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ABOUT THE CUSTOMER:

BALCO Captive Power Plant II is unit of BALCO & Vedanata Resources Pvt Ltd.,
located in Korba, Chattisgargh. BALCO was incorporate in the year 1965 as a
Public Sector Unit of Government of India.

In 2001 government of India divested 51% of its stake to Vedanta Resources. The
captive power plant II has a installed capacity of 540 MW consisting of 04 units of
135 MW each. It is a coal based power generation unit having coal supply from
SECL Kusmunda circuit. The plant has been conceptualised for BALCO’s internal
power requirement for Aluminium production. Out 540 MW only a small pie of
power is being contributed to the state power grid for distribution.

SEPCO (Shanghai Engineering & Power Company Ltd) has designed the power
plant.

ABOUT THE COMPONENT:

Induced Draft fan is a component of air circuit in Power Plant whose prime
function is to suck out the flue gases from the furnace and release them into
atmosphere. It is a dynamic component which finds it place before the chimney and
after ESP (Electro Static Precipitator). This particular ID fan is of backward curved
centrifugal design and has a aerofoil design. As the picture indicates air is being
sucked from the centre and is delivered radially out. The fan is composed chiefly of
the casing, air suction box, air inlet, driver, and
impeller, bearing box, damper and the electric
driven part. And it is directly driven by the
electric motor through a foil coupling. The type of
the motor is YKS560-6.

Specifications of the ID fan:

Make : Shanghai BlowersPvt ltd.

Volume of Air 512820 m3/hr
Handled:
Pressure rating: 5357 Pa
Prime Mover : 1120 KW
Size: 1768 mm(Diameter)
Base Metal: Alloy Steel( SAE 8640)

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ABOUT ITS FUNCTION:

ID’s fan main function is to create a draft such that the flue gases after passing
through the ESP can be easily released into the atmosphere. In order to achieve
this, fan rotates at high speed (1080 rpm) thus the high velocity of air and pressure
creates a negative pressure of -1700 mm of Hg inside the boiler. This not only
prevents from backfiring but also creates a draft that is capable of sucking out the
flue gases from the boiler. The fan is subjected to maximum temperature of 200˚C.

AREA OF CONCERN:

Since fan is rotating equipment it comes into the range of dynamic auxiliaries. The
balancing plays a vital role in the performance of the equipment which in turn
reflects in the overall performance of the plant. Here in this case fan has a
backward curved aerofoil design hence the blades have a hollow section in between.
As it handles fly ash borne high pressure air, fly ash particles being highly abrasive
in nature erodes the blades surfaces and also it makes fine holes, through it
particles enters into the hollow section and it results into unbalancing of the fan.
The air flows at very high pressure and the ash particles erode the blades surface of
the fan severely. In this case particularly the sides of the fan body which is in
contact with the edges of the blades faces severe brunt of erosion.

The customer faces main problem of repeated balancing of the fan after only a
period of 30-35 days.

It is the main area of concern where due to

puncturing, ash was being accumulated inside the
blades.

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Our Solution:

After studying wear out pattern we have suggested combination of Chrome Carb
6006 and Endotec DO 390N. The following reason justifies our recommendations.

It faces severe erosion due to fly ash particles.

Unable to create necessary draft as it was bound to be rotated at below rated
rpm.

It has service temperature of 150˚C - 200˚C

Changing of the keeper plates at inner radius area with the new MS plates.

Chrome Carb 6006 and DO 390 N can easily take care of the service
temperature.

Chrome Carb 6006 has very minimal stress relieving cracks which prevents
the fly ash particles to enter into the hardfacing layer and help in protecting
the erosion.

The dense microstructure of DO 390 N at the inner edges of the blades will
prevent the severe erosion and puncturing of the blades

Protection of the fan blades from puncturing saves the time of repeated
balancing and the downtime cost.

ID Fan After Reclamation

Area of Chrome Carb N*6006 Area of Endotec DO 390 N

After reclamation with Chrome Carb 6006 & DO 390N the fan is running
successfully at rated speed of 1080 rpm without puncturing and balancing for 60
days and still on…

Savings For The Customer:

Downtime Cost(+) Rs 30000000

Cost of New Part(+) Rs 1500000
Cost of Reclamation(-) Rs 550000
Hence Total savings(+) Rs 30950000

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SERVICE REPORT

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