POWER PLANT FANS

By: Dhruv Garg

Engineer/Boiler
PS-TS,BHEL
 TURBO-MACHINES
• A Turbo machine is a head generating machine,
consist of a rotor which changes the energy level
of the continuously flowing fluid through the
turbo-machine. e.g- Fans, Blowers, Compressors,
Pumps , Turbines etc.

• Fans, Blowers, Compressors & Steam Turbine

handle compressible fluids like air, gas or steam
etc.

• Pumps & Hydro Turbines handle incompressible

fluids like water etc.
 Difference between Fans, Blowers
and Compressors
Specific pressure (ratio of the discharge pressure over the
suction pressure) is used for differentiating the fans,
blowers and compressors as mentioned below in the table:

Equipment Specific Pressure Pressure rise (mmwc)

Fans Up to 1.11 1136

Blowers 1.11 to 1.20 1136 – 2066

Compressors more than 1.20 > 2066

 FANS – PURPOSE
(For Power Plant Only)
• Supply air for combustion in the furnace and for
evacuation of the flue gases formed from the
combustion.
• Maintain Balanced Draft inside the furnace.
• Supply air for cooling of equipments working in
hot zones.
• Supply air for sealing of gates, feeders & mills
bearings etc.

Air used for combustion is divided into 2 parts:

1. Primary Air
2. Secondary Air
 Combustion Air
• Primary Air
Portion of total air sent through mills to the
furnace. This air dries the pulverized coal and
transport it to the furnace for combustion.

• Secondary Air
Large portion of total air sent to furnace to
supply necessary oxygen for the combustion.
 TYPES OF FAN
(Classification Based on Flow & Blade
Profile w.r.t Direction of Rotation)
 TYPES OF FAN

• Axial fan
Impulse type
Reaction Type

• Radial or Centrifugal Fan (Single/Double Suction)

Backward Curved Vane
Straight or Radial Vane
Forward Curved Vane
 Total Head Developed By Fan
• Fan develops pressure in any medium/fluid termed
as “Head” by imparting energy into the medium.

• Total Pressure(T.P) of fluid in motion is algebric

sum of Velocity pressure(V.P) & Static Pressure(S.P)
i.e T.P = V.P + S.P

• Static Pressure of fan is the pressure difference

(i) Between the outlet and inlet of the fan
(ii)Entry & exit of Impellor blade.

• Velocity Pressure of fan is equivalent to velocity at

which the fluid flows i.e K.E imparted by Impellor is
converted into Pressure energy inside the diffusor.
 Axial Fan
The axis of inlet flow of air is PARALLEL to the
fan axis.

The axis of outlet flow of air is also PARALLEL to

fan axis.
 Axial Flow Fan: Types
Tube Axial Vane Axial Propeller
(F.D & P.A Fan)
 AXIAL IMPULSE FAN
Also called as Axial Non Profile Bladed Fans
(AN Fans) has uniform blade cross-section from
root to tip.
Static Pressure is constant at entry & exit of
blade.
 AXIAL (PROFILE) REACTION FAN
Also known as Axial Profile Bladed Fans (AP
Fans) has profile bladed cross-section from root to
tip.
Static Pressure at exit of blade is 1.7 – 2.8 times
the entry static pressure.
Radial or Centrifugal Fan

The axis of inlet flow

of air is PARALLEL to
the fan axis.
The axis of outlet flow
of air is
PERPENDICULAR to
the fan axis.
Radial or Centrifugal Fan
 Types of Centrifugal Fan
( Single or Double Suction)

• Backward Curved Bladed Fan

• Radial or Straight Bladed Fan

• Forward Curved Bladed Fan

 Backward Curved Vanes

• Angle between blade tip and direction of rotation

is greater than 90 deg. i.e blade is curved
backward to the direction of rotation of shaft.

• Gives high reliable operation & max. efficiency of

86 %.

• Operate at higher speed, develops less velocity

head & converts more energy into static head for
removal of flue gas out of chimney.
 Backward Curved Vanes
Contd…

• Tolerance to erosive environment is medium.

• Not self cleaning type blades as the same degree

as that of Straight blades & can’t handle dust
laden flue gases, therefore use after ESP in Flue
gas path as I.D Fan applications in utility power
plants.
 Straight or Radial Vanes
• Angle between blade tip and direction of rotation
is equal to 90 deg. i.e straight blade.

• Gives low efficiency of 65 %.

• Operate at low speed & pressure.

• Simple design blades & its maintenance is easy.

• Self cleaning type blades & can handle large dust

laden flue gases and can be use in I. D Fan
applications in plants without ESP.
 Forward Curved Vanes
• Angle between blade tip and direction of rotation
is less than 90 deg. i.e blade is curved forward to
the direction of rotation of shaft.

• Has Low speed & produces higher velocity head &

lower static head & can handle large volume of
air in low resistance system.

• Auxiliary power consumption is high at higher

loads due to overloading characteristics.

• Blades are of self cleaning type, therefore fan can

be use in exhauster, gas recirculation & I.D fan
applications.
 Centrifugal Fan: Types

Paddle Vane Forward Curved Backward Curved

(Radial or straight Vane (Multi vane) Vane
Vane)
 Degree of Reaction (R)
• Ratio of Head developed across the Impellor to the
head developed across the fan is known as
“ Degree of Reaction”.

R = Hi / Hf

Hi - Pressure difference across the impellor.

Hf - Pressure difference across the fan.

For Impulse Fan , R < 0.2

For Reaction Fan, R = 0.8
 Types of Flow Control System in Fans

• Speed Control: varying the speed of the shaft.

• Inlet Guide Vane (IGV) Control: Varying the

angle of the inlet guide vanes.

• Damper Control: varying the angle of dampers.

• Blade Pitch Control: varying the angle of blades

by control oil system.
FD Fan Blade Close Position

BOILER FANS
 FD Fan Blade Open Position
FANS CLASSIFICATION
(Typically used in Utility Power Plants)

• FORCED DRAFT FAN (FD)

• PRIMARY AIR FAN(PA)
• INDUCED DRAFT FAN (ID)
• SEAL AIR FAN
• SCANNER AIR FAN
IGV CONTROL
Types of Speed Control System of Fans

• Two Speed Drive Motor with IGV Control

• Variable Speed Hydraulic Coupling

• Variable Speed Drives with Step or Step-less

Variation

• Frequency Controlled Variable Speed Drive (VFD)

Designation and Nomenclature
of Fans
(Axial & Radial Fans)
 AXIAL FANS- (IMPULSE TYPE)
DESIGNATION
A N m e6

stands for

A – Axial Fan
N – Non-Profile Bladed (constant thickness)
m – Nominal Tip diameter of impellor in decimeter
e6 – Diffusor designation
 AXIAL FANS (REACTION TYPE)
DESIGNATION

A P X - Y/Z or A P 1 – 18 /11 or A P 2 – 19/12

stands for

A – Axial Fan
P – Profiled Bladed (thickness varies from root to tip)
X – No. of blade stages
Y – Nominal Tip diameter of impellor in decimeter
Z – Nominal Hub diameter of impellor in decimeter
 RADIAL FANS DESIGNATION

NDV Y Z or NDV 14 Sidor or NDV 21 Sidor

stands for

NDV – Radial Single Suction Fan – Simply Supported

Impellor
Y – Nominal Tip diameter of impellor in decimeter
Z – Type of impellor wheel
 RADIAL FANS DESIGNATION

NDFV Y Z or NDFV 27 Sidor

stands for

NDFV – Radial Single Suction Fan

(Overhung Impellor)
Y – Nominal Tip diameter of impellor in
decimeter
Z – Type of impellor wheel
 RADIAL FANS DESIGNATION

NDZV Y Z or NDZV 44 Sidor

stands for

NDZV – Radial Double Suction Fan

(Simply Supported Impellor)
Y – Nominal Tip diameter of impellor in decimeter
Z – Type of impellor wheel
 TYPES OF
POWER PLANT FAN

(Based on their Application)

 Forced Draft (F.D) Fans

• Supplies secondary air to the furnace through APH

to assist in combustion.

• Supply total air flow to the furnace except where

an independent atmospheric P.A fan is used.

• Provides air for sealing requirement and excess air

requirement in the furnace.

• Axial fan-reaction type with blade pitch control is

use in the Pulverized fired boiler(210/250/500
MW).
 Forced Draft (F.D) Fans
Contd..

• Radial Fans-single suction-backward curved vanes

with inlet guide vane (IGV)control is use in CFBC
boiler.

• Overcome the pressure loss inside the cold air duct,

APH, hot air duct and the wind box in the balanced
draft system.
 F.D Fan Design Parameters
(Contract Data Sheet)
125 MW 250 MW 500 MW
(Giral-CFBC (Suratgarh-1 (Rihand-3
Boiler) Conventional) Conventional)
Type Radial, NDV 21 Axial, AP1-18/11 Axial, AP1-26/16

Nos 2 2 2
Flow (m3/sec) 48.12 105 261.6
Pressure 156 528 391
(mmwc)
Temp. 45 45 50
Drive Motor Motor Motor
Speed (rpm) 1480 1480 980
Motor (KW) 1025 700 1300
Control IGV Blade Pitch Blade Pitch
 Axial fan Erection

FAN LOWER CASING

FAN MOTOR
Axial fan Erection
 Primary Air (P.A) Fan

• Supply high pressure primary air through APH

needed to dry & transport coal directly from the
coal mills to the furnace.

• Primary air for mills is divided into cold & hot

primary air.

• Axial fan-double stage-reaction type with blade

pitch control is use in the Pulverized fired
boiler(210/250/500 MW).
 Primary Air (P.A) Fan
Contd..

• Radial Fans -single suction-backward curved

vanes with inlet guide vane(IGV) control is use in
CFBC boiler.

• Overcome the pressure loss inside the cold air

duct, APH, hot air duct, mills, coal piping and
burners.
 P.A Fan Design Parameters
(Contract Data Sheet)
125 MW 250 MW 500 MW
(Giral-CFBC (Suratgarh-1 (Rihand-3
Boiler) Conventional) Conventional)
Type Radial, NDV Axial, AP2- Axial, AP2-20/12
14 17/12
Nos 2 3 2
Flow (m3/sec) 34.54 83.3 185
Pressure (mmwc) 265 1322 1278
Temp. 45 45 50
Drive Motor Motor Motor
Speed (rpm) 2880 1480 1480
Motor (KW) 1200 1400 2950
Control IGV Blade Pitch Blade Pitch
 Induced Draft (I.D) Fan

• Suck the gases out of the furnace and throw

them into the stack by creating sufficient
negative pressure in the furnace (5-10 mmwc) in
the balanced draft units.

• Located in between the ESP and Chimney in the

flue gas path.

• Radial Fans -double suction-backward curved

vane with inlet guide vane(IGV)control and VFD
control is use in all boilers.
 Induced Draft (I.D) Fan
Contd..

• Handles large volume hot dust/ash laden flue gas

(temp upto 150 deg C) from furnace and all
leakages occurring in the system till the inlet of
the fan.

• Overcome the pressure drop inside the furnace,

Super heater, Reheater, Economizer, Gas ducting
& ESP.

• Consumes max. power in all boiler auxiliaries as

it handles the large volume and heavy pressure
drop of the flue gas.
 I.D Fan Design Parameters
(Contract Data Sheet)
125 MW 250 MW 500 MW
(Giral-CFBC (Suratgarh-1 (Rihand-3
Boiler) Conventional) Conventional)
Type NDZV 28- Sidor NDZV 33 Sidor NDZV 47 Sidor
Nos 2 3 2
Flow (m3/sec) 149.9 250.5 593.3
Pressure 35 487 502
(mmwc)
Temp. 170 150 150
Drive Motor Motor Motor
Speed (rpm) 740 740 580
Motor (KW) 775 1750 4050
Control Inlet Damper IGV + IGV+VFD
Hydraulic
Coupling
INDUCED DRAFT FAN
 Scanner Air Fan
• Scanner Air Fan is belong to Centrifugal Fan
category.

• Supply cooling air to all the flame scanners at

different elevations housed in the furnace for
sensing flame.

• A.C scanner fan boost the pressure of cold

secondary air from F.D fan discharge duct in
normal operation.

• D.C scanner operates only in case of a.c power

failure and sucks air directly from the
atmosphere.
 Seal Air Fan
• Seal Air Fan is also belong to Centrifugal Fan
category.

• Supply seal air at a pressure higher than system

or equipment pressure.

• Supply seal air to raw coal feeders, mills

bearings, gates etc

• Seal fan either boost the pressure of cold

secondary air from F.D fan discharge duct or
takes air directly from the atmosphere in normal
operation.
Seal Air Fan Design Parameters
(Contract Data Sheet)
250 MW
(Suratgarh-1)
Type HPSF 10.6
(Horse Power Supply Fan)
Nos 6
Flow (m3/sec) 3.9
Pressure (mmwc) 1650
Temp. 45
Drive Motor
Speed (rpm) 2880
Motor (KW) 120
Control Damper
 Construction Features
of Radial or Centrifugal Fan
(NDZV TYPE)
 Construction Features of
Radial Fan
• Air drawn into the eye of the impellor axially
through the inlet cone which provides slight
acceleration to the air.

• Consist of an impellor which has blade fixed

between the inner-outer diameter of two circular
plates.

• The action of impellor blades imparts kinetic

energy to the air & swings the air radially from a
smaller to a large radius & delivers at a high
pressure & velocity to the spiral casing.
SPIRAL CASING OF RADIAL FAN
SPIRAL CASING OF RADIAL FAN
RADIAL FAN IMPELLOR
RADIAL FAN CONSTRUCTION
 Major Sub-Assemblies of Radial Fan
1. Spiral Casing
• Two parallel side walls
• Spiral Wall
• Suction Chamber
• Inlet cone
2. Impellor
3. Shaft
4. Bearings
5. Inlet Guide Vanes Assembly
6. Sealing System
RADIAL FAN CONSTRUCTION
Construction Features
of Axial – Reaction Fan
Blade Pitch Control
(A.P TYPE)
 Construction features of
Axial-Reaction Fan
• Suited for low resistance applications & where
outlet velocities required is higher.

• Consist of the cylindrical casing encloses the rotor.

• Rotor made up of a no. of blades(varies from 2 to

50) fitted to the hub of the rotating shaft. Blade
pitch can be either of fixed or variable type.

• Rotor receives flow of air from suction chamber

through a well shaped converging nozzle &
discharge it through a diverging nozzle or diffusor.

• Guide vanes are fixed in downstream of the rotor

to recover static pressure from the spinned air.
 Major Sub-Assemblies of
Axial-Reaction Fan
1. Stator Parts
• Suction Chamber
• Impellor Housing
• Diffusor
• Expansion Joints

2. Rotor Assembly
• Shaft
• One or Two Impellors Assembly
 Support Body houses the blade
shafts & blade bearings
 Hub
 Aerofoil Blades
 Hydraulic Servomotor
 Major Sub-Assemblies of
Axial-Reaction Fan
3. Hydraulic Servomotor
• Control Slide
• Cylinder
• Double Acting Hydraulic Piston
• Adjusting Disc

4. Rotor Bearings

5. Rigiflex Coupling with Intermediate Shaft

6. Oil Supply Unit

• Lubricating oil for fan bearings
• Control oil for Blade pitch variation

7. Silencer
AXIAL – REACTION FAN
CONSTRUCTION
AXIAL FAN CONSTRUCTION
AXIAL FAN (TWO STAGE ROTOR)
CONSTRUCTION
Motor - Fan - Diffuser
AXIAL- FAN CONSTRUCTION