OBJECTIVES

1
To reduced pressure drop of 5 % in ducts across air
heater and ESP inlet.
To Improved flow regime would reduce ID fan current
consumption.
To reduction in high velocity and turbulence will
reduce erosion of ducts.
To ensure proper distribution of flue gas in all passes
of ESP , thus improvement in ESP performance.
To ensure Increased ID fan margin.
To reduced erosion of ID fan impeller.


GOAL
2
The main goal while carrying out CFD analysis in
Ducts is to design turning vanes for ducts in order
To optimize pressure drop.
To reduce turbulence .
To reduce velocity at high velocity zones by
proper distribution of flow to minimize erosion of
duct.



STEPS

3
PURFORMING CFD ANALYIS.

IMPLIMENT THE PROPOSED MODIFICATION
DURING OVERHAULING PERIOD.



CFD ANALYSIS
4
Modeling
Meshing
CFD simulations
FEA simulation


Modeling
5
Study drawings of Flue Gas Duct.

Study regarding the parameters and
erosion pattern of Flue Gas Ducts.

Develop computer model of ducts to
stimulate the existing flow conditions.
Modeling
6
Study drawings of Flue Gas Duct.

Study regarding the parameters and
erosion pattern of Flue Gas Ducts.

Develop computer model of ducts to
stimulate the existing flow conditions.
Meshing
7
Locate flow disturbances like turbulence,
high localized velocities, uneven flow in
branching ducts, non uniform velocities,
localized erosions in duct etc.

Meshing
Study drawings of Flue Gas Duct.

Study regarding the parameters and
erosion pattern of Flue Gas Ducts.

Develop computer model of ducts to
stimulate the existing flow conditions.
Meshing
Study drawings of Flue Gas Duct.

Study regarding the parameters and
erosion pattern of Flue Gas Ducts.

Develop computer model of ducts to
stimulate the existing flow conditions.
CFD simulations
10
CFD simulations

Various modifications /alternatives tried out
on model to achieve desired/improved flow
in flow disturbed areas.

CFD simulations
Study drawings of Flue Gas Duct.

Study regarding the parameters and
erosion pattern of Flue Gas Ducts.

Develop computer model of ducts to
stimulate the existing flow conditions.
CFD simulations
Study drawings of Flue Gas Duct.

Study regarding the parameters and
erosion pattern of Flue Gas Ducts.

Develop computer model of ducts to
stimulate the existing flow conditions.
FEA simulation
13
Velocity test before modification was carried
out in running plant at Air Pre heater outlet
duct to ID inlet duct by S-type Pilot tube.
Finalize Design ,Location and Curvature of
diverters Plates as per CFD software.
Finalize use of chemical bonded refractory in
erosion porn zone.

FEA simulation
14
Velocity test before and after modification
in running plant at Air Pre heater outlet duct
after APH and at ESP inlet duct before ESP
by inserting S-type Pilot tube.
Finalize Design ,Location and Curvature of
diverters Plates as per CFD software.
Use of chemical bonded refractory in erosion
porn zone.

Software Used
15
Modeling - ANSYS Design Modeler, Solidworks.
Meshing - ANSYS ICEMCFD, Gambit,
HyperMesh.

CFD simulations - ANSYS CFX, ANSYS Fluent,
AcuSolve ,OpenFoam.
FEA simulation - ANSYS Mechanical, Radioss.


CFD RESULT
Table shows pressure drop
across different sections for
existing and modified case

16
MATERIAL REQUIREMENT
For AH Outlet To ESP Inlet:
NO. OF LOCATION DIVERTER PLATE MODIFIED 10
NO. OF LOCATION DIVERTER PLATE NEWLY FITTED-10
DIVERTER PLATES REQUIRED - 422 Sq.m (10 mm thick).

NO. OF LOCATION DUCT PLATE MODIFIED- 10
DUCT PLATES REQUIRED - 172 Sq.m (6 mm Thick).

TOTAL PLATE WEIGHT 43 MT
TOTAL REFRACTORY WEIGHT 10 MT


IMPLIMENTATION OF THE
PROPOSED MODIFICATION
DURING OVERHAULING PERIOD
18
PROCUREMENT


MANPOWER PLANNING

JOB PLANNING


IMPLIMENTATION OF THE
PROPOSED MODIFICATION
DURING OVERHAULING PERIOD
19
Acti
vity
of
AP
H
Out
let
to
ESP
Inle
t
SR.
NO.
Activities D-
3
D-2 D-
1
D1 D2 D3 D
4
D
5
D
6
D
7
D
8
D
9
D1
0
D1
1
D1
2
D13
1 Pre shutdown
Activities
Pr
es
h
ut
d
o
w
n
Ac
ti
vi
ti
es


2 Old Diverter Plate
Cutting
Old
Div
erte
r
Plat
e
Cutt
ing


3 Fabrication Plates
Modified Diverter
E
r
e
c
ti
o
n
o
f
P
l
a
t
e
s
/
M
o
d
if
i
e
d
D
iv
e
rt
e
r


4 Duct Patching
Du
ct
Pa
tc
hi
ng
s
to
be
crr
ie
d
ou
t
by
se
pa
rat
e
ve
nd
or


5 Refectory Ref
ect
ory
BEFORE AFTER
BEFORE

AFTER
BEFORE AFTER
BEFORE
AFTER
BEFORE
AFTER
BEFORE
AFTER
AFTER AFTER
NEW LOCATION DIVERTER PLATE DUCT PLATE MODIFICATION
C
O
M
P
A
R
A
TI
V
E
S
T
U
D
Y
(
O
F
F
LI
N
E
)
LOAD -252 MW UNIT
NO. #3
BEFOR
E
OVERH
AULIN
G
UNIT
NO.
#1
AFTE
R
OVER
HAUL
ING

SR.
NO
.
LOCATION STATIC
PR.
DYNA
MIC
PR.
AVERAGE
VEL.
TOTAL
PR.
STATIC
PR.
DYNA
MIC
PR.
AVERAGE
VEL.
TOTAL
PR.
UNIT LOAD mmwc mmw
c
m/sec mmwc mmwc mmw
c
m/sec mmwc
1 APH OUT LET A PASS -176 5.49 10.21 -170.65 -207.45 6.96 11.29 -200.49
2 APH OUT LET B PASS -179 6.71 11.29 -176.39 -209.21 7.05 11.36 -202.16
3 ESP INLET A PASS -291 20.54 24.1 -270.48 -278.02 19.7 19.06 -258.32
4 ESP INLET B PASS -273 24.8
26.46
-248.17 -266.34 23.8
20.93
-242.54
5 ESP INLET C PASS -300.7 27.42
27.86
-273.29 -285.04 17.01
17.71
-268.03
6 ESP INLET D PASS -283.5 19.73 23.61 -263.78 -275.07 14.99 16.62 -260.08
7 ESP OUTLET A PASS -325.8 20.69 19.98 -305.13 -291.28 15.03 16.65 -276.25
8 ESP OUTLET B PASS -292.7 24.2 21.58 -283.12 -287.04 14.73 16.49 -272.31
9 ESP OUTLET C PASS -313.7 13.58 16.18 -300.08 -283.64 8.35 12.41 -275.29
10 ESP OUTLET D PASS -315.3 22.81 20.97 -292.45 -285.74 10.27 13.77 -275.47
COMPARATIVE STUDY (ON LINE)
Sl.No. PARAMETER DESCRIPTION UNIT Desig
n
value
#1 #3
BEFOR
E O/H
AFTER O/H BEFO
RE
O/H
AFTE
R
O/H
1 LOAD MW 250 254 254 254 254
2 FG PRESSURE AFTER LTSH L mmwc -32 -62 -76 -35 -41
3 FG PRESSURE AFTER LTSH R mmwc -32 -39 -46 -27 -33
4 FG PRESSURE APH OUTLET A mmwc -222 -204 -214 -165 -190
5 FG PRESSURE APH OUTLET B mmwc -222 -218 -229 -175 -195
6 DP ACCROSS APH A mmwc 131 141 121 130
7 DP ACCROSS APH B mmwc 152 155 122 127
8
FG PRESSURE BEFORE ID
FAN A
mmwc
-291
-317
-294
-294
-276
9
FG PRESSURE BEFORE ID
FAN B
mmwc
-291
-325
-304
-295
-269
10
ID FAN A CURRENT
Amp 182
153
195
144
11
ID FAN B CURRENT
Amp 185
152
194
144
12 ID FAN A IGV OPENING % 86 70 81 83
13 ID FAN B IGV OPENING % 87 72 84 83
14 ID FAN A SCOOP OPENING % 78 57 83 48
15 ID FAN B SCOOP OPENING % 81 74 69 56
16 AIR FLOW T/H 838 875 839 850
17 FURNACE DRAFT mmwc -9 -12 -5 -6
Results
29
Reduction pressure in drop of in ducts from air
heater outlet to ID fan inlet.
5.1% to7.5% with respect to design
Reduction in ID fan current consumption.
5.2% with respect to overhauled unit #1.
Reduction in high velocity and turbulence will be
ensured after velocity measurement.
Proper distribution of flue gas in all passes of will
ensured after velocity measurement. There is
substantial improvement in Opacity.
Reduced erosion of ID fan impeller will be ensured
later.


Thank you