Study on Alternate Arrangements For Air and Gas Tightness Test of Furnace and Ducts

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Introduction.................................................................................................................................. 3 Study Details and Conclusion .................................................................................................. 4 Drawing Reference ..................................................................... Error! Bookmark not defined.

Air Tightness Test Alternate Arrangements

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1.0

Introduction

Air and Gas tightness test of furnace and ducts is a critical commissioning activity to check and arrest the leakage points in furnace and ducts before application of the insulation. Leakages in the furnace have following negative effects: 1. As majority of the furnace operates under negative pressure, any leakage shall result into ingress of cool atmospheric air at ambient temperature. Furnace heat is consumed by the ingress air reducing the steam evaporation as well as Boiler Efficiency. Thus, it has penalty on unit load generation with same fuel consumption or extra fuel consumption for same unit load generation. 2. The furnace heat consumption by atmospheric air has tendency to reduce the Air Preheater cold end temperature. This results into increased tendency of acid dew point formation and hence cold end corrosion. 3. In general during normal operation, due to dynamism of fuel burning, especially the top zone of the furnace first pass comes under positive pressure. This results into ash leakage and accumulation in the penthouse. 4. As the air ingress into the furnace increases the volume handled by the Furnace increases. So, the flue gas velocity in the furnace increases leading to increased erosion especially in constricted zones. Leakages in the flue gas ducts have following negative effects: 1. The air leakage in flue gas ducts before Air-Preheater has effect of increased acid attack tendency at Air Preheater cold end as described above. 2. The additional air ingress in the ducts has to be handled by ID Fans in addition to flue gas volume. This results into increased Power consumption by Fans and penalty on Auxiliary Power Consumption of the unit. 3. The additional air ingress over and above flue gas volume increases the flue gas velocity for the ducts and fans. This results into increased duct and fan impeller erosion. The erosion for ducts has avalanche effect, the more it erodes the more is leaks, which again supports more erosion. 4. Leakage in the flue gas duct before Air-Preheater gives misleading oxygen content at Air-Preheater inlet which is generally used as reference for maintaining excess oxygen content.

Also, leakages in the primary air and secondary air ducts, leads to increased fan flow and hence fan power. Thus, leakages in the system has negative effect on all the performance indices of the Unit, viz. Heat Rate or Efficiency, Auxiliary Power Consumption and Availability. In this view successful air leakage test of furnace and ducts is considered critical for smooth Unit operation and is performed before application of insulation.

In view of this the system readiness is studied for performing the test. As, the test requires completion of majority of the systems and sub-systems of the unit, possibility of alternate arrangements is explored in detail.

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Study Details and Conclusion

As per commissioning procedure submitted by BHEL on Air and Gas Tightness Test of Furnace and Ducts, following is the brief table explaining the different stages of testing: Sl. No Test Approx Availability of Dampers if Press in Volume in done through FD/ PA Fan mmwc m3 SAD 2A/ 3A/ 4A and 5A and SAD 2B/ 3B/ 4B and 5B SAD 2A/ 3A/ 4A and 5A and SAD 2B/ 3B/ 4B and 5B and GD 1A1/ 1A2/ 1B1/ 1B2/ 2A1/ 2A2/ 2B1/ 2B2 and Secondary Air Dampers SAD 2A/ 3A/ 4A and 5A and SAD 2B/ 3B/ 4B and 5B and GD 1A1/ 1A2/ 1B1/ 1B2/ 2A1/ 2A2/ 2B1/ 2B2 and Wind Box Secondary Air Dampers SAD 2A/ 3A/ 4A and 5A and SAD 2B/ 3B/ 4B and 5B and GD 1A1/ 1A2/ 1B1/ 1B2/ 2A1/ 2A2/ 2B1/ 2B2 and Wind Box Secondary Air Dampers and GD 3A1/ 3A2/ 3B1/ 3B2/ 3C1/ 3C2/ 3D1 and 3D2

Stage

Circuit Description FD Fan discharge to APH inlet Secondary Air Damper including SCAPH and its bypass ducts (SA Ducts)

Remarks

Stage-I

200

700

StageII

APH inlet Secondary Air Damper to Furnace Windbox (SA Ducts)

200

Drawing NA

StageIII

Complete Furnace (1st pass, 2nd pass and extended WW) upto APH outlet Flue Gas Damper (FG Path)

50

30,000

If one secondary air/ primary air/ flue gas circuit is tested the other should be in isolated condition or both the circuits may be tested simultaneo usly.

StageIV

APH outlet Flue Gas Damper to ESP Inlet Damper (FG Ducts)

200

Drawing NA

Air Tightness Test Alternate Arrangements

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Sl. No

Stage

Circuit Description

StageV

ESP Outlet Flue Gas Damper to ID Fan Inlet Damper (FG Ducts)

StageVI

ID Fan Inlet damper to Stack (FG Ducts) PA Fan Discharge to APH inlet Primary Air Damper including Cold Primary Air ducts up to Mill Cold Air Gates and Seal Air Pipes

Test Approx Availability of Dampers if Press in Volume in done through FD/ PA Fan mmwc m3 SAD 2A/ 3A/ 4A and 5A and SAD 2B/ 3B/ 4B and 5B and GD 1A1/ 1A2/ 1B1/ 1B2/ 2A1/ 2A2/ 2B1/ 2B2 and Drawing 200 Wind Box Secondary Air NA Dampers and GD 3A1/ 3A2/ 3B1/ 3B2/ 3C1/ 3C2/ 3D1/ 3D2/ 4A1/ 4A2/ 4B1/ 4B2/ 4C1/ 4C2/ 4D1/ 4D2/ 5A1/ 5A2/ 5B1/ 5B2 Nil (Kerose 3000 Nil ne Test) PAD 2A/ 2B/ 3A/ 3B and Mill Cold Air Gates and Seal Air Fan Discharge Gates PAD 2A/ 2B/ 3A/ 3B and Mill Cold Air Gates and Seal Air Fan Discharge Gates and Mill Hot Air Gates PAD 2A/ 2B/ 3A/ 3B and Mill Cold Air Gates and Seal Air Fan Discharge Gates and Mill Hot Air Gates and Mill Discharge Valves and Burner Isolation Gates

Remarks

StageVII

500

1000

StageVIII

APH inlet Primary Air Damper to Mill Hot Air Gates

500

Drawing NA

StageIX

Mill Hot Air Gates to Furnace Burners

500

Drawing NA

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(Note: These figures are tentative based on available drawings)

In addition to the dampers in question, it requires completion of the various ducts and FD/ PA fans, and these stages can be completed in sequence. The fans require start-up power, CW system, DM Plant, DMCW system and ACW system readiness. As, these systems are not ready and insulation on ducts and furnace are time intensive activity, alternate arrangements are explored to carry out the test. The ducts in question from Stage-I to IX have very small volumes and can be tested with temporary blower of suitable capacity in isolated sections with application of suitable blanks at various locations. The availability of Blowers/ Fans at site was also explored and details are furnished as under: Fan Name FD fan PA fan Seal Air fan HVAC Fans HVAC Fans Voltage (KV) 11 11 0.415 0.415 0.415 Motor Rating(KW) 1325 3900 132 28.75 (Fan Power- BKW) 18.62 (Fan Power- BKW) Pr. (mmwc) 415 1350 508 70 60 m3/hr. 864000 792000 28800 10000 75000 Marathon Electric Make/ Model No. AF-BCDI-120 available at site Marathon Electric Make/ Model no. AF-BCSI-130LGO available at site Remarks

Seal Air Fan seems the most suitable option for carrying out the test on the ducts as it can develop higher head than required test head of 200/ 500 mmwcl. The flow capacity of the fan also is very high to meet the demands of the test. The fan can be operated with suction from atmospheric air. As, motor rating is <200 KW, the same can be started on the construction power and availability of start-up power is not required. Further, the fan is lubricated with sump oil and external cooling water is not required for this lube oil. Hence, it can be run independent of availability of other systems viz. CW, ACW and DMCW. Detailed Seal Air Fan and Motor details (derived from Seal Air Fan commissioning Procedure is furnished below: Sl. Parameter No. Fan Ratings Capacity Total Head Temp of Medium Density Speed Fan Drive Coupling Lubrication Motor Ratings Rating Speed Unit Value

m3/ Hr mmwcl Deg C Kg/ cm3 RPM KW RPM

28800 508 50 1.055 1480 Pin Type Sump Oil (ISO VG 68) 75.7 1480 Page 6

Air Tightness Test Alternate Arrangements

Sl. No.

Parameter Volt Current Type of Duty

Unit Volts Amps -

Value 415 72 IS Continuous

The, HVAC fans can also be used but the test cannot be conducted at recommended test pressure and hence not recommended. The tightness test on Furnace is also studied in detail in view of high volume (30,000 m3 approx.) of total furnace including first pass, second pass, extended water wall and flue gas duct up to Air Preheater. Seal Air Fan is found suitable for this application also. The HVAC fans are equally suitable for the furnace test as test pressure is 50 mmwcl only. Besides, following additional arrangements/ readiness shall be required for Boiler: Completion of Pourable Insulation Blanking of openings for Soot Blowers Blanking of openings for Observation Doors Blanking of opening for manhole doors Furnace Trough Sealing readiness or blanking with temporary seal plate and scalloped bars (if required) 6. Plugging of instruments tapping points 7. Completion of Coal Pipe line first section from furnace burner including manual isolation gates 8. Installation of Windbox dampers Note: Welding on pressure parts is not required and blanking can be done with adhesive agents. Thus air tightness test can be conducted with Seal Air Fan or HVAC system blowers with consultation from OEMs of these fans. 1. 2. 3. 4. 5.

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