DOC NO:

OPGS POWER GUJARAT PVT LTD

OPGS-0-BLR-OPN-19-09-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR FD FAN REV NO 0 DATE 04-02-2017

FORCED DRAUGHT FAN

(FD FAN)

PREPARED BY APPROVED BY

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-09-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR FD FAN REV NO 0 DATE 04-02-2017

DATE DATE

Applicable Elements of Standard:

ISO 14001(2004) 4.4.4.6 Operational control.
OHSAS 18001 (2007) 4.4.6 Operational control.

1. OBJECTIVE
This procedure covers all the operational activities related to starting & operating FD fan, which are
carried out by operation personnel who are responsible for improving efficiency of the plant.

2. DESCRIPTION
The FD fans delivers pressurized fresh air into the boiler combustion chamber for aiding
combustion of fuels and also it will maintain the draught in balanced condition. FD fan
designation for this plant is AP1-15/11.
AP - Axial profile fan.
1 - Number of Stage.
15 - Tip Dia. of impeller in Decimeter.
11 - Hub Dia. of impeller in Decimeter.
And its speed is controlled by Pitch Control Device. Suction orientation is vertical and
delivery orientation is horizontal. Fan’s reserve flow is 33% and its reserve pressure is 48%.

3. REFERENCE DOCUMENT
1. Operation and maintenance manual of M/s. BHEL.
2. FD fan lube oil scheme, drawing no: - 2-55-910-01530.
3. Scheme of air & flue gas path, Drawing no: - 0-97-288-90708.

4. SAFETY PRECAUTIONS
1. Hazard Identification and risk assessment of the activity shall be made available to the operator.
2. Only authorized person is allowed to operate the equipment.
3. All the access to the equipment shall be kept clear.
4. All the persons operating the equipment shall be provided with the proper training.
5. All the guards and coverings of the equipment shall be covered.
6. No flammable material or oil shall be scattered or spilled around the equipment.  
7. Field operator should wear the relevant personal protective equipment like boiler suit, safety
shoes, helmet, safety hand gloves, safety goggle and others.

5. TECHNICAL SPECIFICATION
5.1 FAN
Make BHEL

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-09-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR FD FAN REV NO 0 DATE 04-02-2017

Capacity (m3/s) 60
Total head developed (mmwc) 400
Temperature of medium (deg C) 75
Density (kg/m3) 1.065
Speed (rpm) 1480

5.2 FAN DRIVE COUPLING

Make UNIQUE/KOLKATA
Type Rigiflex coupling

5.3 MOTOR
Make BHEL
Specification of induction motor IS: 325
Type Sq. cage induction motor
Capacity 375 KW
Stator volt 6600 V
Stator Current 41 Amps
Speed 1488 rpm
Phase 3
Frequency 50 HZ
Class of insulation F
Connection STAR
Degree of protection IP 55
DE Bearing NU22M6222C3
NDE Bearing NU219M
Weight 3650 kg

5.4 LUBRICATION
Lube oil used in fan OIL - ISO VG 68
Lube oil used in motor Grease Servogem 3

5.5 LUBE OIL PUMP

Make Tushaco pumps
Type Screw pump
No 2 (1S+1W)
Flow 80 lpm
Pressure 12 kg/cm2
Speed 2875 rpm

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-09-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR FD FAN REV NO 0 DATE 04-02-2017

5.6 LUBE OIL MOTOR

Make NGEF
No 2(1S+1W)
Capacity 5.5KW/ 7.7HP
Speed 2875 rpm
Voltage 415 V
Current 10.5 Amps
Efficiency 88.30%

5.7 LUBE OIL FILTER

Make BHAGWAT FILTER PVT. LTD
No 2(1S+1W)
Flow 225 lpm
Pressure 25 bar
Material 2.225-G60-V
Basket size 60 microns

5.8 HEAT EXCHANGER

Make SOUTHERN LUBRICATION PVT. LTD
No. 2 (1S+1W)
Description Shell Tube
Operating fluid ISO-VG-46 Water
Flow rate lpm 80 180
Operating pressure ksc 12 3
Test pressure ksc 15 12
Inlet and outlet temperature deg C 64/54 38/40
Heat capacity 21600 Kcal / min

6. PRECHECKS
Following Engineer checks required before starting the Equipment.

6.1 FIELD ENGINEER CHECKS

1. Check all permits issued related works are completed for the equipment’s.
2. Check all safety and firefighting equipment are in line.
3. Ensure cleanliness of the area for combustible materials are removed properly.
4. Check for the availability of the CCCW system.
5. Check all the Manhole door in the air and flue gas side is in closed condition.
6. Check all the peep holes closed.
7. Check the fan casing manhole door is closed.
8. Check Pitch Control Device (PCD) connecting links are fixed properly (damaged or not).
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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-09-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR FD FAN REV NO 0 DATE 04-02-2017

9. Ensure the air preheater is running and its emergency air motor service airline (service air header
pressure=6-7ksc) is opened.
10. Check the Oil level in tank bottom.
11. Check fan DE/NDE, motor DE/NDE TG, TE are fixed in proper.
12. Check the fan & motor base bolt and coupling bolt status.
13. Motor double Earthing to be checked and motor terminal cover to be close.
14. Motor switch gear is available for both fan & delivery damper actuator is in remote.
15. Check the instrument airline is in open condition and its operating pressure (In header=6-7ksc &
power cyclinder≥2ksc) is obtained.

6.2 SWITCH GEAR ENGINEER CHECKS

1. Check all the permits issued for the equipment are returned.
2. Check 6.6kv VCB proper rack in and circuit breaker healthiness, spring charging condition, trip
circuit healthy, rated bus voltage.
3. If unit is in trip condition required VAR increased by using capacitor banks.
4. If above conditions ok give clearance to the control room engineer.

6.3 CONTROL ROOM ENGINEER CHECKS

1. All permit clearance to be checked.
2. Before starting the fans discharge damper open/close to be checked for any feedback problems
PCD open/close to be checked with proper FB.
3. Check all RTD values whether it shows nearby ambient temperature in DCS.
4. Check all PT, TE & FT transmitters are lined up or not in local.

7. PERMISSIVE
The following permissive must be satisfied
1. FD fan motor bearing temperature not high (< 95 °C).
2. FD fan motor winding temperature not high (< 115 °C).
3. FD fan bearing temperature not high (< 95 °C).
4. FD fan Switchgear available.
5. FD fan blade pitch control minimum (< 2 %).
6. FD fan outlet damper closed.
7. FD fan lube oil pressure OK (> 0.8 kg/cm2).
8. FD fan control oil pressure OK (> 8 kg/cm2).
9. FD fan electrical trip not operated.
10. ID fans A&B (or) any one ID fan ON & FD fan B OFF.
11. FD A OFF feedback.

8. PROTECTION
1. FD fan post purge trip.
2. FD fan motor bearing temperature very high (> 100 °C for 2 sec.).
3. FD fan bearing temperature very high (> 100 °C for 2 sec).

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-09-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR FD FAN REV NO 0 DATE 04-02-2017

4. FD fan motor winding temperature very high (> 130 °C for 5 sec.).
5. FD fan bearing vibration very high (12.6 mm/s for 10 sec.).
6. Both ID fan OFF.
7. Both FD fan ON and any one ID fan OFF.
8. FD fan ON and outlet damper not open for 120 seconds.
9. Both LOP off > 30 seconds.
10. Electrical trip operate.

9. STARTING PROCEDURE
1. Check the oil cooler in line.
2. Open the isolation valve for the cooling water outlet & inlet, close the drain isolation valve for
the lube oil cooler.
3. Check the inlet and outlet pressure & temperature gauges at the cooler.
4. Check the cooling water flow in the sight glass.
5. Close the filter and cooler equalizing valve in the oil line.
6. Open the valve for all the pressure gauges & switch and DP switch.
7. Release both the local push button of lube oil pump & Start the lube oil pump.
8. Check the direction of rotation of the lube oil pump.
9. Check for any leakages in line and inform the running status.
10. Open the standby filter vent valve & equalizing valve. Charge the standby filter.
11. Close the vent valve after venting the air and equalizing valve.
12. Check the status of filter DP in the gauge and DP switch indication in the Control room, if
required change the filter
13. Check the lube oil and control oil pressure is normal.
14. Press the local push button of the running pump & check the stand by pump pickup automatically
and Vice versa.
15. Check the oil flow in the sight glass at the lube oil return and control oil return.
16. Check the instrument air pressure at the power cylinder gauges.
17. Check the equalizing valve is in closed position and manual lock is not engaged in the power
cylinder.
18. Check whether the blade pitch control is in minimum position.
19. Check the delivery damper of the fan is in closed condition and in remote mode.
20. Check all the bearing & winding temperature is normal.
21. Release the local push button of FD fan.
22. Start the FD fan and check the direction of rotation.
23. Check the delivery damper of the fan opens within 120 seconds.
24. Check the vibration in the fan and motor bearing.
25. Gradually load fan by increasing blade pitch angle.
26. SWGR engineer should note starting current, no load current, voltage drop and breaker spring
charge condition.
9.1 STARTING OF ANOTHER FD FAN (FAN B)
1. Start permissive and protection for FD fan B is similar to FD fan A as described before.

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 DOC NO:
OPGS POWER GUJARAT PVT LTD
OPGS-0-BLR-OPN-19-09-00
2X150 MW THERMAL POWER PLANT

DOC TITLE SOP FOR FD FAN REV NO 0 DATE 04-02-2017

2. Start the FD fan B using above said procedure, once started gradually load both fans by adjusting
blade pitch angle by observing both fan’s current.

9.2 PUTTING FD FAN A & B AUTO

1. After reaching required air flow maintain both fans current almost equal.
2. Open master pop up window on both fan and put fan in auto mode simultaneously
3. Carefully observe any deviation in fan characteristic if so take back to manual inform to C&I
department. If not proceed.
4. Match required air flow in set point and maintain Furnace pressure between -10 to -15 mm WC.

10. SHUTDOWN PROCEDURE

1. Bring PCD position to minimum and manual mode by ensuring furnace pressure is always -10 to
-15 mm WC.
2. Give STOP command to fan.
3. FD fan outlet damper will close ensure for feedback both in control desk and local.
4. Then open PCD and outlet damper to maximum and open position respectively for natural draft.
(According to requirement).
5.
11. CHANGEOVER PROCEDURE
Not applicable.

12. STANDBY OPERATION PROCEDURE

Not applicable.

13. CONCLUSION
The purpose of this procedure is for proper understanding about the interlock and protection of the
FD fan & safe operating procedure.

14. RECORD
Boiler desk log book.
Boiler local log book.

15. AMENDMENT HISTORY

PREVIOUS
PRESENT
CONDITION PREVIOUS REV. CURRENT REV. NO
S.NO CONDITION
(BEFORE THIS NO.& ISSUE DATE & ISSUE DATE
(REASON MADE)
REVISION)
1.
2.

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