Boiler Draught System

Dr. K.C. Yadav, Director

 Learning Agenda

• Description of the boiler draught system (i.e. Purpose,

Definition, Classification and functioning)
• Role of fans in draught system management and
Influences of other equipments
• Description of PA Fans, FD Fans, ID Fans, Gas
Recirculation Fans, Scanner Air Fans, Igniter Air Fans
and Seal Air fans.

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 Purpose
To ensure sufficient, efficient and
safe flow of fuel, air and products
of combustion through the steam
generator

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 Purpose
To match the center line of the fire
ball with the vertical center line of
the furnace with the prescribed
dimensions (shape, size & density)

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 Purpose
To maintain the standards of other
combustion control parameters
such as Oxygen in Flue Gas,
Carbon in Ash, Sox & NOx in Flue
Gas, Flue Gas Velocity, Flue Gas
Exhaust Temperature etc.

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 Definition
Draught System is combination of equipments
and processes for maintaining differential
pressure through out the fuel, air and flue gas
path. The system is consisted of feeders,
pulverizers, fans (PA, FD, ID, GR, Seal Air, Scanner
Air, Igniter Air etc), burners, Wind Box, SADC,
boiler fire side (First & Second Pass), APH, ESP,
and Chimney.

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 Definition
Draught System Can also be defined as the
process of maintaining prescribed absolute
pressure in and differential pressure across the
feeders/pulverizers, burners, Wind Box, SADC,
Furnace, Platen Super Heater, Re Heater, Final SH,
LTSH, Economizer, APH, ESP, and Chimney by
controlling the respective processes and Fans (ID,
FD & PA).

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 Classification
• Natural Draught
• Induced Draught
• Forced Draught
• Balanced Draught

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 Draught System Layout

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 Primary
Air
System

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 Secondary Air System

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 Flue
Gas
System

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 Factors Affecting Boiler Draught
• Coal quantity and quality parameters
• Air quantity and quality parameters
• Flue gas quantity and quality parameters
• Improper functioning of the coal, air and flue gas handling
equipments (feeders, pulverizers and mainly fans)
• External/internal deposits/choking of the boiler tubes
• Air in leakage to the boiler
• Air pre heater choking
• Poor performance of the ESP
• Improper functioning of the pressure parts

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 Boiler Fans
• PA Fans
• FD Fans
• ID Fans
• GR Fans
• Scanner Air Fans
• Igniter Air Fans
• Seal Air fans
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 Definition
Fan is a rotary machine, which maintains a
continuous flow of air/gas at a pressure
ratio not normally exceeding 1:3.

IS Code – 3588/1987

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 Purpose of Fans

To develop moderate pressure of

the air/gas in order to transport it
from one place to an other at
desired parameters

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 Purpose of Boiler Fans

Primary Air Fan

PA Fan is required to provide air to
dry the coal in mill and transport it
from mill to furnace. This air is
termed as “ Primary Air”

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 Purpose of Boiler Fans

Forced Draught Fan

FD Fan is required to provide air to ensure
proper flow of products of combustion and
also to ensure complete combustion of
coal/oil inside the furnace. This air is termed
as “Secondary Air” because it is supplied
after the primary air

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 Purpose of Boiler Fans

Induced Draught Fan

ID Fan is required to extract the product of
combustion called flue gas form the
furnace and discharge the same to the
chimney, which in turn to the atmosphere.

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 Purpose of Boiler Fans

Gas Recirculation Fan

These fans receive flue gas from the boiler down
stream and discharge it into relatively up stream
to met different objectives such as
supplementary fuel firing, steam temperature
control, coal drying etc. These fans are most
troublesome amongst all the boiler fans and
required to be selected appropriately in
accordance with application specific operating
parameters and extant standards.
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 Purpose of Boiler Fans

Seal Air Fan

Seal air fan boost up the cold primary air
pressure to cater the need of sealing the
bearings of the rotating component of
pulverizers. For example, three rollers and
upper bearing of the bowl of each ‘Bowl &
Roller Mill’ are supplied with seal air to
protect its abrasion by coal particles.

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 Purpose of Boiler Fans

Scanner Air Fan

These fan takes suction either from FD
Fan discharge duct or from atmosphere
and always supply its discharge air to the
‘Flame Scanners’ for their cooling and
cleaning.

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 Purpose of Boiler Fans

Igniter Air Fan

Boilers with conventional Igniters
essentially have these fans to
continuously supply sufficient air to cool
and clean the igniters, even when these
are not in service or otherwise the same
air supports the combustion of igniter
fuel.
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 Working Principle of Fans
Fans convert kinetic energy of a prime mover (a
electric motor or turbine) partially into pressure
head and remaining into velocity head (kinetic
energy), which in turn also converted into
pressure head by the diffuser and thus build up
the pressure of air/gas being displaced.

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 Working Principle of Fans
• The energy changes occur by two main parts of the
fan, the impeller and diffuser (volute or vane
diffuser).
• The impeller is the rotating part that converts
driver energy into the pressure energy and kinetic
energy of the air/gas.
• The volute or diffuser is the stationary part that
converts the kinetic energy into pressure energy.

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 Classification of Fans
• Radial Fans - Single Suction
- Double Suction
Radial Impeller may have straight, forward or
backward curved blades on the basis of
application
• Axial Fans - Single Stage
- Double Stage
Axial fans are further classified as Propeller, Tube
axial and Vane axial
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 Designation of Radial Fans
NDV y z
NDFV y z
NDZV y z
NDV – Single Suction Simply Supported Impeller
NDFV – Single Suction Overhung Impeller
NDZV – Double Suction Simply Supported Impeller
y – Impeller tip dia in decimeter
z – Type of wheel (Impeller)

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 Designation of Axial Fans
AN m n
AP x y/z
A – Axial
N – Non Profiled
m – Impeller tip dia in decimeter
n – Diffuser designation
P – Profiled
x – Number of stages
y – Impeller tip dia in decimeter
z – Impeller hub dia in decimeter
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 Construction Feature of Radial Fans

Sub-assemblies of NDFV, NDV & NDZV fans

• Spiral casing
• Impeller
• Control assembly
• Shaft with bearing assembly
• Seal assembly

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 Construction Feature of Axial Fans

Sub-assemblies of AN and AP fans

• Suction Chamber
• Impeller assembly
• Control assembly
• Shaft with bearing assembly
• Diffuser assembly

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 NDV x y

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 NDFV x y

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 Specific Radial Fan Used as PA Fan

• Application : For supplying Air to the boiler

• Number per boiler : Two
• Type : NDFV 22 b
• Medium handled : Air
• Orientation : Axial suction & radial delivery
• Total head : 1000 mm WC
• Speed : 1460 rpm
• Regulation : IGV Control.

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 NDZV x y

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 Double Suction Radial Fan

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 Specific Radial Fan Used as ID Fan
• Application : For extraction of Flue gases.
• Number per boiler : Two
• Type : NDZV 33 Sidor
• Medium handled : Flue gas
• Orientation : 45 Deg.inclined suction & Horizontal
delivery
• Capacity : 258 cu.M / sec
• Total head : 496 mm WC
• Speed : 701 rpm (Max at 100% Scoop)
• Regulation : Speed and Damper Control.

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 Specific Radial Fan Used as ID Fan
• This is a Single Stage, Double Suction Radial Fan and is
used for extracting flue gas from the furnace.
• In this type of Fan, a large part of energy transferred to
the medium is converted in to pressure energy as the
medium passes through the impeller.
• Remaining Kinetic energy after the impeller, is
converted in to pressure energy by means of Spiral
casing.
• The output of the fan is controlled by either Inlet Guide
Vane or Variable speed hydraulic coupling.

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 Radial Fan Blades
• Backward-curved
– Has a self-limiting power characteristic, so if sized correctly the
motor won’t overheat or burn out even if conditions change.
– High efficiency and stable operation make this blade type popular.
– Pressure rise falls with increasing flow rate
• Radial (straight)
– Similar performance to a backward-curved except that it’s easier to
overheat.
– Easier to maintain, so it’s used in dirty situations
– Pressure rise fairly independent of flow rate
• Forward-curved
– Have problems with stability
– Pressure rise increases with flow rate

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 AN m n

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 IGV

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 Specific Axial Fan Used as ID Fan

• Application : For combustion of coal.

• Number per boiler : Two
• Type : AN 25 e6
• Medium handled : Flue gas
• Orientation : Horizontal suction and delivery
• Speed : 1480 rpm
• Regulation : IGV control

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 AP x y/z

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 AP x/y z

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 Specific Axial Fan Used as FD Fan

• Application : For combustion of coal.

• Number per boiler : Two
• Type : AP1 – 18/11
• Medium handled : Air
• Orientation : Vertical suction & Horizontal
delivery
• Capacity : 111 cu.M / sec
• Total head : 502 mm WC
• Speed : 1480 rpm
• Regulation : Blade pitch control
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 Specific Axial Fan Used as FD Fan

• This is an Axial Reaction type Fan and is primarily used

for fresh air application.
• In this type of Fan, a large part of energy transferred to
the medium is converted in to pressure energy as the
medium passes through the impeller.
• Remaining velocity energy after the impeller, is
converted in to pressure energy by the diffuser.
• The discharge pressure of the medium can be adjusted
by means of blade pitch control.

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 Specific Axial Fan Used as PA Fan
• Application : For Coal transportation and drying.
• Number per boiler : Two
• Type : AP2 – 17/12
• Medium handled : Air
• Orientation : Vertical suction & Horizontal delivery
• Capacity : 80 cu.M / sec
• Total head : 1320 mm WC
• Speed : 1480 rpm
• Regulation : Blade pitch control

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 Specific Axial Fan Used as FD Fan
• This is an Axial Reaction type Fan and is primarily used
for fresh air application.
• In this type of Fan, a large part of energy transferred to
the medium is converted in to pressure energy as the
medium passes through the impeller.
• Remaining velocity energy after the impeller, is
converted in to pressure energy by the diffuser.
• The discharge pressure of the medium can be adjusted
by means of blade pitch control.

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 Black & Vetch

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 Black & Vetch

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 FD Fan 600 MW Unit

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 Double
Suction,
Radial
ID Fan
Discharge
Duct

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 Double Suction, Radial ID Fan

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 Chimney

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 Internal view of Chimney

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PA Fan U9

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 Fan Controlling Devices
• Damper Control
• Inlet Guide Vane Control
• Speed Control
• Pitch Control
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 Damper Control
Fan flow and pressure can be changed by
varying the cross section at the suction side of
the fan. This type of control has been provided
on the suction ducts having rectangular cross
section, which is achieved by damper regulating
mechanism powered by different types of
motors.

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 Inlet Guide Vane Control
This type of control has been provided on
the suction ducts having circular cross
section. In principle, it same as that of
damper control but reported to more
effective.

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 Inlet Guide
Vane
Control
Assembly

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 Speed Control
Flow and pressure can be controlled by varying
the speed of the fan by using either a infinitely
variable speed hydraulic coupling are by using a
variable frequency electric motor. Many ID Fans
in the thermal power plant have been provided
with infinitely variable speed hydraulic coupling
and hence due weight age has been given in
this session.

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 Operating Principle of HC
• The drive machine torque accelerates the operating oil in the
coupling’s primary wheel (pump impeller).The oil then decelerated
by the secondary wheel and thus transmits the torque to the
secondary shaft. Oil can only circulate if there is a pressure
difference between the primary and secondary wheel, this in turn
requires a speed differential (Slip) between the primary and
secondary wheel, i.e. slip is required for power transmission.
• The coupling is sized so that full power can be transmitted at 2-3 %
slip. he output speed can be sleeplessly varied by changing the slip
which is achieved by increasing or decreasing the amount of oil in
the working chamber between the primary and secondary wheel.
This is achieved by positioning the scoop tube to match the required
output speed.

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PRIMARY SECONDARY
WHEEL WHEEL

SCOOP TUBE
HSG.

SCOOPING CHAMBER

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 OPERATING PRINCIPLE

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 OPERATING PRINCIPLE

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 CUT VIEW OF HYDRAULIC COUPLING

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 Blade Pitch Control
• Variation in blade pitch vary the flow and
pressure of the air/gas being handled.
• Blade pitch is controlled by means of
Servomotor.
• Control oil is used for the operation of
Servomotor.

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Complete Assembly of
Servomotor
.
The reciprocating movement of adjusting disc is then converted in to rotary motion of the
blades by means of jewel bearings and levers connected to blade shaft.

LEVER
 Blade shaft connected with lever at one
end and with blade at other end.

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 Connecting shaft is provided in
PA Fan to transfer the motion
from one end to the other as it
consists of two hubs.

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 Fan Performance
Total Efficiency
= Energy equivalent to total dynamic head / Shaft
Energy
Static Efficiency
= Energy equivalent to total static head / Shaft Energy

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Static Suction Lift - The vertical distance from the
suction air line to the centerline of the impeller.
Static Discharge Head - The vertical distance from the
centerline of the impeller to the point of discharge.
Dynamic Suction Head - The Static Suction Lift plus the
friction in the suction line. Also referred to as a Total
Suction Head.
Dynamic Discharge Head - The Static Discharge Head
plus the friction in the discharge line. Also referred to
as Total Discharge Head.
Total Dynamic Head - The Dynamic Suction Head plus
the Dynamic Discharge Head. Also referred to as Total
Head.

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 System Pressure Effects
• Fan curves are typically given in terms of total
pressure vs. volumetric flow rate.
• A typical fan running at a fixed speed can
provide a greater volumetric flow rate for
systems with smaller total pressure drops.
• Total pressure loss is total of static pressure
loss and dynamic pressure loss.
• If exit and inlet area of a duct are about the
same, the dynamic pressure loss (or gain) may
be minimal.

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 Notes on Performance Characteristics
• Manufacturer will provide a fan curve for each fan
produced.
• The fan curves predict the pressure-flow rate
performance of each fan.
• Choose a fan that gives you the volumetric flow rate
you need for system pressure drop.
• Choose a fan that has its peak efficiency at or near
operating point.
• Sometimes Characteristics are provided in a tabulated
data format rather than in a graph.

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Thank you