Post on 28-Oct-2020
HRL Technology Group Pty Ltd ABN 89 609 887 327 info@hrl.com.au hrl.com.au
Melbourne Level One Unit 4 677 Springvale Road Mulgrave VIC 3170 Phone +61 3 9565 9888 Fax +61 3 9565 9879
Regional Victorian OfficeGippsland Enterprise Centre50 Northways RoadChurchill Vic 3842 Phone +61 3 5132 1500
Fax +61 3 5132 1580
Queensland Unit 2 33-37 Rosedale Street Coopers Plains QLD 4108Phone +61 7 3423 4300Fax +61 7 3345 5937 1
IDFan
Cap
ability
hrl:
IDFanCapabilityOptimisinginduceddraftfanperformanceandreliability
Challenges
Sub-optimalinduceddraft(ID)fanperformancecanleadtoshort-andlong-termissuessuchas:• prematurecrackingoffanimpellers• increasedpowerconsumptionandhenceauxiliaryload• damagetofanimpellersthrougherosion.
Solutions
HRL canhelpplantoperatorsmeetthesechallengesby:• providingindependentIDfanperformance/acceptance
testingtorelevantcodessuchasASMEPTC11-Fans• auditingfandesignusingstressandmodalanalysis
(finiteelementmethods),impulsetesting,fatigueassessmentsandstraingaugesurveys
• undertakingprocessmodellingandcomputationalfluiddynamics(CFD)modellingofthefansandsurroundingductworkunderexistingandpotentialoperatingconditions.
Benefits
HRL servicesandexpertiseprovideplantoperatorswithnumerousbenefits,including:• independentacceptancetestingtoensureoriginal
equipmentsuppliersperformanceguaranteesaremet• performancetestingandprocessmodellingproviding
insightintohowplantoperatingconditionsareimpactingonIDfanperformanceandefficiency
• auditingfandesignstodeterminethesteadystate,staticanddynamicstressesexperiencedduringoperation;andthemodefrequenciesandshapes,tohelpdeterminethecauseandriskofprematurecracking
• auditingthatcanalsodetermineexpectedfanlifeandassistindevelopingweld-repairprocedures
• usingcomputationalfluiddynamicsmodellingtorevealtheunderlyingflowstructureswithinthefanandsurroundingductworktodiagnoseperformanceissuessuchasvibrationcausedbythefanoritsinteractionwithsurroundingductwork
• usingCFDmodellingtopredicterosionpatternscausedbyparticle-ladenflowstohelpplanmaintenanceandcomparescenariostominimisesucherosion.
2
Case Study
Investigating premature cracking in an ID fan
AnAustralianpowerstationfoundsignificantcrackingwithintheimpellerononeoftheirinduceddraftfans.Theimpellerhadbeenreplacedthreeyearsearlierandhadbeensubjectedtoseveraldesignchanges,suchthatthereplacementimpellercouldbeconsideredasadifferentstructuretotheoriginal.HRL wasengagedbythepowerstationoperatorstoinvestigatetherootcauseofprematurecrackinginthenewimpeller.
HRLinvestigatedthecrackingby:• installing(wireless)straingaugesontothenewimpeller
tosurveystrainduringstart-upandnormaloperation• undertakingafiniteelementanalysis(FEA)ofthefanto
determinetheresonantfrequencyoftheimpellerandmodeshapeofthenaturalfrequencies
• undertakingsteady-stateanalysistocomparetheoperatingmeanstressofthenewimpellertotheoriginal
• performingastiffenedmodalanalysistodeterminethesystem’snaturalfrequenciesandmodalshapes
• performinganunstiffenedmodalanalysistodeterminestaticnaturalfrequenciesforvalidationagainstimpacttestingresults
• performancetestingofthefanduringoperationtodetermineitsefficiencyunderdifferentoperatingconditions.
HRLestablishedthemostprobablecauseofthecrackingtobevibration,possiblylinkedtothechangedimpellerdesign.HRLprovidedthepowerstationoperatorswithoptionstopreventfurthercrackingoftheirIDfans.HRLrecommended:• thefanmanufacturerreviewthefanflow-design
characteristicsbasedontheperformancetestdataHRLcollectedunderplantoperatingconditions–nearstallatlowload
• tomitigatetheflow-inducedvibration,thestationtoconsiderasmallerfan,orinstallingavariablespeedfanorbypassductsystem
• installingflue-gasflowmeasurementdevicesonbothfanstoeliminatebiastoonefan
• specificoperatinginstructionstoavoidrunningthefanatnear-stallcondition.
Contact JamesTaylor
Telephone+61395659867Mobile+61438862702Emailjtaylor@hrl.com.au
Contact DaoNguyen
Telephone+61395659783Mobile+61427184907Emaildnguyen@hrl.com.au
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