Fans & Heaters technical seminar Centrifugal Fan Retrofit Presentation Brian Carson Aftermarket Retrofit Team Leader

Howden Centrifugal Retrofits Subjects Covered 1 What is a Retrofit – Defining the Problem and Solution 2 Example 1 – Seal Issue on GR Fan 3 Example 2 – Fan Performance Issue 4 Example 3 - Flow Control Issue on FD Fan 5 Defining the Value – By Savings and by Cost

Retrofits and Enhancements What is a Retrofit?

Retrofits and Enhancements What is a Retrofit? Retrofit A complete replacement fan or impeller installed on existing foundation.

Retrofits and Enhancements What is a Retrofit? Retrofit Enhancement A complete replacement fan or impeller installed on existing foundation. The existing fan impeller or auxiliaries are modified to change performance.

Typical Problems with Centrifugal Fans

Typical Problems with Centrifugal Fans Process limitations Misalignment Too much volume Rotating stall Not enough volume flow To much time repairing Replacing parts Catastrophic Failure Problems With Centrifugal Fans High vibration Cost increase Fatigue cracking Excessive erosion High bearing temperatures Lack of control Lost production Leakage of flue gas Bearing failure Excessive corrosion Increased power consumption Fouling of Impeller

The simplified retrofit process What is a Retrofit The simplified retrofit process

The simplified retrofit process Component Reliability Issue What is a Retrofit The simplified retrofit process Current Situation Performance Issues Component Reliability Issue

The simplified retrofit process What is a Retrofit The simplified retrofit process Current Situation Performance Issues Component Reliability Issue Desired Situation Optimised Performance Increased Equipment Availability

The simplified retrofit process What is a Retrofit The simplified retrofit process Current Situation Performance Issues Component Reliability Issue Desired Situation Optimised Performance Increased Equipment Availability Howden Solution

The simplified retrofit process What is a Retrofit The simplified retrofit process Current Situation Performance Issues Component Reliability Issue Desired Situation Optimised Performance Increased Equipment Availability Howden Solution All retrofit opportunities can generally be reduced down to performance issues and/or reliability issues.

Issues: causes, consequences and Howden solutions Fan Reliability Fan Reliability Issues Process/Flue Gas Leak Erosion Corrosion High Vibration Consequences Increased corrosion on fan shaft at seal and on fan casing etc around leak area. H&S issue for local personnel. (Poisonous, hot or explosive gas) Reduced Performance. 1. Reduced impeller life. 2. Risk of impeller failure. 3. Reduced performance. 1. Damage to equipment. 2. Risk of impeller failure. Main causes Leakage from: 1. Seals 2. Expansion Joints 3. Holes in casing Impeller/casing not designed for current level of abrasive particles in process gas. Fan has not been properly maintained during it service life. Impeller/casing not designed for corrosive environment. Fan has reached the end of its design life. 1. Imbalance or misalignment 2. Fouling 3. Structural/ Rotor dynamic issues. Howden Solutions 1. Replace seals with upgraded Howden design. 2. Replace Expansion Joints. 3. Repair/replace casing. 1. Add abrasive resistant or sacraficial materials to equipment to protect main components. 2. Replace worn components with new parts designed for increased errosion protection. Replace corroded components with new parts designed for increased corrosion protection. 1. Contact Howden Services for balancing/alignment service. 2. Clean impeller and contact Howden Services for balancing service. 3. Perform vibration analysis and replace defective part or fan with Howden replacement.

Issues: causes, consequences and Howden solutions Fan Performance Fan Performance Issues Lack of Fan Control Not Enough performance Changed Performance Too Much Performance Consequences Limited process output. Loss of revenue. Reduced availability. 1. Limited process output. 2. Loss of revenue. 1. Limited process output. 2. Loss of revenue. 3. High energy costs. Main causes 1. Seized flow controls. 2. Problem with actuator and/or linkages. 1. Fan undersized at design. 2. Process demands have changed. 1. Process system has changed. 2. Operating density has changed. 1. Fan over sized at design. 2. Process demands have changed. Howden Solutions 1. Install Howden design flow control. 2. Replace actuator and/or linkages. 1. New Howden impeller in existing casing. 2. Fan on existing foundations

What is a Retrofit Reliability Issues Performance Issues

What is a Retrofit Reliability Issues Performance Issues Flue Gas Leakage Erosion Corrosion High Vibration

What is a Retrofit Reliability Issues Performance Issues Flue Gas Leakage Erosion Corrosion High Vibration Low Performance Performance Changed High Performance

What is a Retrofit Reliability Issues Performance Issues Flue Gas Leakage Erosion Corrosion High Vibration Low Performance Performance Changed High Performance Lack of Fan Control

GRF Fan Seal Issue at PP in KSA Example 1

GRF Fan Seal Issue in KSA Example 1 Power Plant in KSA Problem Summary MHI FGD fans leaking gas at casing seal. MHI seal difficult to set and maintain. Unacceptable down time for fan/boiler. Gas leakage a health hazard to personnel. Accelerated corrosion of components when leaked gas condenses to form acid.

Component Reliability Issue GRF Fan Seal Issue in KSA Example 1 Power Plant in KSA Problem Summary MHI FGD fans leaking gas at casing seal. MHI seal difficult to set and maintain. Unacceptable down time for fan/boiler. Gas leakage a health hazard to personnel. Accelerated corrosion of components when leaked gas condenses to form acid. = Component Reliability Issue

GRF Fan Seal Issue in KSA Example 1 Power Plant in KSA Desired Improvements Client wished to achieve: 100% sealing of boiler flue gasses. Easy set up and maintenance to reduce fan/boiler down time. Reduce unplanned outages to fix seals.

GRF Fan Seal Issue in KSA Example 1 Power Plant in KSA Desired Improvements Client wished to achieve: 100% sealing of boiler flue gasses. Easy set up and maintenance to reduce fan/boiler down time. Reduce unplanned outages to fix seals. Howden Solution Howden would perform a retrofit of the current MHI casing seals and replace with a Howden designed purged double carbon ring seal.

GRF Fan Seal Issue in KSA Example 1 Power Plant in KSA Issues with Labyrinth Seal Type 1±0.3 mm clearance between labyrinth brush and labyrinth ring. Potential wear of labyrinth brush. Reduced sealing and escape of gas. Difficult for seal setting and maintenance. Labyrinth Seal

GRF Fan Seal Issue in KSA Example 1 Power Plant in KSA Benefits of Howden Seal Retrofit 100% gas sealing due to high pressure purge air. “Floating seal” arrangement accepts thermal expansions. Increased radial clearance prevents shaft & seal housing contact. Double Carbon Ring Seal

GRF Fan Seal Issue in KSA Example 1 Power Station in KSA Howden replaced the original seals arrangement with the following equipment: Double carbon ring seal, in stainless steel housing, with purge air Stainless steel seal carrier to connect to fan casing. Stainless steel shaft sleeve. Purge air filter and regulator. Cast aluminum cooling disk. Howden also provided onsite Technical Assistance during installation and commissioning phase of the project.

GRF Fan Seal Issue in KSA Example 1 Power Station in KSA Before installation of Howden designed shaft seal After installation of Howden designed shaft seal

After installation of Howden designed shaft seal GRF Fan Seal Issue in KSA Example 1 Power Station in KSA After installation of Howden designed shaft seal

GRF Fan Seal Issue in KSA Example 1 Power Station in KSA Outcome All seals (16 off) successfully operating since 2014 Saving approx 1 week down time per year per boiler.

PA Fan Performance Issue at PP in Malaysia Example 2

PA Fan Performance Issue in Malaysia Example 2 Power Station in Malaysia Problem Summary Environmental legislation changes meant improvements were required to the combustion in the boiler. New coal mill required in each boiler. Current volume flow from Howden Primary Air fans not enough for additional mill.

= Performance Issue PA Fan Performance Issue in Malaysia Example 2 Power Station in Malaysia Problem Summary Environmental legislation changes meant improvements were required to the combustion in the boiler. New coal mill required in each boiler. Current volume flow from Howden Primary Air fans not enough for additional mill. = Performance Issue

PA Fan Performance Issue in Malaysia Example 2 Power Station in Malaysia Desired Improvements Client wished to achieve: Primary Air Fan to deliver increased volume flow to accommodate an additional mill. Retain and reuse the existing fan foundations, casing and motor. Carry out improvement work during normal shutdown.

PA Fan Performance Issue in Malaysia Example 2 Power Station in Malaysia Desired Improvements Client wished to achieve: Primary Air Fan to deliver increased volume flow to accommodate an additional mill. Retain and reuse the existing fan foundations, casing and motor. Carry out improvement work during normal shutdown. Howden Solution Howden would perform a retrofit of the current Howden impeller, with a larger impeller of the same family.

PA Fan Performance Issue in Malaysia Example 2 Power Station in Malaysia Performance Guarantees and Testing The end user required an increase of 5 % volume to achieve the minimum flow requirements of the new mill. Howden carried out fan performance testing before and after the retrofit to determine the level of improvement in performance. This testing determined if Howden had exceeded the minimum guaranteed increase of 5%. The test results over 2 off fans ranged from 5.3 to 7.6 %. This indicated that the minimum target had been exceeded.

PA Fan Performance Issue in Malaysia Example 2 Power Station in Malaysia Outcome The test results for the 2 off fans of the 1st boiler indicated that the 5% target had been exceeded. The end user then contracted Howden to roll out the same solution on the 4 off fans on the remaining 2 off boilers. After installation and testing, all fans achieved a volume increase of 5.3 to 7.6 % on volume flow.

FD Fan Flow Control Issue at PP in KSA Example 3

FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Problem Summary Boldrochhi Forced Draught Fan flow controls sticking. Causing limitation of fan volume output, limiting boiler output. Unplanned down time and maintenance unacceptable.

Performance and Component Reliability Issue FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Problem Summary Boldrochhi Forced Draught Fan flow controls sticking. Causing limitation of fan volume output, limiting boiler output. Unplanned down time and maintenance unacceptable. = Performance and Component Reliability Issue

FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Desired Improvements Client wanted: Flow controls to work fully and freely and allow full fan and boiler performance to be achieved. To reduce and eliminate unplanned maintenance and down time.

FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Desired Improvements Client wanted: Flow controls to work fully and freely and allow full fan and boiler performance to be achieved. To reduce and eliminate unplanned maintenance and down time. Howden Solution Howden would perform a retrofit of the current Boldrochhi flow controls and replace with a Howden designed Inlet Louvre Damper.

Boldrochhi Radial Vane Control FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Issues with Flow Control Sand/dust entrained in air clogging the lubricating/wear parts in the flow control leading to seizing. Seized parts are inside fan meaning fan must be turned off for maintenance. Boldrochhi Radial Vane Control

FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Benefits of Howden ILD Retrofit All operational duties achievable. No change required to actuator. No change required to DCS operation. All serviceable parts external to air flow. Inlet Vane Control

FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA To meet our client’s requirements, Howden, along with our local partners in Saudi Arabia, provided the following services:   Site Investigation Work. Design of all required parts. Manufacture and Supply of all required parts. UK based project management of supply scope. Installation planning. Removal of existing equipment. Installation of new Howden equipment. Post installation commissioning and hand over. Site supervision and local project management from our UK team on site. Local skilled site labour. Scaffolding services. Lifting equipment

FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Before installation of Howden designed flow control After installation of Howden designed flow control

FD Fan Flow Control Issue in KSA Example 3 Power Plant in KSA Outcome 1st boiler FD fans have been successfully retrofitted and been in satisfactory operation since Q1 2016. 2nd and 3rd boiler FD fans have been successfully retrofitted and been in satisfactory operation since Q1 2017.

Defining the Value By energy savings

Current Non-Howden Fan Proposed New Howden Fan Defining the Value By Energy Savings Howden FD Fan Vs Non Howden FD Fan Based on $ 0.11 kWh Current Non-Howden Fan Proposed New Howden Fan Savings/Year Abs. Power (kW) Cost/Year ($) kW $ PEAK 942 907711 Rated 1016 979018 MCR 802 772807 75% 583 561779 50% 505 486618 25% 477 459637

Current Non-Howden Fan Proposed New Howden Fan Defining the Value By Energy Savings Howden FD Fan Vs Non Howden FD Fan Based on $ 0.11 kWh Current Non-Howden Fan Proposed New Howden Fan Savings/Year Abs. Power (kW) Cost/Year ($) kW $ PEAK 942 907711 808 778589 Rated 1016 979018 860 828696 MCR 802 772807 625 602250 75% 583 561779 412 397003 50% 505 486618 335 322806 25% 477 459637 290 279444

Current Non-Howden Fan Proposed New Howden Fan Defining the Value By Energy Savings Howden FD Fan Vs Non Howden FD Fan Based on $ 0.11 kWh Current Non-Howden Fan Proposed New Howden Fan Savings/Year Abs. Power (kW) Cost/Year ($) kW $ PEAK 942 907711 808 778589 134 129122 Rated 1016 979018 860 828696 156 150322 MCR 802 772807 625 602250 177 170557 75% 583 561779 412 397003 171 164776 50% 505 486618 335 322806 170 163812 25% 477 459637 290 279444 187 180193

Current Non-Howden Fan Proposed New Howden Fan Defining the Value By Energy Savings Howden FD Fan Vs Non Howden FD Fan Based on $ 0.11 kWh Current Non-Howden Fan Proposed New Howden Fan Savings/Year Abs. Power (kW) Cost/Year ($) kW $ PEAK 942 907711 808 778589 134 129122 Rated 1016 979018 860 828696 156 150322 MCR 802 772807 625 602250 177 170557 75% 583 561779 412 397003 171 164776 50% 505 486618 335 322806 170 163812 25% 477 459637 290 279444 187 180193 MCR Yearly Savings per fan = $ 169,835 per fan

Defining the Value By costs

Defining The Value By Cost By Costs Defining The Value By Cost SAR GBP USD Selling Price of Electricity 0.12 SAR / kW / hr 0.025 GBP / kW hr 0.032 USD / kW hr

Defining The Value By Cost By Costs Defining The Value By Cost SAR GBP USD Selling Price of Electricity 0.12 SAR / kW / hr 0.025 GBP / kW hr 0.032 USD / kW hr Cost of 1 boiler outage/day = 600,000 kW x 24 hr 1,728,000 SAR / day 360,000 GBP / day 460,800 USD / day

Defining The Value By Cost By Costs Defining The Value By Cost SAR GBP USD Selling Price of Electricity 0.12 SAR / kW / hr 0.025 GBP / kW hr 0.032 USD / kW hr Cost of 1 boiler outage/day = 600,000 kW x 24 hr 1,728,000 SAR / day 360,000 GBP / day 460,800 USD / day Material cost/failure 16,800 SAR £ 3,500 / fan $ 4,480 Labour costs 24,000 SAR £ 5,000 / day $ 6,400

Defining The Value By Cost By Costs Defining The Value By Cost SAR GBP USD Selling Price of Electricity 0.12 SAR / kW / hr 0.025 GBP / kW hr 0.032 USD / kW hr Cost of 1 boiler outage/day = 600,000 kW x 24 hr 1,728,000 SAR / day 360,000 GBP / day 460,800 USD / day Material cost/failure 16,800 SAR £ 3,500 / fan $ 4,480 Labour costs 24,000 SAR £ 5,000 / day $ 6,400 Duration of failure repair 3 days Total energy costs x Duration 5,184,000 SAR £ 1,080,000 $ 1,382,400 Total labour costs x Duration 72,000 SAR £ 15,000 $ 19,200

Defining The Value By Cost By Costs Defining The Value By Cost SAR GBP USD Selling Price of Electricity 0.12 SAR / kW / hr 0.025 GBP / kW hr 0.032 USD / kW hr Cost of 1 boiler outage/day = 600,000 kW x 24 hr 1,728,000 SAR / day 360,000 GBP / day 460,800 USD / day Material cost/failure 16,800 SAR £ 3,500 / fan $ 4,480 Labour costs 24,000 SAR £ 5,000 / day $ 6,400 Duration of failure repair 3 days Total energy costs x Duration 5,184,000 SAR £ 1,080,000 $ 1,382,400 Total labour costs x Duration 72,000 SAR £ 15,000 $ 19,200 Max potential costs/failure 5,272,800 SAR £ 1,098,500 $ 1,406,080

Defining The Value By Cost By Costs Defining The Value By Cost If cost of 1 boiler outage = 5,272,800 SAR (£ 1,098,500) Assuming 1 unplanned outage, on 1 boiler, every 2 years:

Defining The Value By Cost By Costs Defining The Value By Cost If cost of 1 boiler outage = 5,272,800 SAR (£ 1,098,500) Assuming 1 unplanned outage, on 1 boiler, every 2 years: Cost over 1 years of managing problem = (5,272,800 / 2) = 2,636,400 SAR (£ 549,250) Cost over 10 years of managing problem = 26,364,000 SAR (£ 5,492,500) Cost over 20 years of managing problem = 52,728,000 SAR (£ 10,985,000)

Defining The Value By Cost By Costs Defining The Value By Cost If cost of 1 boiler outage = 5,272,800 SAR (£ 1,098,500) Assuming 1 unplanned outage, on 1 boiler, every 2 years: Cost over 1 years of managing problem = (5,272,800 / 2) = 2,636,400 SAR (£ 549,250) Cost over 10 years of managing problem = 26,364,000 SAR (£ 5,492,500) Cost over 20 years of managing problem = 52,728,000 SAR (£ 10,985,000) If an average retrofit of boiler fan flow controls (FD or ID) costs £ 600,000 GBP (N.B. Retrofit price dependant on project scope)

Defining The Value By Cost By Costs Defining The Value By Cost If cost of 1 boiler outage = 5,272,800 SAR (£ 1,098,500) Assuming 1 unplanned outage, on 1 boiler, every 2 years: Cost over 1 years of managing problem = (5,272,800 / 2) = 2,636,400 SAR (£ 549,250) Cost over 10 years of managing problem = 26,364,000 SAR (£ 5,492,500) Cost over 20 years of managing problem = 52,728,000 SAR (£ 10,985,000) If an average retrofit of boiler fan flow controls (FD or ID) costs £ 600,000 GBP (N.B. Retrofit price dependant on project scope) Then payback on typical Howden retrofit = 1.1 Years.

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