease gun.
DATA SHEET:
FORCED DRAUGHT FANS:
Lumber of >.& >ans per boiler CTwo
1anufacturer C1E5 Juhnle' Joop and
Jausch' Kermany.
Type CAxial pro(led balding
>an A=
"@E"E"%
A=- Axial
pro(led
-5ingle stage
?apacityC /n parallel operation C *9.7*mXEhr
=ressure developed C 66.8 m bar
?apacityC /n single fan operation C 6).9 mXEsec
=ressure developed fan operation C *9.9 m bar
?apacity >or "@1; load C 9 mXEsec
=ressure developed for "@1; load C ).*7 m bar
,otor diameter C "@@@ mm
!ub diameter C "8@ mm
Lo. 0f blades on the impeller C "%
+lade material C >orged aluminum alloy
Al 1g 5i > %"
?hemical composition C 1g @.6 to ."W
5i @.7* to .%W
1n @.) to .@W
?r @ to @.%W
>e @.*W
?u @.W
Yn @."W
Ti @.W
DRIVE MOTOR:
=hase C %
Moltage C 6.6 -M
0utput C )@@ J;
5peed C )8* rpm
?urrent C )* amps
=ower factor C @.9
#fciency C 9)W
;eight C @.% tonnes.
FD FAN LUB OIL SYSTEM:
Lumber of reservoirs per fan C 0ne
0il charge C 6%@ liters
0il C Turbine oil
Miscosity C )% to 68 ?5T at )@G?
Lumber of 3ub oil pumps C Two
Type of lub oil pumps C Kear pump L, E@
?apacity C @* liters per minute
&elivery pressure C "@ bar
?ontrol oil pressure C @-" bar
3ubricating oil pressure C "-".* bar
DRIVE MOTOR:
=hase C %
Moltage C )* M
0utput C *.* J;
5peed C ))@ rpm
?urrent C @.) amps
=ower factor C @.8*
#fciency C 86."W
1ounting C Mertical
LUBRICATING OIL PROPERTIES:
3ub oil $uality C 3-T& 68
Miscosity class C /50 MK 68
Miscosity at "@G? C "@@ mmZEs
Miscosity at )@G? C 6." to 7).8 mmZEs
Miscosity index C 1inimum 9*
=our point C -6G?
>lash point as per ?leveland C 1inimum "@*G?
;ater contents C [ @. gmE@@ ltrs of oil
5olid foreign matter C [@.@* gmE@@ ltrs of oil
&ensity at *G? C @.9 gmEml
INDUCED DRAUGHT FANS:
Lumber of /& >ans per boiler CTwo
1anufacturer C1E5 Juhnle'Joop and
Jausch'
Kermany.
Type CAxial pro(led balding
>an A=
%@E"@E"%
A=- Axial
pro(led
-5ingle stage
?apacityC /n parallel operation C "99.7*mXEsec
=ressure developed C )7.@6 m bar
?apacityC /n single fan operation C %7@ mXEsec
=ressure developed fan operated C )%.7% m bar
?apacity >or "@1; load C ""7.* mXEsec
=ressure developed for "@1; load C %@.@ m bar
,otor diameter C %@@@ mm
!ub diameter C "@%@ mm
Lo. of blades on the impeller C "%
+lade material C 5pherolitic ?ast /ron
<Lodular /ron KKK )@:

?!#1/?A3 ?01=05/T/0L C ? %.) to %.8
5i ".@ to ".*W
1n @. to @.%W
= @.@" to @.@*W
5 @.@W
1g @.@) to @.@6W
Li @ to @.@*W
DRIVE MOTOR:
=hase C %
Moltage C 6.6 -M
0utput C 8@@ J;
5peed C 99@ rpm
?urrent C 9* amps
=ower factor C @.8*
#fciency C 9*W
;eight C .9 tonnes.
ID FAN LUB OIL SYSTEM:
Lumber of reservoirs per fan C 0ne
0il charge C @@@ liters
0il C Turbine oil
Miscosity C )% to 68 ?5T at )@
Lumber of 3ub oil pumps C Two
Type of lub oil pumps C Kear pump L, %E@
?apacity C "@) litres per minute
&elivery pressure C "@ bar
?ontrol oil pressure C @-" bar
3ubricating oil pressure C "-".* bar
3ubricating oil temperature C )@- )*G? < maximum
7@G?:
DRIVE MOTOR:
=hase C %
Moltage C )* M
0utput C J;
5peed C )6@ rpm
?urrent C "@.6 amps
=ower factor C @.8)
#fciency C 89."W
1ounting C Mertical
COOLING AIR FAN:
Lumber of cooling air fans per /& fan C Two
?apacity C "88@ mXEhr
=ressure developed C "69 -gEmZ
DRIVE MOTOR:
=hase C %
Moltage C )* M
0utput C ).7 J;
5peed C "8"@ rpm
?urrent C 8.8 amps
=ower factor C @.9
DRAUGHT SYSTEM
INTRODUCTION:
To have uninterrupted and intensi(ed combustion in the
furnace' enough air is to be supplied and the products of combustion
have to be removing efectively and continuously. The $uantity of air to
be supplied and the amount of products of combustion to be exhausted
from furnace depend on the steaming rate of the boiler' which in turn
depends on the $uantity of fuel consumed in the boiler per hour.
?reating a pressure diference' which is called draught' can ma-e the
movement of air or gas. /f this draught is caused naturally by the
provision of a chimney alone' it is called natural draught and if it is
caused arti(cially with the use of fans' it is -now as arti(cial draught.
They should be sufcient enough to create the re$uired air or gas fow
and also to over come the frictional losses in the system.
/n a natural draught system' the draught depends on the
height of the chimney and the density diference between the clod
atmospheric air and the hot fue gas leaving the chimney. ;ith
increased boiler capacities' the draught re$uirements are also more.
!ence' adoption of natural draught for high capacity boilers may not
be feasible' since it would warrant a very high chimney or the need to
-eep the temperature of outgoing gases at a very high level. The
former involves increased initial cost and the latter causes increase in
operational losses. !ence' arti(cial draughts are employed in all high
capacity units.
Arti(cial draught systems created with the help of fans may be
classi(ed as forced <pressure creation: or induced <vacuum creation:
types. ;hen both the above systems are combined' it is called
balanced draught system' in which' the difculties of both draught
systems are eliminated are draught generators in modern power
stations.
The fans used may be centrifugal fans efciency than the
centrifugal fans though their cost is also more. Among the diferent
power station auxiliaries' fans consume considerable auxiliary power
next to the feed pump. 5aving on auxiliary power consumption can be
efected with the use of efcient fans and careful design of furnace and
heat transfer element to practice' axial fow fans with variable blade
angles are employed to achieve a high efciency at all loads.
FANS:
/n neyveli thermal power station F //' a balanced draught
system is #mployed with two forced draught fans and tow induced
draught fans' both if which are axial fow type.
FORCED DRAUGHT FANS:
#ach forced draught fan is capable of supplying *'7*'@@mcube
air per hour at a pressure of 66.8 millibar <66.8U@."mm of water
column:. At 1.?.,. each fan is re$uired to supply only )'"8')@@mcube
air per hour <9mcube Esec: at a pressure of ).*7 millibar at %9.)G.
The >.&. fans are of A=/- "@E"-"% types. #xplanations for the
nomenclatures of the type are as under.
A F Axial fow
+ - pro(led blading
F single stage
"@ F peripheral diameter in decimeter
" F hub diameter in decimeter
"% F number of blades
INDUCED DRAUGHT FANS:
The induced draught fans are of A=/ F %@E"@-"% type
and are capable of discharging at the rate of
@'79'@@metercubeEhour. <"99.7*metercubeEsec: at a pressure of
)7.@6 millibar. +ut at @@W 1.?.,. each fan is re$uired to discharge
8'7'7)@metercubeEhour <""7.*metercubeEsec: at a pressure of %@.@
millibar. +oth >.& and /.& fan are having variable pitch control blades
for regulation of output efectively and economically.
STEAM COIL AIR PREHEATER (SCAPH!:
At the discharge side of each >.&. fan' four steam coil
air preheaters are arranged in two sets' in series' each set consists of
two 5?A=! section one at the right side and an other at the left side of
the discharge duct. Two isolation dampers provided for the 5?A=! on
each side' help to divert the air through 5?A=! or to allow the air
through the sections in between the 5?A=!. The dampers are -ept
fully opened during normal operation and closed or partially opened
during initial lighting up and oil (ring.
5?A=! consists of N 2 N shaped horizontal coils
through which steam at 7."-gEcm s$ pressure and ""@ G temperature
fows. /ts direction of fow is as from the boiler front to rear. 0utside the
tube' air fows in a counter fow pattern and gets heater up' before it
reaches ,A=. The 5?A=! is designed to heat air from *.6 G to %9.) G
at @@W 1.?.,. And to 8@ G at %@W 1.?.,. <which oil (ring only:.
. Air inlet pressure at 5?A=!C - %%.* millibar
". Air pressure drop across 5?A=!C - %.% millibar
REGENERATIVE AIR PRE ) HEATER (RAPH!:
The combustion air after 5?A=! goes to the
regenerative air preheated of the 3 .ungstrom type for further
preheating. #ach boiler has two ,A=!' each one of which is placed in
the discharge duct of the respective >.&.fans. The air is heated up from
%9.) G ? to "86G ?. The ,A=! heating elements rotating at a slow
speed of " ,=1 ta-e heat from the hot fue gases moving downwards
and convey it on to the air moving upwards. Though air heater is
provided with necessary seals' there will be some <8W: air lea-ages
into the gas stream.
&ATA relating to air and gas fow and air pressure in
the system are as under.
<MA32#5 AT LT=:
Airfow before ,A=!
7')9'8*@metercubeE!r
Airfow after ,A=!
6'9)'8@@metercubeE!r
Kas fow before ,A=!
@'@"'76@metercubeE!r
Kas fow after ,A=!
@'*7'8@metercubeE!r
Air pressure before ,A=! %@." millibar
Air pressure after ,A=! ".* milli bar
The centerline of the ,A=! lies at "7-meter level. /f
has a bypass duct' which is made use of' during the starting up' to
minimize the efect of cold and corrosion. The bypass duct has an
isolating damper <four faps' " in each damper shaft: at %".*-meter
level and .oins the hot air distribution duct at %6.9-meter level. There is
an isolating damper also in the ,A=! hot air discharge duct' at %".*-
meter level <8 faps' two in each of the 9 shafts:.
HOT AIR DISTRIBUTION DUCT:
The hot air from ,A=! goes to the hot air
distribution duct' which is arranged at %6.7 meter level in two box li-e
sections' one at the left side and the another at the right side and are
interconnected by a duct' of diameter "7"@ mm. The ,A=! bypass
duct also .oins this hot air distribution duct. The interconnecting duct is
provided li-e a 2 bend to give the room for the hot fue gas duct
coming horizontally at this elevation. >rom the hot air distribution duct'
tapping are ta-en for the secondary air' mil hot air and air to oil
burners. Krate air and mill sealing air tapings are ta-en from the 2
interconnection between the hot air distribution ducts.
MILL HOT AIR:
1ill hot air at a temperature of "86G ? is used to
temper the hot fue gases' which is at a temperature of @*.8G ?.
Thus the fue gases which is at a temperature of @*.8G ? Thus the
fue gas and hot air mixture going through the resuction duct is bought
to a temperature of 8)G?.
1ill hot air is ta-en from hot air distribution duct at a
%9-meter level elevation' through 6 ducts of @6 mm diameter and
.oins the respective resuction ducts at %9.8-meter level. #ach duct is
provided with a venture type fow meter. At %8.6-meter level' the cross
section of the duct reduces to 6@@ mm \ pneumatically operated
damper is provided to regulate the mill hot air fow.
The hot air is supplied at a pressure of 7.%-milli bars
and at a temperature of "86G ?. Lormal fow rate for mill hot air is
".866 -sc. And the duct can handle a maximum fow of 7." -sc.
;ith only ) mills at a service at 8@W load' each hot air duct gets
divided in to six circular ducts of )@6.)mm diameter and .oins the
starting point of the elliptical resuction duct at 6 points' % on each side
through a distribution piece shaped li-e a horseshoe. This type of
arrangement ensures the uniform mixing of hot air with the fue gas.
SECONDARY AIR:
#very mill feeds two p.f. +urners' one at "@
meters elevation and the other at "7-meter elevation. 1a.or portion of
combustion air is supplied as secondary air to the above p.f. +urners.
5econdary air is ta-en from hot air distribution
duct at %6.9-meter elevation' through six ducts <for six mills: of
9"@mm diameter' three on each side of the furnace. #ach duct has a
horizontal travel at %6.9-meter level for a certain distance' ta-es a
bend and descends. At a point before it ta-es a turn' a venturi type
foe meter is provided.
The duct is provided with an inner plate portion
from %)-meter level onwards. At %%-meter level' a two-fap gang
operated regulating damper is provided. The fap in one portion
regulates air admission to the top p.f. +urner at the top elevation and
the other fap serves similarly for the p.f. +urner at the bottom
elevation. The above damper is pneumatically actuated type.
The duct with its portion extends up to and .oins
the distribution box at "9.*-meter elevation' causing two sections in
the box itself. The secondary air distribution box with a rectangular
cross section reduces in cross section from top to bottomI this
arrangement helps to maintain a uniform velocity throughout the
entire height of the distribution box.
Ten ducts leave the above distribution box' (ve for
the top p.f. +urner' and the other (ve for the bottom p.f. +urner. The
secondary air is distribution as under' by the above (ve ducts at
diferent points of a p.f. +urner.
Top p.f. +urner +ottom p.f.
+urner
Top air "8.6* 1.3. ".** 1.3.
Top primary mixing air "7.*) 1.3. "@.)) 1.3.
1iddle air "6.8@ 1.3. 9.7@ 1.3.
+ottom primary mixing air "6.@6 1.3. 8.@6 1.3.
+ottom air ").9* 1.3. 7.%*
1.3.
Top air is admitted through a rectangular duct
with two vertical partitions <% seconds:.
Top primary mixing air is admitted through a circular duct
and distribution through six pipes.
1iddle air is admitted through a rectangular duct and
distributed through three pipes.
The arrangement for the bottom primary mixing is similar
to the one provided for the top primary mixing sir.
>or bottom air' a rectangular duct is provided with a
horizontal partition. The top section <which is again divided into three
section by two vertical partitions: is utilized for admission of bottom
air. A damper is provided only in the top section' and the bottom
section is left free fow of a certain $uantity of air' when is termed as
cooling air.
The p.f. +urners is of double walled construction' and the
above said cooling air has an unrestricted fow through the chamber
formed between the two walls of the burner' and escapes at two
elevations' one between that of top air and top primary mixing air and
the bottom air. At each elevation' four pipes outlets are provided for
the escapes of cooling air' which is restricted by a partition at the
outlet of each pipe.
The rectangular ducts of top' middle and bottom air
connections are provided with an electrically operated damper in each.
Top and bottom primary mixing air ducts are circular in shape and have
a hand-operated damper in each and are set to fux optimum position.
5econdary air supplied at 7.%-millibar pressure and "86G ?
temperature at the rate of %6.)JgEsec. /ts pressure after the fow
meter throat is *.6 millibar.
HOPPER AIR:
#ach boiler has two after burning grates at 7-meter level' where
combustibles in slag are burnt. 5ir for the combustion of the lignite
particles in slag is supplied as hopper air' at the rate of ").9* JgEsec at
a pressure of 7.% millibar.
The hopper air duct of 6"@mm diameter is ta-en at "7-meter
level from the N2O shaped interconnection of the hot air distribution
duct. A venturi type fow-measuring element located at 7.)-meter
level is used to determine the rate of fow of hopper air. The circular
duct coming downwards' changes to an 8*@mm s$uare cross section at
6 meter level and is provided with a pneumatic operated diaphragm at
* meter level. The duct then divided into two 6"@mm s$uare ducts'
which go to left and right side grates respectively. #ach of these ducts
is provided with a hand-operated damper.
>ive distribution ducts leave the above duct. #ach of the two
end ducts of small cross section are divided into two ducts' and each of
the above six ducts are divided into two ducts again and connected to
the grate area. Thus the hopper air is supplied to the grate at 6
points
MILL SEALING AIR:
1ill sealing air is supplied at both sides of the mill. /n the
coupling end side' it is supplied at two points one on each side of the
shaft to provided efective sealing. /n the free end side' it is supplied
at three points at "@G interval in between dipper fange and beater
wheel' for the purpose of preventing beater wheel erosion due to the
abrasive silica in the lignite even through the centrifugal force of the
mill rotation itself will prevent beater wheel erosion' the above sealing
air admission is provided to serve as an additional protection and the
$uality of sealing air used for this purpose is a meager fraction of the
total air.
5ealing air duct of diameter 8% mm is ta-en from the N2O
shaped interconnecting duct of the hot air distribution ducts at "7-
meter level. The duct meanders down vertically up to meter level
and then divides into two <6@ mm diameter each: and go to the right
side and the left side of the boiler horizontal mills A.+ D ? get their
sealing air supply from the right side duct and mills >' # and & from the
left side duct. The diameter of this duct gets reduced from 6@ mm to
*@8 mm and then to )9 mm gradually after every tap of. 1otor
operated regulating damper are provided at 6.7-meter level for
regulation while service. 5ealing air pipe for the dipper fange has a
detachable piece to facilitate moving of the mill door away' when
maintenance is ta-en up in the mill.
OIL BURNER AIR:
The combustion air supplied to the oil burners on both sides is
speci(cally termed as oil burner air. >or supplying this air' two circular
ducts of 6"@ mm diameter are tapped' one from each side of hot air
distribution duct at %*.8-meter level. #ach duct travels downward and
divides into two <each of diameter "@ mm: at 8.)-meter level and
further meanders down up to "-meter level. Then' they ta-e a turn
and travel upwards to .oin the burner casing at 9 meter level. At 6-
meter level' a pneumatically operated isolating damper is provided in
each duct. Mentures are also provided in the ducts to measure the
airfow to the burner. Air is supplied at the rate of ".8% JgEsec to each
oil burner at "86G ? and its pressure before the fow meter is 7.%-miili
bar.
The oil burner air is distributed as primary air and secondary air.
=rimary air component entering through a 8@mm duct passes through
a concentric tube of )96mm' surrounding the burner gun. The primary
air $uantity can be regulated with the help of a hand-operated damper
and itOs usually set at an optimum permanent position. This air goes
through 8 stabilizer vanes near the burner tip and gives the vertex
motion for the primary mixing of oil and air. The secondary air
component passing through a 7)6-] 9*@ mm duct goes in the annual
space of width *".*mm. This air along with the primary air helps in
complete combustion of the fuel oil.
AIR DISTRIBUTION:
The total air supplied to the combustion system will be
distributed as followsC
: 1ill hot air "%.7"W
": 5econdary air 67.@8W
%: !opper air or grate air 9."@W
GAS PATH
FURNACE:
+oiler is having a single pass furnace with more or less' a s$uare
cross section. All heat transfer elements except air preheaters are
located in the furnace itself.
The furnace dimensions are as underC
&epth - front to rear - "'97* mm
;idth - left to right - "'8"* mm
!eight - - 8 meters
Molume - - '%@@ J5?
>urnace plan area - - 66.)m s$uare
The left and the right side of the furnace are vertically straight.
At 8m' meter level' the left and the right side of the walls ma-e 3
bend and .oin in a roof header at the top middle of the furnace. At the
bottom' the front and rear walls form a hopper portion from 6.* meter
elevation to 7.68 meter elevation' to facilitate collection of slag and
unburned lignite' over the beds of the after burning grates.
/n the furnace' the fue gas is traveling upwards. The gas fow is
opposed by the fy ash particles falling down' there by limiting the
velocity to 8.7 mEsec. 5ince the value of velocity is less than the
normal limit of @ mEsec.' the tubes are not much afected by ash
erosion. >lue gas reaches an 8-meter diameter fue gas duct through a
rectangular opening of ".8"*-meter ] 6.6 meter from the furnace. /n
this zone' rear evaporator wall tubes overlap each other to give way to
fue gas to escape.
5uper heater ' super heater %' reheater "' super heater "'
reheater and economizer are arranged one after another in the gas
fow path in the furnace.
The following essentials are (xed to the furnace in the related
areas and the evaporator tubes are suitably bent to accommodate
them.
: =ulverized fuel burners - " nos
": 0il burners - ) nos
%: ;ater soot blowers - %6 nos
): 5team soot blowers - )" nos. <T8 nos for future use if foun
necessary:
*: 3ignite fame monitors -) nos.
6: After burning grates <bottom: F no 0pening
7: ,esuction duct openings - 6 nos.
8: ,ear top opening for fue gas exit F no
9: 1an holes <)*@ mm \: - %6 nos
@: =eep holes <*@ U %@@ mm \: - " nos
: >urnace temperature measurement <at %7.) meter level: - "nos.
G*+ te,-e.*t/.e *01 2/.0*3e 4*3//, *t 156e.e0t 7o3*t5o0 50
t8e 2/.0*3e:

Lo3*t5o0 Te,- 50 1e9.3 V*3//, 50 M5775 :*.
: +efore 5!
": After 5!/
%: After 5!%
): After ,!"
*: After 5!"
6: After ,!
7: After economizer bottom
ban-
8: After economizer middle
ban-
9: After economizer top
ban-
@)7
96*
866
77"
*7
)**
%89
%%
*
%
@
.)
."
@.9
@.9
.%
".%
-
-
%.%
A4e.*9e ;/e 9*+ 4e7o35t< *t e*38 +t*9e'
Lo3*t5o0 Ve7o35t< 50 ,=+e3
. 5!/
". 5!%
%. ,!"
). 5!"
*. ,!
6. #conomizer middle
ban-
7.7
7.*
8.7
8.
8.@
*.)
HEAT RELEASE IN THE FURNACE:
The volume of combustion zone <i.e.: the volume below 5! is
*"8*-meter cube. !eat release at @@W 1.?., is ).9"7 ] @^8
-calEhr. heat release per cubic meter per hour is ''6@@ -cal.
<"8.@) -calEmeter cubeEsec.
FLUE GAS DUCT TO RAPH:
The fow path of fue gas from the furnace to ,A=! is as under.
: A ,ectangular opening of dimensions "8"* ] 66@@ mm is
provided at the furnace outlet' through which the fue gas leaves
then fows through a circular duct of 8 meter diameter from 6*
meter level to %8 meter level.
": At %8 meter level' it ta-es an NlO bend' changes to a rectangular
cross section of 8@@@mm ] 6%@@mm and travels to the rear.
At the rear' the above duct diverges to two ducts of cross
section 6%@@mm ] %%@@mm at a NTO .oint. These ducts travel
downward' .oining there respective ,A=! at "7-meter level.
/solating dampers' of 8 faps each' are provided in these ducts
at %)-meter level for the isolation of Air heater gas side. The above
damper has 9 shafts with " faps in each.
At the bottom of the circular fue gas duct' a big conical hopper
is placed and connected it to through an expansion .oint. The hopper
bottom is at "7.) meter level and is connected to a pipe of ash mixing
vessel at N@O meter level for the disposal of ash that may be collected in
the hopper.
The fue gas duct is supported by two cantilever hanging
supports with rectangular frame in the rear' one on either side. These
are actually the extension of horizontal roof girders. 1ultiple expansion
.oints in the ducts are provided with collapsible frames with aid in
uniform expansion and contraction and also prevent axial
misalignment. >lue gas velocity in the duct is @mEsec.
FLUE GAS IN RAPH:
/n the ,A=!' the fue gas gives out the heat to the
combustion air and the temperature of gas drops from %6G ? to )9G
? gas velocity is ).86 mEsec. And there is gas pressures drop of %.%
millibar across the air heater <fue gas vacuum increases from @.% to
"%.6 millibar:. The gas volume is increased from '@@"'76@ Lm
cubeEhr. to '@*7'8@ Lm cubeEhr. because of 8W lea-age of air in to
the gas stream. Let fow area of gas fow is "8.6) meter s$uare.
The air duct is in the front side and the gas duct is in the rear.
The centerlines of the air and the gas ducts are 6"@@mm apart. The
two-fue gas ducts after ,A=! travel downwards and then ta-e a 9@G
bend towards the rear at 7.@-meter level. #ach duct is divided in to
two and forms two inlets to each of the two streams of electro static
precipitator.
Two hoppers are provided at %.8 13 below the air heater gas
outlet ducts. The fy ash particles collecting here' go to the two ash
mixing vessels at N@O13.
FLUE GAS ELECTRIC STATIC PRECIPITATOR:
The boiler is provided with an #5= of streams' each stream
having 6 (elds in series along the gas fow direction. #ach (eld has 6
rows of collecting electrode plates forming 6@ gas passages.
At the inlet of each stream' the cross section of duct increases
from %m]%m to 9.8m]9.8m forming of funnel shape. This reduces the
velocity of the fue gas from ).)mEsec. At the inlet to .""mEsec in the
electrode zone. Two perforated gas distribution screens' which are
located before the electrodes zone uniformly' distribute the gas
throughout the cross section of the #=.
The overall dimensions of the #= are'
3ength along the gas fow %.7* m.
;idth %m.
!eight ""m
Ash loading in gmsEmU% of gas is %." with "Wash in lignite and
7.8*8 with 7W ash in lignite <design:. Ash collection efciency is 99W
with * (elds in service. =ressure drop across #D = as . mill bar.
Macuum before #= ").* millibar
Macuum after #= "*.6 millibar
/n the outlet also' a gas distribution screen is provided. The funnel
shaped outlet duct reduces in size from 9.@ meter to %.)]%.) meter.
The two fue gas ducts from each stream outlet .oin together and go to
the respective /.& fan suction.
There are )8 ash hoppers below the #5=' ") in each steam <6 per
(lled:. #ach hopper has a mixing vessel below it.
NOTE:
There are no interconnections of gas duct between ,A=! and #=
streams and also between #= and /& fans.
INDUCED DRAUGHT FANS:
>rom the electro static precipitator' the gases fow to the /.& >an.
At the suction of the /& fan the vacuum is "9.* millibar' and at its
discharge the pressure is )." millibar. The discharge duct when
ac$uires a rectangular shape after the difuser' is provided with a
motor operated isolation damper with 8 faps <6 shafts with % faps in
each:. A silencer is also provided after the damper and then the duct
rises to .oin the chimney at %.*-meter level. Lon-metallic bellows are
provided at the entry and the exit points of #= and /& fans.
CHIMNEY:
The fue gases of the both /& fans are left out of a chimney of
7@ meters height. The height of the chimney enables the difusion of
ash particles over the very large area and ensures the safe guard of an
environment. 5ince only W of the total ash escaping through chimney
these (ne particles do not settle any where near the power station'
thus ensuring the clean environment for the power station itself.
A hopper is also provided at the bottom of the chimney
extending from 9.*-meter level to ".*-meter level. +elow the hopper
atO@O meter level an ash mixing vessel is provided from whichI the ash
slurry pipe comes out.
DETAILS OF RCC SLAG:
! DIMENSIONS
0uter diameter at N@O meter level F ."67 meters
0uter diameter at 7@-meter level F *.6)" meters.
?oncrete shell at N@O meter level F8)mm
?oncrete shell thic-ness at 7@-meter level F 8 mm
/nternal diameter at %.*-meter level F 8.7)) mm
/nternal diameter at an exit F ).8* meters
"! REFRACTORY LINING:
A minimum air gap of @@ mm between the concrete shell and
the refractory lining is maintained through out. A " mm thic- ?./ cap
covers it at the top.