FORCED DRAFT FAN

BY JUSTICE. A. OFUGARA

INTRODUCTION
For combustion to take place, we require
the 3 T and one A which refers to
Time, Temperature, Turbulence and Air.
It takes time to establish combustion, it
requires the right temperature which is
the source of spark or ignition, the
mixing (turbulence) of the fuel and
oxygen, and then air which provides the
oxygen.

THE NEED FOR COMPLETE

COMBUSTION
In accordance with existing Environmental laws, we are
mandated to ensure we always carry out efficient
combustion and to control the flue gas emissions.
When the quantity of air supplied is insufficient (i.e. the airfuel ratio is below that required for complete combustion),
we would have an increase in fuel wastage, a decrease in
efficiency and increase in pollution as we would have unburnt carbon particulates, carbon monoxides and potentially
explosive gases in our exhaust system as by-products of
combustion.
On the other hand, excess air tends to reduce the heating
effect of combustion. Hence we need to control the quantity
of air supplied so that we have the right air-fuel ratio.

 For complete combustion of natural

gas, the Air/Fuel ratio is
approximately 10:1 by volume.
Any mixture with Air/Fuel ratio less
than 9.5:1 is known as a rich mixture
(higher quantity of fuel).
Any mixture greater than 10:1 is
known as a lean mixture (lesser
quantity of fuel).

THE DRAFT SYSTEMS

The flow of air through the boiler is known as Draft.
Draft can be achieved either Naturally or
Mechanically through the use of fans and blowers.
Natural Draft System is the system in which air
or flue gases flow naturally due to differences in
density between the hotter (less dense) air and the
cooler (denser) surrounding air. In most Electric
Power Generation Plants, Natural Draft cannot
supply the adequate volume of air for complete
combustion due to the high pressure of the fuel
from the nozzles and also the resistance of the fuel
chamber and stack; Hence the usage of fans.

 Mechanical Draft is divided into two which are:

1. Induced Draft (ID) and
2. Forced Draft (FD) systems.
. In the FD fan system, air is blown or forced into the
combustion chamber; While in the ID fan system, air is
pulled or drawn through the combustion chamber.
. The FD fan creates a positive pressure in the combustion
chamber; While the ID fan creates a negative pressure.
. When both systems are used, it is known as a BalancedDraft System.
. Figures 1 to 4 below show the diagrammatic
representation of the Draft systems.

Diagrammatic Representation of
Natural Draft

Diagrammatic Representation of
Forced Draft

Diagrammatic Representation of
Induced Draft

Diagrammatic Representation of
Balanced Draft

 Most boilers today use mechanical

draft rather than natural draft as
more definite control is possible with
this method.
Also a high chimney is not necessary
to produce mechanical draft and
mechanical draft does not vary with
wind and weather conditions but
natural draft does.

 Like the natural draft, both the forced

draft and the induced draft systems also
use a chimney. Although the chimney
does not produce the draft in both the FD
and ID systems, it is necessary to
discharge the combustion gases high
enough above ground level to reduce air
pollution.
Balanced Draft is used only in very large
boilers.

COMPONENTS OF THE FD FAN

SYSTEM
The forced draft fan system in a thermal
station supplies the air required for
combustion and also air required for the
purging of the boiler.
Purging is the process in which fans force
air through the boiler with all the vents
open so as to expel gases that might have
accumulated after the previous
combustion.
Purging reduces the risk of explosion.

 The FD fan system includes the following for

each unit.
(a) Two-50% forced draft fans.
(b) One-100% steam Coil air heater.
(c) One-100% regenerative or main air
heater
(d) Two-100% Ignition and Cooling air fans.
(e) Two-50% air flow measuring Venturis
(f) One-Boiler stack.

 It also includes associated air and flue

gas ducting and dampers.
The combustion air is delivered by the
forced draft fans to the air heaters via
a common cold air duct.
The hot air leaving the main air heater
divides into two, passes through air
Venturis before getting to each burner
via individual burner wind boxes.

COMPONENTS OF THE FD
FAN
The FD fan system consists of the following components:
1. The Duct: This is the channel/piping through which ambient air
enters and passes through to the wind-box of the boiler.
2. Inlet Screen/Mesh: This is the wire mesh at the inlet which
prevents bird and particles from entering into the fan. It filters
and cleans the air.
3. Bellows: These are piping expansion joints which absorb
vibration. They are often made of thick treated leather. They pull
air in when they expand, and push it out when they contrast thus
supplying the required air pressure.
4. Dampers: These are manually or automatically operated panels
used to restrict the inlet or outlet area of air flow thus providing
control of the air or gas flow rate.
5. Inlet Guide Vanes: These direct the air flow towards the eye of
the impeller

6. Outlet Guide Vanes: These direct the air flow towards the
combustion chamber.
7. Electric Motor: This provides power for the fan
8. Lube Oil Pump: This pumps oil for lubrication of fan
bearings and dampers
9. Impeller: This is the part of the fan which directly
pressurises the air
10.Shaft and Coupling: This transfers the power from the
motor to the fan.
11.Base: This provides support for the FD Fan System.
12.Silencers: Modern FD fans such as those in Egbin Power
Plc are fitted with Silencers to reduce the noise and
vibration.

Left And Front View Of The

FD Fan

Right Side View OF FD FAN With

Impeller

Typical FD Fan Specifics

The FD fan has a large capacity induction motor (3phase) and has an impeller carrying moving vanes.
It has dampers that control the air-flow in and
linkages which link the dampers and the vanes to
the outside.
The vane is controlled by a pneumatic actuator.
The linkage is a shaft that aids transmission of
power for control purposes of the vanes.
The mechanism inside the actuator pushes the
linkages which in turn moves the vanes.
Moving the handle thus moves all the glasses.

 The forced draft fans are of the double inlet

type and are located at basement floor level at
the rear of the boiler with the suction end
located on the 4th floor.
The fans are controlled by variable Vanes in the
inlet boxes and can be isolated with a power
operated shut off damper in the discharge duct.
Each fan is driven by constant speed, air cooled
electric motor through a flexible spacer type
coupling.

 The FD fan has Radial and Thrust

bearings which are ring lubricated.
In addition a forced lubrication
system is provided which is designed
to be put into service prior to the fan
start but may be taken out of service
later.
The lubricating oil system is cooled
by water taken from the general
service water system.

CHARACTERISTICS OF FD
FAN

 The inlet of the fan is placed in the Plant house

and not directly outside as the Plant house is
warmer and this raises the temperature of the air.
The FD fan inlet has a wire mesh to prevent birds
and particles from entering into the system.
In cold regions, some FD fan inlets are fitted with
heaters to raise the air temperature and prevent
ice/snow from entering thus increasing the thermal
efficiency of the plant.
If this isnt done, more fuel will be used up in
heating the air during combustion.

 The FD fan used in a typical Steam

Plant is a centrifugal fan and it can
be driven by a motor or a turbine.
The assembly of the hub, disk and
blades is known as the fan wheel or
impeller.
The fan uses the centrifugal force of
rotation of the wheel to impart
movement to the air and thus
increase its pressure.

 Although FD Fans are used to control the

flow of air using damper adjustments,
flow control by the use of variable speed
is smoother and more efficient.
Variable speed can be achieved through
the use of an adjustable frequency AC
controller, a DC motor and drive, a
steam turbine driver, or a hydraulic
variable speed drive unit (fluid drive).

FD FAN PROBLEMS
CASE 1: DAMAGED VANES
Vanes naturally get stiff with time and thus
gets damaged when they are forced to
open. Hence, vanes must be lubricated
efficiently.
Linkages must be greased regularly.
Check bearing oil regularly.
Also check cooling water valves to ensure
cooling water is flowing as water cools the
oil that cools the bearings.

 CASE 2: INCOMPLETE COMBUSTION

A typical scenario of FD Fan problem is that of
incomplete combustion in the boiler.
It was noticed that the fan wasnt supplying enough
air for combustion.
Troubleshooting the fan revealed that one of the
damper pins sheared off so the linkage connection
was separated so that damper would move without it
moving the vane.
This led to insufficient air coming in.
A new pin was installed and the damper was properly
positioned. This solved the problem.

 CASE 3A: NOISE AND VIBRATION

The boiler was provided with a high pressure FD fan to meet the
combustion air requirement of a 30 TPH (tonnes per hour) FBC Boiler.
Client reported issue of noise and vibration from the FD fan especially
at partially loaded condition. The sound could be heard at the factory
entrance which was nearly half a km away from the boiler house.
FAN vendor could not resolve the problem
On a close inspection of the Inlet Guide Vane (IGV), it was observed
that the IGV would induce a swirl motion of the entering air in a
direction opposite that of the Fan rotation.
The linkages were removed and the IGV was totally modified so that
the rotation of swirl was in the same direction to that of the Fan.
Incidentally the Fan vendor had tried just reversing the IGV. This would
not change the swirl direction. The problem was solved after the
turbulence created by the IGV was removed.

 CASE 3B: NOISE AND VIBRATION

Excessive noise and vibration was noticed during
operations.
Troubleshooting revealed misalignment between
the fan and motor.
Re-alignment of the shaft and motor, after
ensuring that the coupling is still in proper
condition, solved the problem.
Noise and vibration leads to a decrease in
efficiency as energy is lost in the form of the
kinetic energy of vibration.

 A list of possible causes of noise and vibration includes:

1. Worn bearings
2. Unstable foundation
3. Foreign material in the fan causing an imbalance
4. Misalignment of bearings, couplings, wheel or v-belt drives
5. Damaged wheel or motor
6. Bent shaft
7. Worn coupling
8. Loose dampers or variable inlet vanes
9. Speed too high or incorrect fan rotation
10.Vibration to fan transmitted from other source
11.Uneven blade wear
12.Loose or broken bolts or set screws

 CASE 4: OVERHEATING OF BEARINGS

Inadequate lubrication leads to overheating of bearings. Poor
lubrication may arise due to the use of substandard lube oil.
It may also arise from the use of lube oil pumps which are
not of the rated capacity.
A list of possible cause of bearing overheating includes:
1) Improper lubrication
2) Poor alignment
3) Damaged wheel or driver
4) Bent shaft
5) Abnormal end thrust
6) Dirt in bearings
7) Improper belt tension

CASE 5: OVERLOAD ON DRIVER

Overload on driver occurs when:
Speed is too high
Direction of rotation is incorrect
Bent shaft
Poor alignment
Improper lubrication
Wheel wedging or binging on fan housing

 CASE 6: FAN CAPACITY BELOW RATING

This can occur due to:
I. Dampers or variable inlet vanes are not
adjusted properly
II. Fan inlet or outlet conditions are impaired
III. Multiple air leaks within the system
IV. Damage sustained to the fan wheel
V. Direction of rotation is incorrect.

FD FAN OPERATIONS
4.1) CONDITIONS FOR FD FAN TO START
For us to start the FD fan we will first start
the MAH.
Check that the 3.3kv breaker is racked in and
ready to start
Check that the lube oil is running and the
pressure is up to 1.2kg/cm2
The damper must be closed
The Vane must be closed
MAH in service

 4.2) ISOLATION OF THE FD FAN

Rack out the 3.3kv breaker and tag it
Close the Vane and it will show that
you closed it
Rack out the lube oil pump of the FD
fan and tag it
The damper closes on its own when
you close the Vane

THE END