Thompson R, Wong D

Proc Aust Soc Sugar Cane Technol Vol 32 2010

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BOILER INDUCED DRAFT FAN OPTIMISATION

By
RHYS THOMPSON, DANE WONG
Aireng Pty Ltd, Boronia, Victoria
dane@aireng.com.au
KEYWORDS: Induced Draft Fan Selection,
Boiler Fan Design, Sugar Mill Boilers.
Abstract
THE PURPOSE of this paper is to educate the younger generation of
engineers currently working in the sugar industry and to help them avoid
certain pitfalls that are generally associated with boiler induced draft fan
selections. We have been asked by the engineering sections of many
sugar mills, both in Australia and overseas, to write a paper so they can
avoid consequences of poor boiler induced draft (ID) fan selection.
Knowledge and examples put forth in this paper are a result of many
years of experience working with industrial fans and their applications
and, as a result, can provide valid reasons as to what type of fan is best
suited for each application and why.
Introduction
Boiler induced draft (ID) fans are a crucial item of plant production and down
time and loss of production can be a result of a poorly designed or installed fan.
Therefore, it is important to have a fan system that is designed exactly to the
specifications of the plant.
For energy consumption to be kept as low as possible and for fan durability,
the fan system should run at or as close as possible to its best efficiency point (BEP).
Operating away from this point can increase energy consumption and excess airflow
noise.
There are many different fan designs and arrangements available for each
application, some more suitable than others. Wear resistant impellers and wear liners
can be integrated into the design of the impeller for abrasive airstreams.
Ducting setup is extremely important so as to not unduly increase the system
effect or cause inappropriate conditions at the fan inlet or outlet. Fan accessories can
also be incorporated to further increase the fan efficiency and fan life.
Maintenance is crucial to efficient and successful machinery; therefore care
must be taken to ensure adequate access around the fan so that maintenance work can
be conducted without too much hassle. Condition monitoring is also available in the
form of vibration monitoring, which is cheap insurance to maintain a successful
working fan.
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Boiler ID fan selection

The designer should be proficient in applying the correct fan design to ensure
optimum selection criteria of duty point, capital cost, efficiency and power
consumption.
There are many factors that need to be taken into account when looking at the
fan requirements and these will impact on the duty requirements. Some examples of
what needs to be considered are:

Noisewhat is the allowable noise limit?

Applicationdoes the gas stream contain solids or particulates? Is the

gas stream explosive? Is the fan in a hazardous zone?

Corrosionis the gas stream corrosive? If so, a selection of materials

and/or coatings should be designed to resist corrosion.

Controlwhat type of control does the fan require? Devices such as

variable inlet vanes, dampers and variable frequency drives should be
considered.

Gas densitythis needs to take into account the altitude, temperature,

humidity, and negative barometric pressure and gas combinations.

Duty locationwhat part of the fan curve is the system to operate in?

Entry/exit conditionswill the entry/exit conditions allow the fan to

operate at its design point? If excessive turbulence is present, then the
impeller may not properly impart energy on the airstream.

Accessoriesconsider application and cost or accessories such as

vibration or temperature monitoring, flow control or acoustic
treatment.

Foundationswhere is the fan to be located? If above ground on a

structure, then consider what level of isolation is required.

Maintenanceconsider fan location; provide safe and adequate

working space and access for lifting equipment.

Uncertaintiesadd a margin of 1530% on pressure calculations.

ID fan requirements: duty
Fan selection starts with a basic knowledge of the system operating
parameters as these conditions determine the size and design of the fan required.
Certain parameters, including volume flow rate, pressure, temperature,
elevation, gas density, moisture content, contaminants (carryover, corrosion, erosion,
sticky particulates etc.) and conveying velocities (to avoid product dropout or
velocity erosion), are all crucial to an appropriately sized and designed fan system.
For example, if a fan is designed to work in a clean air environment, but is
subjected to dirty air (particulate), then build up is likely to occur. This in turn can
create an imbalance in the impellor and, if left un-checked for long enough, can
totally destroy the fan assembly.
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A conservative design tendency is to source a fan/motor assembly that will be

large enough to accommodate uncertainties in the system design, fouling effects, or
future capacity increases (Air Movement and Control Association, 2003).
This creates other problems such as excess noise, inefficient fan operation and
excessive energy costs.
Therefore, care must be taken when determining the fan requirements so that
the air volume flow rate and pressure rise are not over or under delivered.
Fitting variable speed drives (VSDs) imparts flexibility into the system and
can save large quantities of power by operating at a speed correct for flow
requirements.
This also gives the benefit of a possible future increase in duty, as long as the
fan system can support it.
Selecting gas cleaning device
Selecting a gas cleaning device is important when designing a boiler ID fan;
traditionally we recognise two distinct categories, particulate control devices and
gaseous control devices.
Particulate control devices (such as baghouses) collect dust, mists and other
solid and liquid particles, whereas gaseous control devices (such as wet scrubbers)
capture or convert gaseous emissions.
It is important to know at the design stage which type of gas cleaning device
is going to be used so an appropriate fan design can be chosen. For example:

Airfoil and backward inclined impeller design fans work best with
electrostatic precipitators (ESPs) but if they are handling high dust
loads consider using radial tip (i.e. field loss).

Airfoil and backward inclined impeller design fans work best with
baghouses but if they are handling high dust loads consider using
radial tip (i.e. broken bags).

More radial type impeller design fan works best with wet scrubbers.
Stage/inlet requirements
Double inlet, double width
As can be seen in Figure 1, double inlet double width (DIDW) fans use two
inlets and one common outlet to deliver the duty they are designed for.
A DIDW centrifugal fan is created by combining a clockwise and counterclockwise fan into one unit.
DIDW fans are used when the air volume flow rate requirements are too large
for the size and speed of a single width single inlet (SISW) fan.
Therefore the height of the scroll housing stays the same; only the total width
of the housing is increased.
DIDW fans are best suited to large volume flows with medium pressure rise
requirements and by having dual inlets the DIDW fans can be better suited for large
electrostatic precipitators or baghouses.
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Fig. 1Double inlet double width boiler fan with inlet boxes.

Single inlet, single width

Figure 2 shows a single inlet, single width (SISW) fan that uses one inlet and
one outlet to deliver the design duty. SISW fans are best suited to smaller volumes
flow rates and medium pressure rises. SISW fans can be up to 0.51.5% more
efficient than DIDW fans for some applications.

Fig. 2Single inlet single width fan assembly.

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ID fan wear materials/wear resistance

Materials handling fans are designed to withstand abrasive and sometimes
corrosive environments. There are certain types of materials that can withstand
abrasion better than others, therefore impellers and casings can be designed using
materials other than mild steel.
For example, quenched and tempered materials such as Bisalloy can have
three times the wear resistance of mild steel (Anon., 2006) so, for a highly abrasive
environment, Bisalloy can be used instead of mild steel to extend the life of the
impeller. Austenitic stainless steel can also be used in light to medium dust loads as it
has approximately 20% better wear resistance than normal carbon steel.
Another option to increase the wear resistance of impellers is to use checker
plate or studded wear liners. These wear liners work by creating a boundary layer of
air above the material surface which deflects the particulate away from the impeller
surface. These types of wear liners can also break the particulate up into smaller
particles. Previous applications using these types of wear liners have yielded twice
the service life of Bisalloy 80.
ID fan ducting setup
Poor airflow conditions (turbulent air) at the inlet of a fan decrease the
efficiency and effectiveness with which a fan can impart energy on an airstream (Air
Movement and Control Association, 2003). Therefore, adequate engineering
consideration is required when designing the ducting setup for a fan system so as not
to increase the system effect, which is discussed in more detail later, too much.
In most fan systems, friction between the airstream and the ducting surface
accounts for most of the energy consumed by the fan. This resistance between the
airstream and the duct surface is a function of the square of the velocity.
Consequently, the larger the duct diameter, the lower the friction loses and hence the
lower the operating costs.
The key to a successful ducting system is to design the system so that fan
entry and exit losses are kept to a minimum. For this to be achieved, the air must be
delivered to the fan in a stable fashion. The industry accepted standard for achieving a
uniform flow is the equivalent of six effective duct diameters after the last fitting. As
space is often a requirement for most fan installations, common practice is to install
bends to the inlet of the fan.
This is far from ideal and a better alternative is to install inlet boxes as these
are the best suited solution and can sometimes save space. Another possible method
is to introduce flow straighteners / flow vanes into the elbow, this helps to straighten
the airstream before entry to the impeller.
As with fan inlet ductwork, fan outlet duct design can have a dramatic effect
on fan performance. Ideally the fan should be fitted with an evase or discharge that
provides a smooth transition to the connecting ductwork.
Bends and changes of direction should not be positioned directly after the fan
wherever possible and care should be taken with the handing of the fan so that the
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discharge flow is sympathetic to the ducting. Air velocities must also be kept high
enough so that product does not drop out of the airstream.
System resistance and system effect
System resistance is the frictional loss it takes to move a given mass of air
through a given duct system. In steady state condition the pressure loss increases by
the square of the volume flow rate.
System effect is the additional loss of performance due to the flow conditions
entering or exiting the fan. During the design process, the system curve is calculated
by adding all of the losses of the system components (dampers, ducts, filters, process
equipment etc.) and the result of this is a parabolic line, shown as the system curve.
This line is based on all components operating in an ideal environment,
whereas in reality there are non-uniform airflow profiles which cause system
components to exhibit losses higher than expected, as can be seen in Figure 3.
It does not matter what type of fan is fitted, the fan operating point will
always lie on the system curve, and even a poorly selected fan that may be a long way
from its optimum efficient point will still be on the system curve. The fan does not
control the system curve; the system does.

Fig. 3Example of a system curve (Air Movement and Control Association, 2003).

Each 2.5 diameters of straight duct between fan and elbow or inlet box will
reduce the adverse affect about 20%. This has been summarised in Table 1.
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Table 1Effect of upstream length of straight duct on the volume flow
loss and pressure loss associated with an elbow or inlet box.
Volume flow loss %

Pressure loss %

No duct

12

30

L/D = 2.5

10

24

L/D = 5

18

L/D = 7.5

12

L/D = 10

Impeller types for boiler ID fans

Some impellers commonly used are airfoil, backward inclined and radial
tipped impellers (Figures 46).
Airfoil impeller

Fig. 4Airfoil impeller schematic.

Airfoil impellers are typically used in baghouse exhaust, supply / exhaust air,
process air / gas applications and boiler ID and forced draft (FD) fans. Some of their
advantages and disadvantages are summarised in Table 2.
Table 2Advantages and disadvantages of an airfoil impeller.
Advantages

Disadvantages

High efficiency =low operating cost

High initial capital cost

Low noise output

Prone to build-up

Ideal for medium volume / medium pressure

Prone to wear
High operating speed for given duty
May not be suitable for high temperature

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Backward inclined impeller

Fig. 5Backward inclined impeller schematic.

A backward inclined impeller is typically used in baghouse exhaust, supply /

exhaust air, process air / gas applications, some scrubber applications and boiler ID
and FD fans. Some of their advantages and disadvantages are summarised in Table 3.
Table 3Advantages and disadvantages of a backward inclined impeller.
Advantages

Disadvantages

High efficiency = Low operating cost

Suitable for high speed applications

Low noise output

High operating speed for given duty

Ideal for medium volume / medium pressure

Suitable for light dust loads
Suitable for high temperature

Radial tip impeller

Fig. 6Radial tip impeller schematic.

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A radial tip impeller is typically used in supply / exhaust air, process air / gas
applications, some scrubbing applications and boiler ID and FD fans. Some of their
advantages and disadvantages are summarised in Table 4.
Table 4Advantages and disadvantages of a radial tip impeller.
Advantages

Disadvantages

Ideal for light to medium dust loads

Low efficiency = high operating costs

High mechanical strength

High noise levels

Low tip speedreduces wear

Geometrically small size for given duty
Less prone to contaminant build up

Boiler ID arrangement set-up

Fans can be configured in different arrangements to allow for the optimum
positioning of components to suit the application.
It is important that the designer is aware of the choice available, as the correct
selection can results in substantial capital cost savings and also provide easier service
access.
The following arrangements are the typical types suited to boiler ID
applications. To determine the best suited arrangement for each application, the
following factors need to be assessed:

Spacehow much real estate is available for the fan footprint?

Accessis there enough room to inspect/maintain the fan system?

Applicationenvironmental conditions (e.g. dust) cause wear and tear

on V-Belts and loss of motor cooling efficiency.

Dutyvolume flow rate and pressure the system has to withstand.

Service intervals.

Bearing load distribution.

Drive type.
Fan rotation orientation (handing) is always viewed from where the main
drive enters the casing. Some examples of different arrangements and where they are
normally used are given in Figures 7 to 12.
The arrangement in Figure 7 is typically used on fans up to 300kW, or larger
if jack shafts are used.
Care must be taken to check the motor shaft suitability for fans utilising
motors above 110kW (e.g. shear stress).
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Fig. 7Arrangement showing belt drive single inlet single width.

The arrangements in Figures 8 and 9 are normally used for motors above
300kW or hot fans due to thermal expansion (centre support on casings). They
distribute the load better between bearings.

Fig. 8Arrangement showing single inlet single width with inlet box.

Fig. 9Arrangement showing DIDW with inlet boxes.

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The arrangement in Figure 10 is typically used on fans over 75kW. It is for

cold applications and distributes the load better between bearings.

Fig. 10Arrangement showing direct drive single inlet single width with inlet box.

The arrangement in Figure 11 is typically used on fans over 150kW. It

distributes the load better between bearings.

Fig. 11Arrangement showing direct drive DIDW with inlet boxes.

The arrangement in Figure 12 is typically used on fans below 1000kW. Care

must be taken on the drive end bearing low load condition versus out of balance load
condition. Larger motors can be used depending on design.
DIDW fans have a better load distribution across the bearings, because of the
centre hung arrangement. But they require a relatively large shaft length and
diameter.
Maintenance
Statistically, most failures are a result of lubrication issues, either related to
incorrect lubricant type, over lubrication, or not enough lubrication. Common
maintenance tasks on fan systems include:

periodic inspection of all system components

bearing lubrication and replacement

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belt /coupling tightening/alignment and replacement

motor repair or replacement
fan cleaning
fan inspection for wear signs/cracking.

Fig. 12Arrangement showing single inlet single width with inlet box.

To minimise the amount of unscheduled downtime, a basic maintenance

schedule should be created and it should be performed at regular intervals. The
maintenance interval should be according to manufacturer recommendations and
experience with similar size and type fans.
Fan maintenance is crucial to the ongoing viability of the plant. In most
instances the fan plays a crucial role in plant operations and regular checks should be
programmed to monitor lubrication, bearings, belts, motors, vibration levels, coating
and general condition.
It is also recommended that for most applications, a spare rotating assembly is
held in the clients store to ensure any breakdown situation can be dealt with promptly.
Typical lead times can be 46 weeks.
Since parts of the fan system can wear out (impellers, motors, bearings, etc.),
there should be ample room to remove and replace the parts if needed. Therefore
provisions for overhead lifting cranes or hoists should be designed into the system; if
this is not possible, then sufficient room for mobile cranes/loaders need to be
considered.
As well as overhead clearance, large inspection doors on the fan casing are a
good investment, so that regular maintenance and checks of the impeller can be
conducted. If the airstream is dirty then contaminant build up on the impeller can
cause an imbalance and if operation continues with a large imbalance, then
catastrophic failure can result.
As well as the above considerations, access around the fan is needed so that
visual inspections can be done on a regular basis.
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Condition monitoring
As well as the basic maintenance and programmed inspections, there is
another form of maintenance called condition monitoring. Condition monitoring or
predictive maintenance is a proactive way of ensuring smooth operation of plant
equipment. Vibration monitoring is best suited for fan applications as it can assess the
vibrations of the motor, fan shaft, fan casing and other areas on the fan system.
Vibration analysis equipment monitors the data over a timeline and can detect
the early symptoms of a bearing problem, motor winding problem, or dynamic
imbalance. By identifying these symptoms at an early stage repairs can be scheduled,
reducing the risk of catastrophic failure.
These devices can be permanently installed with a fan and incorporated into
an alarm or safety shut down system, which is activated if the vibration levels exceed
a certain limit. The alarm and trip limits can also be set to alert the user to any nonstandard operation.
Vibration monitors offer relatively inexpensive insurance for avoiding costly
failures and can improve the effectiveness of scheduled maintenance. The benefit of
having vibration monitors permanently installed on the fan system is that the
monitoring intervals can be increased without incurring any additional labour costs.
Conversely, with the portable units, extra labour is generated for every non routine
check.
Portable vibration monitors can also be used as a part of a plants preventative
maintenance system. These recorded vibrations can be compared against a baseline
set of data obtained after the machinery was fully commissioned. Vibration levels can
be taken at various points on the fan system to determine whether a problem exists
and if so, how quickly does it need to be fixed.
Corrosion
For corrosive airstreams, stainless steel or duplex/super duplex can be used as
an alternative to carbon steel. They offer a much higher corrosion resistance but can
be prone to chloride stress corrosion. If they are to be installed after scrubbers, care
must be taken to ensure that the airstream does not contain heavy chloride
contaminates.
Knowing the exact constituents of the airstream will help the fan manufacturer
design and manufacture the best suited impeller for the application. If the airstream is
unknown, then the impeller material may react and cause an earlier than expected or
complete failure of the impeller after a short time.
Balancing
Balancing the impeller to ISO 1940 G2.5 is recommended. Each component
should be balanced separately (i.e. coupling halves, pulleys, motor and impeller
assembly) and then the impeller, hub and shaft should be balanced as one unit. In
accordance with ISO 14694 it is recommended to trim balance fan impellers after
installation, as installation will change the stiffness and rigidity of the assembled
structure.
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Coatings
Coating systems are offered to provide resistance to certain elements of a fan
system environment. Different thicknesses, types of coatings and coating methods
can be developed and used to suit each individual application. Some examples of
special coating systems would include provisions for high temperature coatings
where airstreams reach higher than normal temperatures, thicker more robust paint
systems where environmental conditions are extreme and coatings that are more
resistant to moisture rich surroundings e.g. if fan is located after gas scrubbers and
airstream is moist. Most coating systems are used to minimise corrosion
Heavy coating systems should be avoided (over 300 microns dry film
thickness) as bolt or matching flanges can cause paint system to crack or flake,
rendering coating useless.
Every location has different requirements for the coating system to be
successful; hence understanding these conditions will ensure longevity of the
structure.
Standard accessories/minimums for boiler ID fans

split casing on fans over 700 mm

inspection doors on all fans

draining plugs on all fans

guards as per OH&S requirements

shaft seals

labyrinth bearing seals

130% margin on shaft critical speed

coupling 150% over installed motor power

V-belts sized 130% over installed motor power

quality/efficient motor

German/Japanese bearing races

lagging or cladding on hot or noisy fans

jacking screws for bearings/motor adjustment

inlet boxes (in lieu of inlet bends)

vibration monitoring on critical fans or fans over $20 000

basic finite element analysis (FEA) on big fansresonance check

suitable shaft earthing for motor and bearing insulation if a variable

speed drive is used

conservative inlet/outlet velocity, suggest 1525 m/s (subject to

system requirements).
REFERENCES
Air Movement and Control Association International (2003) Improving fan system
performancea sourcebook for industry. (US Department of Energy) pp. 186.
Anon. (2006) BISPLATE wear comparisons. Bisalloy Steels.
http://www.bisalloy.com.au/files/techman/bisplate%20wear%20comparisons.
pdf (accessed 8 December 2009).
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