Performance of fans after retrofittinig.ppt

Performance of fans after retrofittinig

1. PERFORMANCE OF FANS
AFTER RETROFITTING
AT VARIOUS PLANTS
At the heart of perfect systems

2. Saving in, power consumed for a period of one year,
considering at Rs. 4.50 per kW for 7000 operating hours.
(252-165) x 7000 x 4.50 = Rs. 27,40,500/-
Therefore average saving in power for one month
=Rs. 27,40,500.00 / 12
=Rs. 2,28,375.00
Return on investment = 10,00,000/2,28,375 = 4.37 Months.
Example : Application : Cooler ESP Fan in Cement Plant
Client : Manikgarh Cement
At the heart of perfect systems

3. Client : Manikgarh Cement Application : Cooler ESP Fan
Before Retrofitting
420,120 m
3
/HrFlow
Static Pressure
Power
Fan Speed
180 mm WG
402 kW
740 rpm
After Retrofitting
500,040 m
3
/Hr
85 mm WG
165 kW
472 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make : ABB
Efficiency 51.2 % 70.1 %
441,360 m
3
/Hr
45 mm WG
252 kW
469 rpm
21.5 %
Design Operating
At the heart of perfect systems

4. Client : India Cements Ltd.. Application : VRM Exhaust Fan
Before Retrofitting
6,30,000 m
3
/HrFlow
Static Pressure
Power
Fan Speed
950 mm WG
2100 kW
980 rpm
After Retrofitting
6,30,000 m
3
/Hr
1000 mm WG
2016 kW
971 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency

Existing Fan Make : Hamada Blower Co.
Efficiency 77.6 % 85 %
At the heart of perfect systems

5. Client : Raasi Cement Ltd. Application : Waste Gas Fan
Before Retrofitting
414,000m
3
/HrFlow
Static Pressure
Power
Fan Speed
900 mm WG
1463 kW
950 rpm
After Retrofitting
414,000 m
3
/Hr
900 mm WG
1424 kW
950 rpm
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make : Andrew Yule
Efficiency 69.4 % 77.26 %
At the heart of perfect systems

6. Client : Orient Cements Application : Pre Heater Fan
Before Retrofitting
384,240m
3
/HrFlow
Static Pressure
Power
Fan Speed
800 mm WG
1186 kW
990 rpm
After Retrofitting
432,000 m
3
/Hr
750 mm WG
1086 kW
880 rpm
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Improving Capacity &
Increasing Efficiency
Existing Fan Make : KHD HUMBOLDT
Efficiency 70.6 % 81.3 %
At the heart of perfect systems

7. Client : ACC - Wadi Application : K3 Waste Gas Fan
Before Retrofitting
293,400 m
3
/HrFlow
Static Pressure
Power
Fan Speed
900 mm WG
1060 kW
980 rpm
After Retrofitting
332,800 m
3
/Hr
975 mm WG
1065 kW
989 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Power Saving and
Increasing Capacity
Existing Fan Make : ABB
Efficiency 67.8 % 78.2 %
At the heart of perfect systems

8. Before Retrofitting
6,50,000 m
3
/HrFlow
Static Pressure
Power
Efficiency
140 mm WG
413 kW
60 %
After Retrofitting
738,000 m
3
/Hr
250 mm WG
646 kW
82 %
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency,
power saving and
increasing capacity
Existing Fan Make : FLS
At the heart of perfect systems
Client : Larsen & Toubro - Awarpur Application : Kiln ESP Fan
Fan speed 300 rpm 365 rpm

9. Client : ACC - Wadi Application : K1 & K2 Waste Gas Fan
Before Retrofitting
189,360m
3
/HrFlow
Static Pressure
Power
Fan Speed
960 mm WG
660 kW
980 rpm
After Retrofitting
189,360 m
3
/Hr
960 mm WG
586.5 kW
992 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Power Saving and
Increasing Capacity
Existing Fan Make : ABB
Efficiency 75 % 84.5 %
At the heart of perfect systems

10. Client : Larsen & Toubro - Awarpur Application : Cooler ESP
Fan
Before Retrofitting
780,000m
3
/HrFlow
Static Pressure
Power
Fan Speed
150 mm WG
501 kW
500 rpm
After Retrofitting
780,000 m
3
/Hr
180 mm WG
474 kW
509 rpm
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Power Saving and
Increasing Capacity
Existing Fan Make : FLS
Efficiency 63.5 % 80.7 %
At the heart of perfect systems

11. Client : Raasi Cement Ltd. Application : Cooler ESP Fan
Before Retrofitting
681,840 m
3
/HrFlow
Static Pressure
Power
Fan Speed
165 mm WG
381 kW
590 rpm
After Retrofitting
732,960 m
3
/Hr
150 mm WG
428 kW
678 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make : Batliboi
Efficiency 81.5 % 70.0 %
591,000 m
3
/Hr
80 mm WG
390 kW
600 rpm
33.0 %
Design Operating
At the heart of perfect systems

12. Client : Zuari Cement Application : Raw Mill Fan
Before Retrofitting
180,000 m
3
/HrFlow
Static Pressure
Power
Efficiency
615 mm WG
520 kW
58 %
After Retrofitting
180,000 m
3
/Hr
615 mm WG
365 kW
82.6 %
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Power Saving and
Improving Efficiency
Existing Fan Make :
At the heart of perfect systems

13. Client : ACC - Lakheri Application : Bag House Fan
Before Retrofitting
300,000 m
3
/HrFlow
Static Pressure
Power
Fan Speed
300 mm WG
298 kW
945 rpm
After Retrofitting
330,000 m
3
/Hr
270 mm WG
309 kW
980 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
& Increasing Capacity
Existing Fan Make : ABB
Efficiency 54.8 % 78.5 %
At the heart of perfect systems

14. Client : JK Corp - Lakshmi Cements Application : Cooler Vent
Fan
Before Retrofitting
2,45,000 m
3
/HrFlow
Static Pressure
Power
Fan Speed
330 mm WG
367 kW
985 rpm
After Retrofitting
4,66,000 m
3
/Hr
172 mm WG
297 kW
980 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
& Increasing Capacity
Existing Fan Make : Andrew Yule
Efficiency 60 % 73 %
At the heart of perfect systems

15. Client : Madras Cements Ltd. Application : Pre Heater Fan
Before Retrofitting
72,000 m
3
/HrFlow
Static Pressure
Power
Fan Speed
650 mm WG
164 kW
985 rpm
After Retrofitting
85,000 m
3
/Hr
750 mm WG
193 kW
980 rpm
Components replaced : Impeller, Casing &
Inlet Cone
Reason for retrofitting : Increasing Capacity
Existing Fan Make : Andrew Yule
Efficiency 78.0 % 79.6 %
At the heart of perfect systems

16. Client : Orient Cement Application : Cooler ESP Fan
Before Retrofitting
405,000 m
3
/HrFlow
Static Pressure
Power
Fan Speed
125 mm WG
187 kW
745 rpm
After Retrofitting
390,000 m
3
/Hr
100 mm WG
135 kW
745 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
Existing Fan Make : Andrew Yule
Efficiency 73.7 % 78.7 %
294,000 m
3
/Hr
70 mm WG
190 kW
710 rpm
29.5 %
Design Operating
At the heart of perfect systems

17. Client : ACC - Chanda Cement Works Application : Kiln ESP Fan
Before Retrofitting
2,00,000 m
3
/HrFlow
Static Pressure
Power
Fan Speed
130 mm WG
120 kW
980 rpm
After Retrofitting
2,00,000 m
3
/Hr
130 mm WG
95 kW
971 rpm
Components replaced : Impeller, Shaft &
Inlet Cone
Reason for retrofitting : Improving Efficiency
& Increasing Capacity
Existing Fan Make : Kilburn
Efficiency 59 % 75 %
At the heart of perfect systems

18. D) Overall dimensions of existing Fan arrangement, as marked `?’ ;
C) Overall dimensions of existing Fan Casing, as marked `?’ ;
IMPROVEMENT OF EFFICIENCY BY INSERTING HIGH EFFICIENCY IMPELLER
IN THE EXISTING CASING OF LOW EFFICIENCY CENTRIFUGAL FANS
A) DESIGN PARAMETERS B) REVISED PARAMETERS,
OF EXISTING FAN : IF ANY :
Application : …….……... : ……………..
Flow rate, m
3
/Hr: …………… : ……………..
Static Pressure, mm WG : …………... : ……………..
Temperature,
o
C : …………... : ……………..
Inlet Density, Kg/m
3
: …………… : ……………..
Fan Speed, RPM : …………… : ……………..
Dust Load, Kg/m
3
: …………… : ……………..
Fan Shaft Power, kW : …………... : ……………..
Arrangement of Fan : …………... : ……………..
Drive Arrangement : …………... : ……………..
Make of the Fan : ………. …. : ……………..
Model No. of the Fan : …………... : ……………..
Motor connected-kw&rpm : …………... : ……………..
At the heart of perfect systems

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