Boiler technology |
Specifying fan packages for power generation applications
A manufacturer’s perspective Ted Older The New York Blower Company
The boilers used in power generation applications range widely in size and require the use of a variety of different industrial fans, including forced draft (FD), induced draft (ID), combustion air, and air recirculation. These fans are exposed to extreme conditions and must be designed to some of the highest standards of performance and reliability to ensure continuous operation. For example, biomass boiler packages must be able to withstand high vibration levels and operating temperatures up to 1800°F (982.2°C). In addition, the harsh conditions encountered in power generation applications can lead to early bearing failures and premature wear due to material buildup on the fan rotor. To combat these challenges, it is critical to specify the appropriate boiler fan to meet the specific demands of the application. It is increasingly important to incorporate remote monitoring and predictive maintenance capabilities into fan installations to ensure any degradation in fan performance or efficiency can be identified and resolved promptly before
Above: Forced draft (FD) fan wheel balancing, factory conditions
significant damage to the equipment or lost production time can occur.
Five considerations
The following are five considerations to keep in mind when specifying or upgrading boiler fan packages for power generation and biomass combustion, including construction material, temperature exposure, vibration analysis, and the addition of remote monitoring equipment.
● Consider the performance requirements
The demands on fan performance are onerous in power generation applications and fans must be designed to handle them. In one recent coal-firing application, the fans needed to support high volumetric flows, in excess of 1 million actual cubic feet per minute (ACFM), and generate upwards of 35” WG fan total pressure at test block conditions. To achieve the rigorous performance requirements, the ID fans often employ 1000 to 10 000 HP motors, compared with around 50 HP for conventional boiler fans.
Left: Induced draft (ID) fan shroud showing corrosion
46 | October 2021 |
www.modernpowersystems.com
Meanwhile, the fans selected should be of high efficiency to keep operating costs in check. It is important to work with a fan manufacturer that understands the unique performance requirements of boiler fan packages and has the flexibility to provide a wide range of fans, both standard and custom designed. It is also important to note that fan performance in lab conditions can differ significantly from the fan’s performance in its real-world environment, especially in harsh operating conditions like those present in power generation applications. Therefore, look for a fan manufacturer that offers both AMCA accredited lab testing and field testing to ensure equipment performance and reliability in the real-world conditions of your application. NYB field service technicians can be scheduled for installation or performance analysis to better understand how actual conditions differ from the specified ones and to make recommendations to minimise the effect on fan performance.
● Design for resistance to harsh conditions
Combustion based power generation processes create an extremely hot and dirty environment for air moving equipment. To prevent early
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