fan ductwork upgrade generating unit 1 forced draft … · induced vibrations and fan pressure...

A REPORT TO

THE BOARD OF COMMISSIONERS OF PUBLIC UTILITIES

Electrical

Mechanical

EPEGS ;y Civiler ,

T A Df.

Cn LLINS Protection & Control

Transmission & Distributionur.nnruu ►:

.j

^am 2^^V

i0

Ca^^ -

ei,A NI)Telecontrol

System Planning

UPGRADE GENERATING UNIT 1 FORCED DRAFT

FAN DUCTWORK

Holyrood Thermal Generating Station

February 2010

newfoundland labrador

h droa nalcor energy company

Holyrood: Upgrade Unit 1 Forced Draft Fan Ductwork

Table of Contents

1

INTRODUCTION 1

2

PROJECT DESCRIPTION 3

3

EXISTING SYSTEM 43.1

Age of Equipment or System 53.2

Major Work and/or Upgrades 53.3

Anticipated Useful life 53.4

Maintenance History 53.5

Outage Statistics 63.6

Industry Experience 73.7

Maintenance or Support Arrangements 73.8

Vendor Recommendations 73.9

Availability of Replacement Parts 83.10 Safety Performance 83.11 Environmental Performance 83.12 Operating Regime 8

4

JUSTIFICATION 94.1

Net Present Value 94.2

Levelized Cost of Energy 104.3

Cost Benefit Analysis 104.4

Legislative or Regulatory Requirements 124.5

Historical Information 124.6

Forecast Customer Growth 124.7

Energy Efficiency Benefits 124.8

Losses during Construction 124.9

Status Quo 12............................................................................4.10 Alternatives 13

5

CONCLUSION 145.1

Budget Estimate 145.2

Project Schedule 15

APPENDIX A A1

APPENDIX B B1

Newfoundland and Labrador Hydro

i


1

INTRODUCTION

The Holyrood Thermal Generating Station (Holyrood) is an essential part of the Island

Interconnected System, with three units providing a total capacity of 490 MW. The

generating station was constructed in two stages. In 1971, Stage I was completed bringing

on line two generating units, Units 1 and 2, capable of producing 150 MW each. In 1979,

Stage II was completed bringing on line one additional generating unit, Unit 3, capable of

producing 150 MW. In 1988 and 1989, Units 1 and 2 were up-rated to 170 MW. Holyrood

(illustrated in Figure 1) represents approximately one third of Newfoundland and Labrador

Hydro's (Hydro) total Island Interconnected generating capacity.

Figure 1: Holyrood Thermal Generating Station

The three main components of each generating unit are the boiler, turbine, and generator.

The boiler servicing Unit 1 is equipped with two forced draft (ED) fans which are commonly

referred to as the east and west FD fans. A FD fan is a system that provides combustion air

to the boiler during operation. The fan consist of a rotating assembly, commonly referred

to as an impellor, that is positioned inside a steel casing which contains both air intake and


Page 1


discharge zones. The impellor is driven by a 1,500 horsepower electric motor. Each FD fan

also contains air intake and discharge ductwork which is connected to the fan casing air

intake and discharge zones respectively. During operation, the intake ductwork conveys

ambient air to the FD fan from both inside and outside the plant. After passing through the

FD fan, the discharge ductwork then conveys the air to the boiler furnace where it is mixed

with the boiler fuel oil for combustion. The Unit 1 FD fan arrangement is illustrated below

in Figure 2.

Discharge Duct

Electric Motor

Intake Duct

FD Fan

Figure 2: Holyrood Unit 1 West FD Fan


Page 2


2

PROJECT DESCRIPTION

This project is required to perform modifications to the ductwork on the east and west FD

fans servicing generating Unit 1 to reduce fan vibration levels and eliminate ductwork

cracking. A Computational Fluid Dynamics (CFD) analysis will be completed on the fans

while they are in operation in order to model the air flow characteristics inside the intake

and discharge ductwork. CFD analysis is a computer modeling technique commonly used in

industry to model fluid flows and analyze problems in mechanical systems by simulating the

interaction of fluid flows with equipment surfaces. Based on the results of the CFD analysis,

custom fabricated equipment will be installed inside the FD fan intake and discharge

ductwork. These modifications will reduce flow induced vibrations and ductwork cracking.

It is also anticipated that the modifications will reduce the overall pressure drop across the

air handling system thereby reducing the fan power consumption. Due to safety concerns

associated with performing modifications to the FD fan ductwork during the regular annual

boiler outage maintenance work in the same congested work area, this project will be sole

sourced to Alstom Power, the boiler service contractor because of their overall experience

and familiarity with Holyrood.


Page 3


3

EXISTING SYSTEM

The existing Unit 1 west FD fan system is illustrated in Figure 2. The east and west FD fan

systems servicing the Unit 1 boiler are identical. During operation, the geometry of the

existing FD fan ductwork causes air flow turbulence which creates vibrations on both the

intake and discharge ductwork. The vibrations result in ductwork cracks which are normally

repaired by Alstom Power during the annual Unit 1 outage. However, extensive ductwork

cracking has the potential to cause an unscheduled outage in order to make repairs. An

unscheduled unit outage during the peak winter load demand would result in a loss of 170

MW of power generation to the Island Interconnected System. This represents

approximately 11 percent of Hydro's Island Interconnected System's capacity. Typical Unit

1 internal ductwork cracking and previous repairs are illustrated in Figure 3.

Figure 3: Unit 1 FD Internal Ductwork Cracking


Page 4


3.1 Age of Equipment or System

The existing oil fired boiler and FD fans are 39 years old.

3.2 Major Work and/or Upgrades

Unit 1 was originally commissioned in 1971 to produce 150 MW and was up-rated to

produce 170 MW in 1988. During the upgrade it was necessary to increase the capacity of

the FD fans in order to increase the volumetric flow rate of combustion air to the boiler. A

higher volume of combustion air was necessary to increase the boiler maximum steam flow

rate required to produce the additional 20 MW. The capacity of the FD fans was increased

by adding tips to the existing fan impellor blades.

3.3 Anticipated Useful life

The anticipated useful life of Unit 1 has been forecasted to extend to the year 2020, absent

an infeed from Lower Churchill.

3.4 Maintenance History

FD fan maintenance is a component of the annual maintenance strategy for Unit 1. During

the annual shutdown Hydro uses a boiler service contractor, Alstom Power, to perform

preventative maintenance inspections and corrective maintenance repairs on the FD fans

and ductwork system. The cost of maintenance for the FD fans is a component of the total

maintenance cost for the whole unit. The five-year maintenance history for the Unit 1 FD

fans is shown below in Table 1.


Page 5


Table 1: Five-Year Maintenance History

Year

PreventiveMaintenance

($000)

CorrectiveMaintenance

($000)

TotalMaintenance

($000)2009 2.0 24.0 26.0

2008 1.0 6.0 7.0

2007 1.0 6.0 7.0

2006 0.0 0.0 0.0

2005 0.0 0.0 0.0

3.5 Outage Statistics

In December of 2008, there was a forced outage on Unit 1 with a one-week duration due to

a failure of the intake guide vanes on the east FD fan. The intake guide vanes are stationary

blades that are welded to the intake ductwork and they function to reduce the air flow

turbulence prior to entering the fan. The failure of the guide vanes was attributed to high

vibration levels caused by air flow turbulence on both the intake and discharge ductwork as

a result of the ductwork geometry.

In addition, following the repairs completed on the intake guide vanes in December of 2008

during the forced outage, Unit 1 was de-rated to produce a maximum of 157 MW for the

entire operating season that ended in May of 2009 as a result of high vibration levels on the

FD fan intake and discharge ductwork caused by air flow turbulence. To address the issue,

turning vanes or stationary blades were installed by Alstom Power inside the FD fan

ductwork during the 2009 annual Unit 1 outage as a temporary measure to reduce the air

flow turbulence and vibration levels in order for Unit 1 to operate at full capacity. This

temporary measure did not address the overall deterioration of the ductwork.


Page 6


3.6 Industry Experience

Flow induced vibration caused by air flow turbulence due to ductwork geometry is common

in FD fan systems. The industry trend is to utilize CFD analysis techniques and perform duct

work modifications to reduce air flow turbulence as opposed to replacing the existing

ductwork to correct geometry design problems. Many companies now specialize in

providing solutions to reduce flow induced vibrations in fan duct work systems and overall

fan pressure loss through the use of CFD analysis techniques.

The application of CFD techniques and modifications to FD fan ductwork was completed in

February of 2004 at New Brunswick Power 's 1,050 MW coal fired power plant located at

Colson Cove. M&l Power Technology (M&I), a company that specializes in the application of

CFD techniques to modify ductwork in order to reduce flow induced turbulence and overall

fan pressure loss, was contracted by New Brunswick Power to perform modifications to the

FD fan ductwork servicing one of the 350 MW coal fired units at the Colson Cove generating

facility. Appendix A provides the background for the project.

3.7 Maintenance or Support Arrangements

Hydro currently has a service contract with Alstom Power to perform boiler maintenance

during the annual scheduled outage. The FD fan maintenance is completed under the boiler

service contract.

3.8 Vendor Recommendations

In December of 2009, Hydro had a preliminary CFD analysis completed on the Unit 1 FD fans

intake and discharge ductwork systems by M&l to reduce pressure loss and flow induced

vibrations in plant air flow systems. The analysis indicated that the air inside the ductwork


Page 7


does not flow through at a uniform velocity. This results in high fan entry loss and poor fan

blade loading. In addition, the analysis also indicated that the fans are operating at a high

flow rate (165 Kg/s per fan) resulting in very high velocity magnitude in the range of 84.5 to

96.6 m/s which creates flow induced vibration. The report from M&l recommends that

Hydro perform a more comprehensive CFD analysis on the FD fan systems and install

aerodynamic diffusers and long turning vanes inside the ductwork to reduce both flow

induced vibrations and fan pressure loss. The report outlining the findings of the analysis is

included in Appendix B.

3.9 Availability of Replacement Parts

Spare parts are available for the existing Unit 1 FD fan system.

3.10 Safety Performance

There are no safety code violations with the current operation of the Unit 1 FD fans.

3.11 Environmental Performance

There are no environmental code violations with the operation of the existing Unit 1 FD

fans.

3.12 Operating Regime

Holyrood operates in a seasonal regime. The full plant capacity is needed to meet the

winter electrical requirements on the Island Interconnected System. The FD fan systems

are an integral component of Unit 1.


Page 8


4

JUSTIFICATION

The FD fans servicing Unit 1 at Holyrood have an ongoing problem with flow induced

vibration on the fan intake and discharge ductwork systems. During operation, the

geometry of the existing FD fan ductwork causes air flow turbulence which creates

vibrations on both the intake and discharge ductwork. The vibrations cause cracks to

develop in the ductwork. The cracks are normally repaired during the annual Unit 1 outage.

However, the development of cracks on an on-going basis threatens the integrity of the

ductwork infrastructure and reduces the reliability of Unit 1.

In December of 2008, there was a forced outage on Unit 1 due to a failure of the intake

guide vanes on the East FD fan. Failure of the intake guide vanes was due to high vibration

levels caused by air flow turbulence on both the intake and discharge ductwork. In addition,

high vibrations levels resulted in a de-rating of Unit 1 during the 2009 operating season. To

address the issue, turning vanes were installed inside the fan ductwork during the 2009

annual Unit 1 outage as a temporary measure to reduce air flow turbulence and vibration

levels.

Failure of the FD fan ductwork can result in an unplanned Unit 1 outage of three to four

weeks duration. An unscheduled unit outage during the peak winter load demand would

result in a loss of 170 MW of power generation to the Island Interconnected System which

represents approximately 11 percent of the Island Interconnected System's capacity.

This project is required to maintain the reliability of generating Unit 1 at Holyrood.

4.1 Net Present Value

A Net Present Value (NPV) calculation was not done, however, a cost benefit analysis was

completed on two alternatives over a study period of ten years. See Cost Benefit Analysis

Section 4.3 for details.


Page 9


4.2 Levelized Cost of Energy

The levelized cost of energy is a high level means to compare costs of developing two or

more alternative generating sources. Therefore, the levelized cost of energy is not

applicable to this project.

4.3 Cost Benefit Analysis

A cost benefit analysis was completed on two alternatives. The study period for the cost

benefit analysis was 10 years.

Alternative 1 - Upgrade Unit 1 FD Fan Ductwork based on Fuel Cost Savings:

This alternative is to complete the proposed modifications to Unit 1 FD fans in order to

reduce ductwork vibrations caused by flow induced turbulence and air handling system

overall pressure loss. Upon completion of Alternative 1, the annual operating and

maintenance (O&M) cost was estimated at $1,000 per year which would cover FD fan

preventative maintenance inspections. It is anticipated that there would not be any

unscheduled FD fan failures or corrective maintenance to repair ductwork cracks after

completing the proposed modifications to the FD fan ductwork. The preliminary CFD

analysis report completed by M&l Technology (Appendix B) indicated that the energy

savings associated with each FD fan will be 16 percent after completing the proposed

modifications to the ductwork. The savings for Alternative 1 were calculated using the

January 2010 Nalcor Energy/NLH Thermal Fuel Oil Price Forecast for No.6, 0.7 percent

sulphur fuel with a PUB approved conversion factor of 630 kWh/bbl. Using an average Unit

1 load of 80 MW and 4,520 operating hours as in 2009, the Cumulative Present Worth

(CPW) for Alternative 1 is a benefit of $489,706 with a payback of six years.

A sensitivity analysis was performed on Alternative 1 using a Levelized Unit Energy Cost

(LUEC). The PUB approved LUEC rate at $0.09 per kilowatt hour was used to calculate the


Page 10


project saving. Using an average Unit 1 load of 80 MW and 4,520 operating hours, the CPW

cost is $182,008.

Alternative 2 - Status Quo:

This alternative is to operate the FD fans under the current operating conditions without

performing any modification to the ductwork. Using the maintenance history available for

the Unit 1 FD fans, the annual O&M cost for this alternative is expected to be $7,000 per

year to perform preventative maintenance inspections and corrective maintenance repairs.

Also, based on the history of forced outages with an occurrence in 2008 and repair cost at

approximately $330,000, it was assumed that an identical forced outage would occur again

in 2018. Using the O&M cost indicated above, the CPW cost for Alternative 2 is $242,526.

The analysis indicates that Alternative 1 is the lower cost option. Table 2 shows the results

of the cost benefit analysis.

Table 2: Cost Benefit Analysis

HRD Unit 1 FD Fan Ductwork ModificationsAlternative Comparison

Cumulative Net Present Value

To The Year

2020

AlternativesCumulativeNet Present

CPW Difference betweenAlternative and the

Value (CPW) Least Cost Alternative

HRD Unit 1 FD fan Ductwork Modifications @Fuel Cost (489,706) 0

Status Quo 242,526 732,232


Page 11


4.4 Legislative or Regulatory Requirements

There are no legislative or regulatory requirements to complete the proposed modification

to the FD fan ductwork to reduce vibration levels and fan pressure loss.

4.5 Historical Information

There is no applicable historical information.

4.6 Forecast Customer Growth

Customer load growth is not affected by this project.

4.7 Energy Efficiency Benefits

It is anticipated that completion of the proposed project will reduce the energy consumed

by the Unit 1 FD fans by 16 percent.

4.8 Losses during Construction

There are no associated losses during the construction of this project as it will be scheduled

during the annual planned unit outage.

4.9 Status Quo

Status quo is not an acceptable alternative. A cost benefit analysis has shown that

upgrading the FD fan ductwork will present a savings to Hydro. Also, an unscheduled failure

during the peak winter load demand could result in a loss of 170 MW of power which

represents approximately 11 percent of the Island Interconnected System's capacity.


Page 12


4.10 Alternatives

Two alternatives were considered as discussed in the Cost Benefit Analysis Section 4.3.


Page 13


5

CONCLUSION

Modifications to the Unit 1 existing FD fan ductwork systems is required to reduce flow

induced vibrations caused by air flow turbulence due to the existing ductwork geometry.

The modifications will also reduce the overall fan pressure drop, thereby reducing the fan

power consumption by 16 percent. Using an average Unit 1 load of 80 MW and 4,250

operating hours as in 2009, a cost benefit analysis indicates that completing the proposed

project is the preferred option as compared to the status quo alternative.

Failure to perform the modifications to the Unit 1 FD fan ductwork systems increases the

likelihood of unscheduled downtime on the turbine and increases the risk of being unable

to meet customer demands during the peak winter load requirement.

5.1 Budget Estimate

The budget estimate for this project is shown in Table 3.

Table 3: Budget Estimate

Project Cost:($x1,000) 2011 2012 Beyond Total

Material supply 20.0 0.0 0.0 20.0

Labour 68.3 0.0 0.0 68.3

Consultant 0.0 0.0 0.0 0.0

Contract Work 619.1 0.0 0.0 619.1

Other Direct Costs 2.0 0.0 0.0 2.0

O/H, AFUDC & Escln. 62.8 0.0 0.0 62.8

Contingency 70.9 0.0 0.0 70.9

TOTAL 843.0 0.0 0.0 843.0


Page 14


5.2 Project Schedule

The anticipated project schedule is shown in Table 4.

Table 4: Project Milestones

Activity Milestone

Project Kick-off Meeting January 2011

Complete Design Transmittal February 2011

Develop Supply & Installation Contract February 2011

Issue Tender & Award Contract March 2011

Installation July 2011

Commissioning October 2011

Project Final Documentation and Closeout December 2011


Page 15

Holyrood: Upgrade Unit 1 FD Fan DuctworkAppendix A

APPENDIX A

Project Background:

M&l Technology's Solution for FD fan Inlet Duct Silencing SystemFor

New Brunswick Power's Colson Cove 1,050 MW Power Plant


Al


M&I Power Tech.

PROJECT BACKGROUND

M&I's Solution for F.D. Fan Inlet Duct Silencing SystemFor

New Brunswick Power's Colson Cove 1,050 MW Power Plant, Canada

N.B Power sought a solution that would reduce noise emanating from the I.D Fan. Theconventional splitter type silencer solution occupies lot of space and it was not possibleto accommodate it in the available space. Additionally, the pressure drop of theconventional silencer was very high to the tune of 36 mm WC and this pressure dropwas resulting in overloading of the F.D Fans. Even an increase of 12 mm W.C wouldhave adversely affected Fan performance, which in turn would have affected qenerationcapacity.

Babcock & Wilcox, Canada which was contracted for this part of the project,approached M&l to employ its "Aero-Acoustic" technology and develop a solution thatwould solve this apparently conflicting requirement.

M&I's approach integrates flow streamlining with noise attenuation. The flow across theducting system and fan was analyzed and the effect of turbulence, flow separation,vortices, etc was determined. M&l then developed a diffusion system that streamlinedflow across the inlet ducting and ensured that the flow into the Fan is uniform. This 3-dimensional diffusion system that M&l designed also acts as a silencer and absorbsnoise. Additionally, the duct is lined with acoustic insulation, which contributes to noiseattenuation A streamlined flow across the duct without turbulence would reduce theflow induced vibration and this also brings down noise generation.

You would note M&l have not employed the conventional splitter type silencer and thisbrings down the pressure drop. Also, by streamlining the flow across the duct, it ispossible to convert unproductive velocity pressure to useful static pressure. In this caseM&I was able to reduce pressure drop by 26 mm W.C. as compared to conventionalsplitter silencer. The noise level that was guaranteed was 84 dBA at 1 m. 1 dB lowerthan conventional silencer.

Please refer enclosed CFD analysis and Drawing carried out at bid stage for thecustomer. We are glad to inform you that M&l met contractual performance guaranteesas demonstrated in our CFD results. Please also refer enclosed reference letter fromB&W, Canada confirming superiority of M&l's aero-acoustic technology overconventional design.

Page 4


A2


Babcock & IAlulcox Canada Ltd.

5E1 Coronation BoulevardCambridge, OntarioCanada N1R 5V3Tel: (519x621-2130Fs: (519) 622-3664

a McDermott company

February 13, 2004

To Whomsoever it Mav Concern

This is to advise that Babcock & Wilcox Canada contracted with M&1 Air Systems Engineering,Mississauga, Canada for the design, engineering and supply of an Aerodynamic inlet silencerducting system. The system will be installed on fi nos. Forced Draft (F.D.) Fans at the 3 x 350MW Coleson Cove Power Station (Owned and Operated by New Brunswick Power, Canada).B&W opted for the M&I design as it offered a noise attenuation solution at a very low pressuredrop across the ducting system, compared to a conventional splitter type silencer solution.Performance guarantees were provided by M&l,

B&W has recently installed two systems for one of the 350 MW units (Unit # 3). B&W issatisfied with design, engineering and workmanship of the silencer units. Moreover, M&1'smodular construction enabled B&W to easily retrofit the FD inlet ducting in spite of the spaceconstraints of the existing station. Unit #}3 is operating at full capacity load of 350 MW, and hasmet the contractual performance criteria.

R.J. JohnstonProject Manager

Page 4A

Newfoundland and Labrador Hydra

A3


M&l Power Tech.

ConventionalDesign M&l's Design

Conventional

M&I'ssplittertype

proprietarysilencer

Aeroacousticdiffusionsystem

High pressuredrop acrosssilencers dueto non-uniformflow

urbulent andnon-uniform flowresults in highpressure dropand unevenloading of fanblades

Tot Relive t,,nI

Streamlinedanduniformflow resultsin lowerpressuredrop

Pressure drop savings in M&I design: 1" W.G

Page 5


A4


M&I Power Tech.

Babcock & Wilcox A/c New Brunswick PowerColson Cove Project (1,050 MW)

FD Fan Aerodynamic Inlet Silencer Duct

Page 6


A5


M&I Power Tech.

M&I

Client: Heyden Power Station, E-ON, Germany

Responsibility:Design, CFD Analysis, Engineering, Manufacturing, Supply andSupervision of Installation.

Project Background:

Heyden Power Station (An E-ON Company) awarded contract to M&1 for CFDAnalysis, Design, Engineering ; Manufacturing, Supply and Supervision of 2 nos 950MW units. Objective of working with M&I was to reduce draft loss of 3.5 mbar beforeESP and total Draft loss reduction of 10 mbar from Economizer outlet to FD Fandischarge. Above draft saving was very important, since Heyden PS is envisaging useof different grades of Coal in place of Brown Coal. This has resulted in to 10-12%higher volumetric flow in the draft system. Heyden PS had two fold problems to tackleabove situation.

1) Suitability of Existing ESP Duct and Structure2) Static Pressure Margins of ID fan

Bigger ID fan could have solved second problem but first problem was still unresolved.Except M&I solution there were no other feasible alternatives to address first issue.

M&I is offering Aero-acoustic solution for following areas of power plant:

I) SCR Inlet System (Between Ammonia Injection and SCR Catalyst)2) Air Pre Heater Inlet System3) ESP Inlet System4) ESP Inlet Transition5) Fan Suction Box6) ID Fan Discharge Duct7) FGD Inlet System

By leveraging Aero-acoustic technology, M&I is proposing pressure drop reduction inthe plant draft system to Heyden PS. Savings are in the tune of 10 mbar to 12 mbar.

Page 7


A6


M&I Power Tech.

M&I

SUMMARY OF SAVINGS OFFERED BY M&I:

Description Current Pr.Drop (mbar)

Iv1&.I design(mbar)

Pressuredrop savingin (mbar)

++ AppxIncrease innet Weight(Kgs)

1 SCR InletSystem

3.43 1.04 2.39 60 tons

2 Air PreHeater InletSystem

1 0.6 0.4 10 tons

3 ESP InletSystem

3.55 2.05 1.5

4 ESPTransition

2.95 2.45 0.5 10 tons

5 ID Fansuction box

1.5 0.75 0.75 4 tons

6 ID FanDischargeSystem

10.5 5.5 5.0 18 tons

7 FGD Inlet 3.28 2.28 1.0 19 tons

Page 8


A7

Halyrood: Upgrade Unit 1 FD Fan DuctworkAppendix A

7.h]aR.20C8 14 : 38

EKW KGM KW-LEI T UNG

NR.094

5.1

e•or^ Kraftwerke

E.ON 1(rahwarke Grrbrl. Po$tfach 11 a0. C•3u59 Peterseagi n

M & I AIR SYSTEMS ENGINEERINGM & I POWER TECHNOLOGY, INC.Mr. Dipti Kr. Dana2140 Meadowpine Blvd.Mississauga, ONCanada L5N 6H6

Petershagen, 2006-03-07

Optimization of Flue Gas Ducts and Fans, including AuxiliaryEnvironmental Equipment

This is to advise that EON hraftwerke GmbH, Tresckowstrafle 5, 30457Hannover, Germany contracted with M&1 Power Technolog/, Inc.,Mississauga, Canada for Design, Engineering, Manufacture and SLpply ofaerodynamic diffusers for our 915 MW Hayden Power Station atPetershagen to reduce the plant draft loss across the following system s:

1) SCR Inlet system2) ESP Inlet duct and transition3) ID fan suction box4) ID fan discharge system5) FGD Inlet system

Above plant draft loss reduction was necessary to accommodate burning ofcoal with less caloric value. This means more flue gas transportation toproduce the same MW. Further it was also necessary to keep same or lowsuction pressure upstream of ESP. to avoid reconstruction of tie ESPcasing.

We are pleased to mention here that M&I fulfilled all our expectaticontractual guarantees through an efficient diffusion system Furthsolution avoided installation of new ID fans. The following tangible

ns andM&I

benefits

Chairman of theSupervisory Board:Bernhard Fischer

were achieved through M&I technology: Managing Directors:Dr. logo Loge(Chairman)Manfred Peters1) Reduction of 2.2 MW ID fan Power Consumption

2) 11 mbar saving in the pressure drop Or. Erich Schmitz

1/2

Gerhard SeibelCarmel St:blelrl

Registered Office HanoverHanover District CourtMRS 58691

Page as

E.ON Kraftwerke GmbhKraftwerksgruppeMittalwose rPlant managerKraftwerkssiedlungD-32469 Petershagenwww. o o n -k raf rw e r ke.c o m

Matthias Eldon7 49-OS702-29 .32 21F 49-05702, 29.30 61m atth ias.e lden®eon-energle.com

our reference T/Eid . Fr


A8


7.M42.200E _4:33

EKW KGM KW-Lel7EJNG

H .094

S.2

e•on Kraftwerke

M&sl executed this job in time without any delay even in a Harr w steelmarket through efficient project management and offered very god co-operation during installation of the above system.

Due to this excellent result, E-ON would recommend this technology beingapplied not only to other existing operating plants, but also in case o addingFGI) or SCR and forthcoming new plants of their own whe^.e mostadvanced technology will be part of the design group to consider in order toreduce costs and raise performance. As such, M&1 technology would beplaced on our list of priority,

The technology itself has other salient benefits such as noise and vibrationsolution without utilizing large conventional silencers, since the technologyaddresses noise at the source.

Eor additional information please feel free to contact the undersigrwish M&I many more years of success in the future business.

Yours sincerely,

E.ON Kraftwerke GruhH

iN.

ed. We

212

Page BB


A9


E-ON - Hey den Power Station 950 MW EachSCR inlet, ESP inlet, ID Fan Suction box inlet, and discharge

(Under Implementation)

M&I0 M&I's OVERALL SOLUTION FOR PS HEYDEN PROJECT

vaociit

•

Old Design

ATTACHMENT #4Mel Power Technology Inc.

M&l Design

Page 9

M&I's OVERALL SOLUTION FOR PS HEYDEN PROJECT

CFD Analysis at the Inlet & Outlet of SCRTotal pressure profile'

Mitt proposed dllllssaAss muter

Total pressuredrop (A B): lllamhar

Total prossuredrop IC-D): 04 miter

Old Design

Tom] pressure dl op tuvtig(-e:'- mhnr M&I DesignM&I Power Technology Inc. Tonal pressure drop raring(r-D): Da mbar

D

513

FJ


A10


Page 10

M&10 M&I's OVERALL SOLUTION FOR PS HEYDEN PROJECT

CFD Analysis at Air Heater Outlet to ESP Inlet

Velocity Str'eamiining Profile

Old Design

M&I Design

ATTACHMENT # 11H&J Power Technology Inc.

M&I0 M&I's OVERALL SOLUTION FOR PS HEYDEN PROJECT

CFD Analysis at Air Heater Outlet to ESP InletTotal pressure profile'

Bra. w.

ee

Total pressure drop (A-B): 3.55 mbar

Total pressure drop (A-B): 2-05 mbar

Total pr es sure drop saving (A-13i: L.50 mbar

Old Design

M&l Design

ATTACHMENT #10H&I Power Technology Inc.


All


Fj M&I's OVERALL SOLUTION FOR PS HEYDEN PROJECT

CFD Analysis at ESP Inlet Transition

Velocity Streamlining Profile

▪ Old Design

ATTACHMENT # 18M&l Power Technology Inc.

• M&I Design

,.

Page 11

M&Ys OVERALL SOLUTION FOR PS HEYDEN PROJECT ICFD Analysis at ESP Inlet Transition

Total pressure profile

To▪

tal pressure drop (A-B): 2.95 mbar

Total pressure drop (A-13): 2.45 mbar

Total pressuie drop roving (A-By 0.50 inbat

Old Design

I= Design

M&l Power Technology IncATTACHMENT.

# 16

Pdl


A12


Toni Pressure Drop : 3.9$ mbar

M&I DesignM&Y Power Technology Enc.

Total Pressure Drop : 4ASnbar

Existing Design

CFD Analysis for PS Heyden projectID Fan Intake SystemPressure SI reran Wre

0 1

Ms OVERALL SOLUTION FOR PS HEYDEN PROJECT

CFD Analysis for Fan Suction Box

Velocity Profile

Old Design

M&l Design

ATTACHMENT # 27M&I Power Technology Inc.

I

Page 12


A13


00 M8d`s OVERALL SOLUTION FOR PS HEYDEN PROJECT

CFD Analysis for Fan Suction BoxTotal pressure profile

Total pressrre drop: 1.50 mbar

Total pressure drop: 0.75 mbar

Tote l i essnre drop saving: 0.75 mbar

Old Design

M&I DesignATTACHMENT # 28

M&I Power Technology Inc.


M&10 CFD Analysis for PS Heyden project

Velocity Streamline

Current Design

M&I Solution

ATTACHMENT # 35

Page 13


A14


Page 14

M&i0 CFD Analysis for PS Heyden project

Total Pressure Streamline

Current Design

M&I Solution

Toilel Pressure Drop Reaches to

6.0 I1ec6 WGI1ecffiding 3.2" Wt.;Silencer Section Lois


Told Pressure Drop Readies toOnly 4.1 Inch NG Including 1.8"WG Silencer Section Loss

E-ON Heyden Power Stn. 950 MW EachFGD Inlet duct c 100% Flow of Full Load

Total pressure drop profile

M&I

Tone 35essu<

sin

Iv9

Total pressure drop (A-Et) : 3.28 mbar Tota l pressure drop (A43) : 228 mbar

Pressure drop saving (A-B) :1.00 mbar

Current Design


M&I Solution


A15


E-ON - Heyden Power Station 950 MW EachSCR Inlet Modification Different Option offered by M&i

Page 14A

CFD Analysis for PS Hoyden project forFGD Inlet duct @ 100% Flow of Full Load

A

Mil Ppw.n TCUHIIEILOQY INn

00 CFD Analysis for PS Heyden project forFGD Inlet duct @ 100% Flow of Full Load

A

Solid ModelM1AI POW la TiCHNOLO•IY IND


A16


Client: Heyden Power Station, E-ON, Germany.M&I is offering Aero-acoustic solution for SCR Inlet, Air Pre Heater System,

ESP Inlet, ESP Inlet Transition. Fan Suction Box, and ID Fan Discharge Duct

Page 15


A17


Page 16


A18


Page 17


A19

Holyrood: Upgrade Unit 1 FD Fan DuctworkAppendix B

APPENDIX B

Commercial Proposal For:

FD Fan Inlet & Discharge Ductwork Modifications To Eliminate FlowInduced Vibration And Capacity Bottleneck

At theHolyrood Thermal Generating Station


B1


Quotation #: P09-001

Techno-Commercial Proposal

For

FD Fan Inlet & Discharge Modifications to eliminate flowinduced vibrations and capacity bottleneck

At

Holyrood Generating Station

Submitted to:

NEWFOUNDLAND AND LABRADOR HYDROST. JOHN'S, NEWFOUNDLAND

M&l Power Technology, Inc.2145 Meadowplne Blvd. Mississauga,

Ontario, Canada, L5N 6R8

02/12/2009


B2


:Inn

f]n onn_I nr_,:Ildl_n7h{nr

m& t

February 12,2009

Newfoundland and Labrador HydroHolyrood Generating StationDuff's Road, HoiyroodNL AOA 2RD

SUB: Quotation for CFD analysis & Modification to FD fan Inlet & Discharge Duct.

Dear Sirs,

At the outset I would like to thank you for the courtesy extended to our engineer VladimirElise. We also appreciate the opportunity to provide you with the proposal for themodifications of FD fan inlet and discharge duct to eliminate flow induced vibrationproblem and debofilenecking of fan capacity limitation. In view of long business relationswith your esteemed organization, we had no hesitation in carrying out preliminary CFDanalysis worth $ 10,000 free of cost to evaluate flow condition inside the FD fan inlet anddischarge duct responsible for vibration and turbulence. Refer "Synopsis" segment of theproposal showing CFD results of the existing duct.

Attached is our techno-commercial proposal & general arrangement drawing showingproposed modification areas. We have diligently worked on the proposal based on theinformation collected by our engineer. Most of our modifications are at the strategiclocations where maximum benefits exist in the above draft system. We propose modulesto be retrofitted at those locations only. We are also envisaging some outside ductmodifications, which can be easily carried out at site..

M&l 's aerodynamic diffusers offer reduction in the vibration and FD fan performanceimprovement by virtue of reduction in pressure drop in inlet and discharge duct.Estimated savings are enumerated below for review:

• Expected Pressure drop Reduction! Savings inFD fan Inlet Duct: 1.5" W.G.

• Expected Pressure drop Reduction! Savings inFD fan Outlet Duct: 2.0" W.G

• Minimal flow induced vibrations in the ducts.

21 4' Pneai i_ veil ie t

7. :_!Id l.^rl r'FR _ 311-N:in

•'f r',aro_eeb aro7 briar,, ooll pe,9 Ili: dacvmerrr remin the Drperrv or,'.g„ Fewer iech,':rc;v and ;ienilbe _e'iJ norr. . , r _ . , e . : :”',r 1 h . - „ r :.,:rI.,cd.rme acr .: licr..:=r1n-,e:.-n^c',v':'c._l^r,r;-_3, t:.r Ir,e a]d:v:-e'r r:r;e.'1


B3


Proposal- Holyrood Generating slalion fD for c4uc1 modificationsClient: HewIonndland ?t Labrador Hyde NI.

At this time we are open to help us to work to gather with you on this project

We now look forward to hear from you to proceed further in the matter. In case you needfurther clarification, please feel free to contact me.

Thanking you and assuring you of our best services at all times,

Best regards,

Pradeep Gaur, P.Eng.PresidentM&I Power Technology Inc.

fvi^.l Pu•arE i is ortn:;Iocy Inc.2145 Meadowine Blvd Missirs;;uca i)l4 I.cN 61;8 Canada

Ph +1 (4161 63/-i,lti±p;i/) 6{)J Fax 1 I4 I of 623-$4°0

III Concept; ono Deno,: obtl,r, 4,o this doc^rrEni remain 4he proper? oF: a.I Fo.^ei ieG-noio_y anti fno:I nor' be xed forOr,

cpnl:nno°n of 'no c.s-nCs,,, :,:c n-r.c.", '; c >~,e^-r e o,ceci

M&I


B4


FD 1' i:In C n . n :f

-t;

I

L

i

1.1

CONTENTS

Section 1

Introduction to M&I !Company profile

Section 2

Synopsis

Section 3

Scope of Work

Section 4

Limit of Supply & Exclusion

Section 5

Design Basis

Section 6

Performance Parameters & Guarantees

Section 7

Price Schedule

Section 8

Drawing

1--

DIccry

2i

E

:.D.

L5N ii-.FS

.

1. 11

i

iii ii

Al Corepl.; arid Da:iv,Ili:

ptuperly

M&IFoweii

Lie.3,,

fu,

M&1


85


'Cr

Section 1

NMI

COMPANY PROFILE

:I

M=714.7.,thr:...E..

C:,L . l L5N .P.1-:1.1M711",•74.71177

•

"'oh.1,011

d

:h IL* 49 GU

rE. rLILIr,lho properly oLM.F.IPc.N.1'ec 11r,,17j,r n,LL,d ;IV!,

lox1 1-,-.: , I : e, Dlhol.: !he applcolk, n

.1' h,r n'---Lh,':

=


B6


M&'I

M&I Power Technology, Inc.Corporate Profile

Incorporated in 1981, M&I and its various divisions, is an applied R&Doriented company. The company's origin wag in niche technologies servingprimarily the IIVAC Industry. M&I's core competence is In Aero.acoudicPrinciples, which offers reduction of horsepower, noise and vibration

M&i developed numerous predicts in the air movement field, especially vaneaxial and centrifugal fan systems, and has been able to improve the overall.system efficiency, utilizing flow field technology. Many other assodatedproducts were developed in the air moving technology, which can be found onour websitc www miair.cont.

M&I has grown steadily and profitably over the last 20 years and is representedthroughout the United States, Europe and Canada though an establishednetwork of manufacturer's representatives. M&1 group operates its IHVACbusiness through M&t Pleat Transfer Products Ltd. and flow solutions forpower and process industries (i.e. boilers, I{RSO, Cos Turbine, Steel, Pellet,Cement, Aluminum, etc.) through M&I Power Technology Inc, M&I Poweroffers expertise in the areas of flow control, draft loss redaction, furnacecombustion performance analysis & optimization and efficiency improvementof rotating & stationary equipments used in Power. Cement. Steel, Pellet &other Process industries. Our website: www an sowertechnoloav, call.

The engineering, manufacturing and procurement aspects of the Company arewet-proven, yet flexible to meet the specific demands en a project-by-projectbads. For example, engineering is done in-house or sub-contracted as neededto meet schedules and remain competitive. Alliances and relationships areformed with industrial experts. scientists, and engineers from reputedconsulting firms and universities to add new approaches. Procuremenl is doneboth locally or internationally, as the Project dictates. Manufacturing issimilarly flexible with corer critical components being manufactured in NorthAmerica and other scope competitively sula-cecaliacted, but always under M&IProject control.

Leadership innovation and technology (with the latest advances inComputational Fluid Dynamics and 3-D engineering modeling and analysi a) tosolve customer problems and offer effective solutions is what dives M&I andseparates it from it's competition. M&I's various products are thus a secondarymeans to affect and satisfy this goal. M&i has been awarded 30 Patents inaero-acoustics with an addtional It pending.

M&I's corporate goals and culture go beyond the best engineering tools andtechnology. The real capital of M&I is the talented personnel, which has beendeveloped in a conducive enviromncan, lending to excellence. M&I's goal!objective goes far beyond the traditional shipment of components andaccepting warranty obligations to taking complete functional and designresponsibility of all the systems that M&I manufactures and puts to beneficialuse.

Mat's 3D Modeling for Furnace Conk usti an Process

M&Cs Bagttoose Fan Exhaust Silencerfor St Lawrence Cement, Canada


B7


H..

rEi

_1-;r_

NIX[

Section 2

SYNOPSIS

?l

E

: -:a, = s td LtiI I F3 CanodoPh +1

i

i

.1 Coriilepli,

wHiiied I, II

prirzierly

NiS.I Pi,..er

and riKI ii,-:.,l

:v7,d


B8


^, _.p•^^c^: ^^^_ayr^_,r-^^ =ma=r i _-1,_Inr.î 5h7h.; r rD t De (1 . ...i rn: 117c-:Jh _n_

SYNOPSIS

M&l has carefully analyzed FD fan inlet duct and discharge duct between fanoutlet and Steam coil air heater (SCAR) to identify potential reasons for flowinduced vibration and fan capacity curtailment. Based on site visit by M&lEngineer and the information collected 1 received from plant ; M&l carried out apreliminary CFD analysis to map flow behavior inside the upstream anddownstream duct of the FD fan. Based on the results of CFD findings, M&l issubmitting a proposal for modification of the above segment using their state ofthe art aerodynamic diffusers to achieve lower pressure loss and elimination offlow stratification and turbulence. To develop an efficient manufactured solution,M&l needs to carryout an advanced CFD analysis. This activity will only becarried out after placement of the order. However preliminary analysis gave usgood indication of problems in the system.

It is quite evident from the CFD pictures attached below that there are very highvelocity hot spots in the certain portion of the duct combined with local flowseparation in the certain areas of the duct causing flow recirculation. Drasticchange in velocity distribution across duct cross section resulting in high fanentry loss and poor fan blade loading. Moreover fan is operating at very high flowrate (165 kg/sec/fan) resulting in very high velocity magnitude creating flowinduced vibrations. It is very important to eradicate those high velocity hotspotsthrough aerodynamic diffusions by bring dynamic pressure values close to areaaverage velocities from mass average velocities. Further pressure regains needsto be achieved at fan discharge to minimize unproductive velocity pressureresponsible for high backpressure and loss across steam coil air heater.

Mal 's proposal comprisesof internalmodificationsand someexternalmodifications to the one side of inlet and discharge duct.:

M&l would propose state of the art aerodynamics diffusion system and longturning vanes to eliminate flow abnormalities like local flow separation,turbulence and eddy's. Utmost care is given to understand flow behavior andinsertion of suitable shape diffusers to achieve proper flow diffusion.

Please refer attached schematic drawing #P09-001-OOt showingindicative areas (final modifications to be confirmed by detailed CFDanalysis) of modifications proposed by M&l( suitable diffusers will bedesigned & developed to retrofit at those locations) to achieve lowerdraft loss and pressure drop savings. indicative pressure drop savings tobe achieved by M&l modifications are given below:

3 .,j. I

<i - Ir. ?I=DIY ^.-

^'1 ^ , eryJ:,v.^n = r -

1 a'^_ >> :,t ^d l 1.51J dPî. arn-o--la

ph

-

-.. Ii -',;

ÎI =o^._2P15 CUCI D iii r^ 0,,111r.5.^ in Ili' JO:.:nini1 r• Heal. Ih2 ,^CPCti^ of Mi i Fnvêt le[I•-w Ia v and .1x711 nel be _;â'•x


B9


r •I. ^_;c: H:,

:a

^cl 7'i i'^:; sfatl.:I F['f-n-_

71'i.-711^;s_..I Ilk

-

RESULTS AT A GLANCE:

Expected Pressure drop Reduction! Savings inFD fan Inlet Duct:

1.5" W.G.

Expected Pressure drop Reduction! Savings inFD fan Outlet Duct:

2.0" W.G

Above reduction in pressure drop will give appx. 15-16% reduction in fan horsepower (if fan efficiency does not change at lower static pressure) or 8-10kg/sec/fan (5%) more air.

Lower flow induced vibrations: Flow stratification causes flow inducedvibration. M&l s aerodynamic diffusers will streamline flow inside the duct and atfan inlet and at SCAR inlet...

We also confirm high quality of manufacturing and stringent quality / inspectionnorms. Every aspect like transient loads, combination loads, are considered inthe design criteria of the system. Our manufacturing process confirms to CSA/equvt, standards.

Efficiency, quietness and reliability is a standard for Mal products Our approachto the total solution to air and plant draft systems and knowledge sharing cultureare the strengths of our organization.

r-=i_A 4! 1a^aacrunnc E ...c:, PA

C AA `N

C7n:"ACI,S.:+'

`... - liidl^i

nil Ocn enln ClrnntL'e;inrr,:JVllirKd!ii Ira_dor:Nnlenl[^nral: the cr•operrv of M$IPnvcrl=.-_h.n:Ijy' And;furlit,r:.

I

14 hc_

M&I


B10


I.

;1CA,^ -^fl [l Y.-In X7.,.1 r1 n 1.:111 :. n .I I_

CFD RESULTS OF EXISTING DUCT:

FD FanDischarge Duct

Very High VelocityStratificationCausing Flow

Induced Vibrations

214; TAW7J'_anne. bk•_.,VI,

ViolI , _'I . ! LSVI CPC)

7r1^ IrV^F.-. _

41 ror.cepls an:1 De_

a-lLn, d in lIc doccinen!^sci c the crcperlY of r,^ Fnwr.r 1nch:l(hi y cad shall nil hn ^..^.d ionu L¢.eo h_. rl

ID E.,clIal h_a-ni^ I ' c,n cl N'i anCOn^: LJ wlc ., ix c. ndclir-


B11


-

17._

.1,4 : 0

i:, I

c, =1 , n .-

::itic n E

NIS.c[

Velocity77.4

69.6

61.9

54.1

46.4

38.7

30,9

23.2

15.5

7 7

0.0

1

n .Dh.l 1_11

:11 - vDJ0+

-

'

.-.271, 17-:4 c,

and De,grE ovWroed In 11* d.7wnenl ,er nnnx N,e prcr ea, .1' Mt r Powerhr,

d

I be sea rc,r

r

1o 4wksOllt,e. L

,, 1H-- ..

e-:1'

'Or

1]_,:•


B12


r

H

I 11

[ rl =1,,I n

r .rI I ,

1

rn I t

1 . k I

-lr

I I

Velocity96.a

\\\\s\

\

87.1

77.4

67.7

58.1

48.4

38 7

29.0

19.4

9..7

0.0[rn

- 1]

2115

B

OM L51 . 1 6F:6 C,-ginaa,

+1 14 ("I ,5.'.7.

=,, - 1 [I !,:,)

41I Con.-.6t, or,•1 0,11 3: ou!l1r.d ,n dr,cv,.,,I

the

o! M?.l P Owes 1

!Toll r-51 b.= .r.ndr^mar


813

Stratified FlowResponsible for FlowInduced Vibrations &

Turbulence

Velocity

[rn

1]

Local Flow Recirculation& Turbulence in Pan

Suction Box


el.l: 1-lolvr,:

rel

1 111

' D "Dl -, Cl

:11 n ,: MS: r

Section 3

SCOPE OF WORK

F

T :,.c

rp:

1'14.5

Pvd.

,DN L I I

,: Dn.7dO=1'.

iAlcl x. ..T./Cell)-i

- I

Concepts Irv.] Er,ozi-4-n.c.Allnd ,n Pis document rar.,jb lhe properly or Nlt.lFa ,.,ar h;ch,"ala.n,

be

Icnny b..,rix.-e

P-..7, raw,l,ole the

at [ha


B14

Holyrood: Upgrade Unit 1 FD Fan DuctworkAppendix 8

ma, f

SCOPE OF WORK

CFD Analysis, Design, Engineering and Supply of carbon steel internal diffusers(same as existing duct material)

M&I will supply diffusers & tong turning vanes (internals) to be integrated insidethe FD fan inlet & discharge duct. At couple of places there will be local outsideduct modification, which is feasible to carry out under present circumstances.M&l will fabricate complete internal diffusers/vanes (as shown in the Dwg # P09-

001-001) and partial external modifications. Broad scope includes

• 3116' / W thick carbon steel (same material as the existing duct) Singledouble walled diffusers..and outside duct wall.

• New expansion joint near fan suction box

• Associated Frames and hardware to hold internal diffusers

• Diffusers and external wall modification is 100% seal welded.

▪ Required hardware including bolts, nuts, washers and gaskets (wherevernecessary) at interfacing point.

• Stiffeners, wherever applicable

• Inspection during manufacturing stage as per M&l standard practice.

212,F

-,h.1 - `.I I rF3 I, ire Jdq

F'I-Iy - L7 ' rl'[S

:JI Cor,,tcC.b c3rdY

,,nrltrEJl,, lIt doc..,l,eni roar bin 1-3r,coe.re c,IM I FCWrcr Tc,'.hr3.%[?]r 3 d 51•Yll ltl be ne- 33

, C'.v4+r,.. ' l i -r I I ' !

I " , .

1 . ' , e .[FriC :;l;: ^ . . . f II'.' .,:,nl^ c r . . - • : I ' . . ' . . . '.^„ f.:. ry..-:^d,y„r, _ _ , _ . .a: I`


B15


1 .:dr •1S .J: Ftyl7.1

Irlic.1-E.

:

n .

I F.

:DI

I. .t

,

-

Section4

LIMIT OF SUPPLY AND EXCLUSION

r./I

10, , _J'I

r FL.1 il

.=

1,1 --,,,

5/dY-11

- E4 h^ r: ,.-

4.1Cd-drteepfs and ftettior e.d,11irct

Ili dopt.mt,etrl ,et-rtt,d 11-,e pc:petty otM&I Fe,,er Tsyp '-d-etagy' and sh.ll ', p i be ,eeJ


B16


an a._,Ci ', . ' 1I cahor,_M&I

LIMIT OF SUPPLY:

• Internal & some external modifications to existing duct an extent tomeet pressure drop saving values as mentioned in the above scopeof work.

EXCLUSION:

o Foundation, anchor bolts, nuts, washers and leveling hardware.

o Unloading, forwarding, and storage of equipment at job site.

o Dismantling, Installation, start-up, testing, commissioning, utilities andconsumables.

o Insulation if any

a Structural support, ladder, grating.

o Plant and equipment lighting.

o Lighting arrestors and grounding system, Fire protection and detectionsystem.

o Site leveling and grading.

o Control and Power cables, Supply of AC or DC power.

o Dampers.

o Third party inspection.

o Emission probes.

o Any statutory clearance.

o Any item not specifically mentioned in our scope

AI' C'er^cenk'Fro7 bai;'a'outlined In His d.: _ .tocnl rem;iri the eropeee or v&I F _wef iechrrJ.t4v;x'id glgil 'SCI uc used to!Ih.r

I_?'-oI . nl

I _

p4•, I

:l th:._r:.^tl-

v

!i . 1V f: 11

7d

. .r,

I


817


d41r i ..,r I

:1- . FE' 1'r:In C . ..

-O r:M&I

Section 5

DESIGN BASIS

E'k-ri,

LEI

.':ar-locio

gip,,--r= ./CeO - l

- i.3'.-5) ri.7.7:r.,;.I.G6

All Cor,OOpl,

DE,ig,oulLIr.od

114, Op pr-me I renroir,lhe properly pr

Fewer or:1,r, logy ant !-r'.ill

tre r-oorr-:1 1t.,

rf fr.

II

77 ,'r,r-LO,r': ,wr,o,l


B18


_e for, d, :11'r: t7i': jt

i..

DESIGN BASIS:

Design pressure:

• FD fan Downstream duct

• Design air temperature

Operational Condition at Rated load:

• Air Temperature at FD inlet:

:

30 deg C

• T Air Flow from one FD fan

:

165 kg/sec

▪ Duct/diffuser Corrosion allowance 1116"

• Maximum Velocity inside the duct 4000 FPM

SITE DATA:

Site location

: Holyrood Generating Station, NLSite ElevationAmbient tempMaximum

: Not AvailableMinimum

: Not AvailableDesign Relative Humidity

: Not AvailableDesign Ambient Pressure

: 14.03 AsiaMax. Rainfall Intensity

: Not AvailableMax. Wind Velocity

: Not AvailableSeismic Zone Factor

: Low intensity - assumedGround Snow Load/Exp. Coeff.

: Not Available

t' f.^^ryt:ovAnS E, : ^ ,. Of l i- ^ Id ,if81_ ^n•.-a=6-:

.1I r'orrrepls urrd

oe^rl'ired.1', Ili: dac.Jnl olr mesa Ir,e PrcE .erly otf ti Power fechreiE.-gv mnd shell'I I be w_^rc?

-101+30"WG

40 deg C


B19


t

d: H ly

7tir _^ [4]r. F[^ f ii i J.

Design Philosophy:

While designing internal diffusers, long turning vanes and fan discharge diffuserduct , following design considerations were considered

Loads are considered as force applied to support structure'+ For primary load calculations, all loads are considered separately

• Duct internals are designed for transient air heater upset condition

Internal diffusers, turning vanes provided at various locations inside the FD fanduct will be thoroughly checked for structural integrity as well as retainedadequately with duct walls.

6 u7, Ff ississa.r:», 0I'd L`5I'1iF,7 . - '- i.r

07.

l

A:I ^=o;,rcrk and DFwig,.x II r.cd vl IM= dco.mrni r?=nivn the G^^^ °-+w ofM&l Prwc ^c-throt2jy and shall nnl bs,s5tl i:+


620


4:fly

1[ r

cl.,-

qv:

D1h:1"c

Section 6

PERFORMA NCE PARAMETERS

•-:

1,

1 , 51 . ] 6E8 r_ 7ro-aJr

Ph

- '1.1.1161

,TvI n cepl:

it IN', dn.

reman II,: p ,c p erl), ol PM'

1.1,11 ncl b,. ed


821


FD

PERFORMANCE PARAMETERS&GUARENTEES:

Performance Guarantees:

Expected flow improvement in air flow:

8-10 Kg/seceach side

Expected Pressure drop Reduction! Savings:

3.5" W.G.

Tolerance:

a Pressure drop:

+1- 2.5%

Basis:

Air Temperature at AM outlet:

30 Deg C

Total Air Flow/ fan :

965 kg/sec

I

:,I.:g,

1 - 1 n:.

'Ii+F rl:i-. .)

A!I n =' n),:epl, or .,J

oollir.d

rer,sir.1he prop-e0y.

]P .:wo

r_.1 II.,

Jr^111 .^,

4,•,7KTl

c.,phoo?ion of IL=

z, 11


B22


Dif,ef . 7t

Section 7

PRICE SCHEDULE

f.f/fLff

f i 45 Mef3.7fC.r.Incl- Bl if CIC5f.:. f4ff '-5116F'. :7.711%0:L71

A 1 f,f

55-5f ,,fr.e0i

-

t.f

Ail Cor,ool .,, s,Lffigns

fr: Irt docowoof ref,

Use properly of W.-I Fower ..,O og, crud

6e .:-!*9 fcr


B23


I^

,lo!yr_ :•J

r^^r^rlrnasiarl-^ r_, F7l7r,:. : _7 1'I: y l`i•CO7irre

M&I

PRICE SCHEDULE:

1) CFD analysis for developing solution: C$ 25,000

2) Design, engineer, manufacture & supplyOf internal diffusers , expansion joint, ;

C$295,000 for 2 fansExternal one side duct wall for FDFan inlet & discharge duct as per enclosedscope of supply and dwg # P09-001-001

Price Basis:

• Price includes transportation of diffusers to Holyrood site.• Does not include dismantling, installation and commissioning• includes supervision of diffuser installation• Above price is in Canadian funds

VALIDITY:

Our quotation is firm and valid for 60 days from the date of the submission

TERMS OF PAYMENT:

25% as advance along with Purchase Order

25% payment against submission of revised CFD analysis, design anddrawings.

40% against dispatch of complete system net 15 days

10% on successful completion of Erection and commissioning

DELIVERY:

To be mutually agreed upon to meet project schedule.

2145 fa•.--1, vnl

F +^. !-Ai.Si=sr...,-±^• •T,1.1 I _`13 r`-F8 r-.:71-^:-19r7_.+: 141x., h_'- ` ^."/fl=.rr, = . -'idl•.n ^,---

- r-.

Fll!,t,^..:eD!E.rr,7 rrs=ig,coulfr pd in Iltis d,=O,n r!^•-nrr^i lne CCrlpoly O;;i"Z.1 F'.?n 4ec Yi: ele r,., end sIr^llr :•I be

Newfoundland and Labrador Hydro B24


, 'DPO-Lal:

]

.71 DT

D f , :r=

F:1

Section 8

Drawings

21 .1'

. ;1:)

'EN

.=

- Al

urvi Dc., igrr: o n,:Iirre..J in I It d.E . Anenr rer-ndr,11-e

o, N.°..1 P:,,q e.r.hr,1w, al id sr.!! ,ol b,,ed rtn,

ri,

f.y


625

Holyrood: Upgrade Unit 1 FD Fan DuctworkAppendix 8

4-

1. AU. DIMENSION FILE IN INKIi^.2.FORAIOPURPOSE ONLY

• 1-. -1

PIS-CC 03:

.gin.

NJA iI. ^.^..:..,

s. 1,

1

1


826

fan ductwork upgrade generating unit 1 forced draft … · induced vibrations and fan pressure...

Documents