A Maharatna Company
NTPC O&M CONFERENCE FEB 13-15, 2013
APPLICATION OF COMPUTATIONAL FLUID DYNAMICS IN IMPROVING POWER PLANTS PROCESSES-CASE STUDIES
NETRA, CenPEEP, TANDA & KORBA presented by
KUMAR SWADHIN, V.K.DIXIT
A Maharatna Company
• INTRODUCTION • CASE STUDY 1: TANDA FLUE GAS DUCT
– 3D MODELING
– SITE MEASUREMENTS
– VALIDATION OF MODEL
– COMPARISON WITH EXISTING DUCT
– EFFECT OF BRACINGS & DAMPERS
– IMPLEMENTATION
– BENEFITS
• CASE STUDY 2: KORBA FLUE GAS DUCT – 3D MODELING & ANALYSIS
– COMPARISON WITH EXISTING DUCT
– IMPLEMENTATION
– BENEFITS
• WAY FORWARD
APPLICATION OF COMPUTATIONAL FLUID DYNAMICS IN IMPROVING POWER PLANTS PROCESSES-CASE STUDIES
A Maharatna Company INTRODUCTION
3
OBJECTIVES Reduction In Pressure Drop
Flow Uniformisation: Reduction In Erosion
Id Fan Power /Current Reduction
To Increase Flue Gas Flow To PAPH (In Case Of Korba)
TEAM WORK
NETRA, CenPEEP, TANDA: BMD/EEMG
NETRA, CenPEEP, KORBA : BMD/EEMG
A Maharatna Company
• INTRODUCTION
• CASE STUDY 1: TANDA FLUE GAS DUCT – 3D MODELING
– SITE MEASUREMENTS
– VALIDATION OF MODEL
– COMPARISON WITH EXISTING DUCT
– EFFECT OF BRACINGS & DAMPERS
– IMPLEMENTATION
– BENEFITS
• CASE STUDY 2: KORBA FLUE GAS DUCT – 3D MODELING & ANALYSIS
– COMPARISON WITH EXISTING DUCT
– IMPLEMENTATION
– BENEFITS
• WAY FORWARD
APPLICATION OF COMPUTATIONAL FLUID DYNAMICS IN IMPROVING POWER PLANTS PROCESSES-CASE STUDIES
A Maharatna Company
TANDA FLUE GAS DUCT MODIFICATION CASE STUDY 1
FLUE GAS DUCT SECTIONS STUDIED APH Outlet to ESP Inlet ESP Outlet to ID Fan Inlet ID Fan Outlet to Chimney Inlet
A Maharatna Company
IMPOSITION OF BOUNDARY
CONDITION AND CASE SET-UP
DEVELOPMENT OF 3-D DOMAIN & MESHING
A Maharatna Company
7
SL.NO PARAMETER UNIT AVERAGE MEASURED VALUE
(28.03.2012)
1 FLUE GAS FLOW, APH-ESP SECTION TPH 930
2 FLUE GAS DENSITY, APH-ESP SECTION Kg/m3 0.8347
3 FLUE GAS FLOW, ESP-ID SECTION TPH 1004
4 FLUE GAS DENSITY, ESP-ID SECTION Kg/m3 0.864
5 FLUE GAS FLOW, ID-CHIMNEY SECTION TPH 1004
6 FLUE GAS DENSITY, ID-CHIMNEY SECTION Kg/m3 0.8997
7 FLUE GAS VISCOSITY Kg/m-s 2.2×10-5
8 PRESSURE Pa As Measured
Mathematical Model: Standard k-Ɛ with Standard wall functions
SITE MEASUREMENTS FOR BOUNDARY CONDITIONS
A Maharatna Company
Measured: 68.01
CFD: 68.9
Error %: 1.31
APH A
APH B ESP B
ESP A
ID C
ID B
ID A
CHIMNEY
P P
P
ALL VALUES OF PRESSURES ARE IN
mmWC
Measured: 54.8
CFD: 52.0
Error %: -5.1
P
P
P
Measured: 56.4
CFD: 52.0
Error %: -7.1
Measured: 55.7
CFD: 54.47
Error %: -2.2
Measured: 74.7
CFD: 69.94
Error %: -6.37
Measured: 71.1
CFD: 72.56
Error%: 2.05
VALIDATION OF CFD MODEL
A Maharatna Company
9
MODEL RESULTS COMPARISON OF VELOCITY CONTOURS
APH-ESP
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BASE MOD
BASE MOD
MODEL RESULTS COMPARISON OF PARTICLE TRACKS
APH-ESP
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MODEL RESULTS COMPARISON OF VELOCITY CONTOURS
ESP-ID
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12
MOD
MODEL RESULTS COMPARISON OF VELOCITY CONTOURS
ID-CHIMNEY
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13
MOD
MODEL RESULTS COMPARISON OF VELOCITY CONTOURS
ID-CHIMNEY
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SECTION ∆p with no bracings
mmWC
∆p with bracings mmWC
% Difference
APH-ESP 34 52 53
ESP-ID 63.5 69.9 10
SECTION ∆p Across Damper mmWC
DAMPER 1 (ESP O/L) 7
DAMPER 2 (ID I/L) 9
DAMPER
DIAMOND DIAGONAL
V-TYPE BRACINGS
MODEL RESULTS EFFECT OF BRACINGS AND DAMPERS
V-TYPE
This can be used to explore optimization of number of braces without
sacrificing structural integrity
A Maharatna Company
MODIFICATION DRAWING DEVELOPMENT & IMPLEMENTATION
A Maharatna Company
Date Section
Fan
Combination
CFD Prediction
for original
duct
Measured
in Modified
duct
ΔP
Gain
ΔP mmWC
ΔP mmWC
ΔP mmWC
11.12.12 Total A&B 313.8 235.1 78.7
12.12.12 Total A&C 302.0 237.2 64.8
ACTUAL SITE RESULTS REDUCTION IN PRESSURE DROP
A Maharatna Company
The flow pattern indicates uniformization of flow post modification; this will
result in reduced erosion of duct.
ESP I/L A ESP B I/L B
Left
Left Right Left
Left Right
Right
Right
View direction
Before
Modification
28.03.12
ID A&C
After
Modification
12.12.12
ID A&C
ACTUAL SITE RESULTS FLOW UNIFORMISATION
A Maharatna Company
SITE MEASUREMENTS VIDEO CLIPS
U2-11 DEC 2012-ID B INLET – FLOW
U2-12 DEC 2012-ID A INLET – FLOW
ACTUAL SITE RESULTS
FLOW UNIFORMISATION
A Maharatna Company CONCLUSION
Total Pressure Drop Reduction by ~ 60 mmWC
Corresponding ID Fan Power Reduction by ~ 50 kW in each ID Fan ( ~ 5 Amp in each ID Fan) Flow Uniformisation in Duct
• Will result in Reduced Erosion in Duct
MODIFICATION RESULTS
A Maharatna Company
• INTRODUCTION
• CASE STUDY 1: TANDA FLUE GAS DUCT – 3D MODELING
– SITE MEASUREMENTS
– VALIDATION OF MODEL
– COMPARISON WITH EXISTING DUCT
– EFFECT OF BRACINGS & DAMPERS
– IMPLEMENTATION
– BENEFITS
• CASE STUDY 2: KORBA FLUE GAS DUCT – 3D MODELING & ANALYSIS
– COMPARISON WITH EXISTING DUCT
– IMPLEMENTATION
– BENEFITS
• WAY FORWARD
APPLICATION OF COMPUTATIONAL FLUID DYNAMICS IN IMPROVING POWER PLANTS PROCESSES-CASE STUDIES
A Maharatna Company
KORBA FLUE GAS DUCT MODIFICATION CASE STUDY 2
FLUE GAS DUCT SECTIONS STUDIED ECO O/L – APH I/L
A Maharatna Company
Duct Geometry used for CFD Simulation, Eco outlet A to
PAPH/SAPH inlet
Problem of Low PAPH outlet temperature
Attributable to less flow of flue gas to PAPH
SIMULATION DOMAIN: ECO OUTLET-TO-APH INLET
KORBA UNIT#6 (500 MWe)
A Maharatna Company
ZONE 1
ZONE 2
TOP VIEW midplane
ZONE 3
SIDE VIEW midplanes
FRONT VIEW midplanes
ZONE 3
TOP VIEW
SIDE VIEW FRONT VIEW
Velocity profile at different cross section of Flue gas duct
E
E
F
F
G
G
A
B
C
KORBA 500 MW FG DUCT ECO O/L – APH I/L
VELOCITY CONTOURS AT VARIOUS SECTIONS: BASE
A Maharatna Company
HORIZONTAL MID-PLANE
Before
After
COMPARISON VELOCITY CONTUORS AT HORIZONTAL MID PLANE
KORBA 500 MW FG DUCT ECO O/L – APH I/L
A Maharatna Company
Sketch of modification implemented and photographs of the modifications being implemented.
IMPLEMENTATION OF MODIFICATION
A Maharatna Company CONCLUSION
Data Collected With Site EEMG on 02.06.2012
Data Analysis Concluded an Improvement of 4-5° C in PAPH Outlet Temperature.
MODIFICATION RESULTS
A Maharatna Company
• INTRODUCTION
• CASE STUDY 1: TANDA FLUE GAS DUCT – 3D MODELING
– SITE MEASUREMENTS
– VALIDATION OF MODEL
– COMPARISON WITH EXISTING DUCT
– EFFECT OF BRACINGS & DAMPERS
– IMPLEMENTATION
– BENEFITS
• CASE STUDY 2: KORBA FLUE GAS DUCT – 3D MODELING & ANALYSIS
– COMPARISON WITH EXISTING DUCT
– IMPLEMENTATION
– BENEFITS
• WAY FORWARD
APPLICATION OF COMPUTATIONAL FLUID DYNAMICS IN IMPROVING POWER PLANTS PROCESSES-CASE STUDIES
A Maharatna Company WAY FORWARD
REPLICATION OF SIMILAR WORK
Potential for pressure drop reduction in FG ducts is
largely untapped, especially in ID Fan to Chimney
section
PROCESS IMPROVEMENT IN OTHER AREAS
CW Pump Sump Study
Application of Boiler Combustion Modeling
OPTIMIZATION OF NUMBER OF BRACINGS
Initiation of Study on Optimization of number of support
braces without sacrificing the structural integrity
A Maharatna Company
A Maharatna Company
Unit
Date Overall
Leakage
ID Fan Current
Average
% Amp
4 26.04.2010 28 70
2
26.12.2012
46 73.5
2 Projected 28 64
U#2 ID Fan current are comparable Despite high leakage.
If U#2 leakages are brought down to U#4 level, the ID Fan current will come down to 64 Amp as against 70 Amp in case of U#4. This 6 Amp Gain is reflection of contribution of guide vanes.
RESULTS ID FAN CURRENT REDUCTION
