INDUCED DRAFT FAN

RITESH KUMAR CONSTRUCTION , M6K221 MECHANICAL ENGGINEER

Reference : shaft alignment hand book", john piotrowski.

Ritesh Kumar M6K221
1

DRAFT SYSTEM

Supply air for combustion Remove air from furnace Transporting pulverized coal to furnace Maintain speed for heat transfer

Ritesh Kumar M6K221

DRAFT SYSTEM

Ritesh Kumar M6K221

TYPES OF FANS
Axial fan
Fluid comes axially . Get compressed while

Centrifugal fan
Fluid comes axially. Get compressed because of

moving axial. Move out axially.

centrifugal action. Comes out of fan radially.

Ritesh Kumar M6K221

CENRIFUGAL FANS

Ritesh Kumar M6K221

ERECTION OF INDUCED DRAFT FANS

Blue matching
Erection of packer plates Primary alignment Secondary alignments Inlet cone erection Erection of casing

Blue matching of machine foot , wedge plates and packer plates is done
Ritesh Kumar M6K221
6

Leveling device
Packer plate

Ritesh Kumar M6K221

Erection of packer plate

Elevation

Flatness
Co planarity positioning

Ritesh Kumar M6K221

Master level

Ritesh Kumar M6K221

Installation of induced draft fan

Ritesh Kumar M6K221

10

Result of improper installation

Lose of production
Premature failure of machine components Loss of energy

To insure ,before alignment some primary checks are done

Ritesh Kumar M6K221

11

Preliminary checks
Coupling half runout
Soft footing Bearing

Ritesh Kumar M6K221

12

Runout check
Runout standards
Shaft speed Maximum runout 0.13 mm

0-1800 rpm

1800-3600 rpm

0.08 mm

3600+ rpm

0.05 mm

Maximum times these standards are provided by manufacturer

Ritesh Kumar M6K221

13

Ways of detecting soft foot

Dial indicator shims

Ritesh Kumar M6K221

14

Checking procedure
Dial indicator
First tight the bolt Place dial indicator Loose bolts See dial show less then 0.06

shims
Check gap between foot and

mm.

pedestal by shims at four sides of foot. They should come same other wise soft footing is there.

Repeat this for all foots

Eliminating soft footing is most time consuming and skilled job. Machines on maximum occasion have vibration problem due soft footing This is very much a trial and error method because every time you need to put shims as per calculation and check for soft footing till you eliminating.

Ritesh Kumar M6K221

15

Example of soft footing

This condition is outcome of

bad blue matching, leveling and complaining of packers

Reasons of soft footing

Insufficient contact between machine foot and pedestal. Noncoplanarity foot or pedestal .
Ritesh Kumar M6K221
16

Alignment basics

Ritesh Kumar M6K221

17

Types of misalignments

Measured in mm

Measured in degree of angle

Ritesh Kumar M6K221

18

Calculation of angular misalignment

Ritesh Kumar M6K221

19

Alignment methods
Face to Rim method Reverse indicator method

There other method to align shafts but these are predominantly used. Reverse indicator method is more accurate then Face to Rim method.
Ritesh Kumar M6K221
20

Face to Rim method

Advantage of Face to Rim method above reverse indicator method , it can be used for alignment when rotating both shaft is not possible

Both shafts are moving so facial reading is going to be effected. To overcome ,we are using two extra dial indicator .
Ritesh Kumar M6K221
21

Set of readings

Making compensation for shaft movement is important .

Ritesh Kumar M6K221
22

Other arrangement used in Face to Rim method

Axial reading = A1- A2/2

Why compensation is this?

Ritesh Kumar M6K221
23

Dimension required

Accuracy of Face to Rim method depends on diameter at which facial reading is taken.
Ritesh Kumar M6K221
24

How to align
Electrical machines have magnetic center , so motor shaft first

needs to be positioned to it magnetic center , only then alignment is done. With above mentioned formula calculate position of Driver and Driven machine inboard and outboard foots. Find out movement of inboard and outboard foots to make shafts collinear and coplanar. This can easily be done by using graph paper Individuals do it on hit and trial basis but by using above process can be done in less time.
Magnetic center of electric machines is specified by manufacturer 25

Ritesh Kumar M6K221

Interpretation of dial reading in 3-D view

Ritesh Kumar M6K221

26

Example

Page 361
Ritesh Kumar M6K221
27

Reverse indicator method

Same process of finding movement of Drive and Driven machine inboard and outboard foot to align shafts we follow here.
Ritesh Kumar M6K221
28

Why to rotate both shaft

Ritesh Kumar M6K221

29

Alignment specification
Most of time provided by manufacturer

Depends on coupling ,speed and power.

NTPC allowable tolerance Parallel misalignment
Output of rotor in KW Coupling Speed rpm
Below 400 (mm) 400-1000 (mm) Over 1000 (mm)

Angular misalignment
Output of rotor in KW Coupling Speed rpm
Below 400 (mm) 400-1000 (mm) Over 1000 (mm)

2500-4000

0.01 0.025 0.04 0-01 0.015

0.02 0.04 0.06 0.02 0.03

0.03 0.06 0.10 0.03 0.04 Rigid coupling Flexible coupling

2500-4000
1300-2500 Below 1300 2500-4000 Below 2500

0.02
0.06 0.08 0.02 0.03

0.03
0.07 0.10 0.03 0.04

0.04
0.10 0.15 0.04 0.05

Flexible coupling

1300-2500 Below 1300

Rigid coupling

2500-4000
Below 2500

Ritesh Kumar M6K221

30

OPERATION PROBLEM
Part load Fluctuating weather

Ritesh Kumar M6K221

31

FLOW CONTROLING
Dampers
Inlet vane Hydraulic variable speed coupling Variable frequency drive

Ritesh Kumar M6K221

32

Inlet vane

Damper

Inlet control valve is also controlled by motor actuators

Actuator

Ritesh Kumar M6K221

33

Ritesh Kumar M6K221

34

Mechanical comparison
Speed (flow) 100 % 90% 80% 70% 60% Hours 400 800 4000 2000 800 Load KW 933 680 477 320 201 Fluid coupling KWh 439,000 725,000 2,935,000 1,143,000 350,000 Variable speed coupling 439,000 648,000 2,229,000 780,000 201,000

Annual KWh
Annual energy cost Maintenance costs Total annual costs Capital costs Total five year cost Total ten year cost

5,559,000
$279,600 $20,000 $299,600 $235,000 $1,733,000 $3,231,000

4,367,000
$218,350 $10,000 $228,350 $295,000 $1,436,000 $2,578,000

Cost summary
Ritesh Kumar M6K221
35

The application considered above is an induced draft fan

Horse power 1250 hp. Cost of energy is $0.05.

Reference :
Fan drive system efficiencies", Universal Dynamics Limited, ADAM CREERY .
Ritesh Kumar M6K221
36

THANK YOU

Ritesh Kumar M6K221

37