Uniper Franken plant - A turnkey case study

Howden expertise solves competitor's long lasting problems

Uniper, an experienced international energy company formerly known as E-On, was subject to a series of problems on a FD fan at its Franken plant in Germany.

The fan was installed and fixed numerous times by a competing fan company but the root of the problem had never been addressed.

Printable PDF/brochure
Inside an Axial fan

The challenge

The Franken plant provides reliable and flexible capacity that can balance supply and demand to maintain grid stability. However, the plant had experienced a series of fan issues over the years. The OEM had tried time and again to make small fixes to the fan but the vibrations were still very high.

Finally, the stiffeners supporting the main bearings cracked and broke off due to vibrations, and Uniper established that the damage caused to the rotor was beyond repair. Tired of continuous small fixes, the operators sought Howden’s opinion on the matter due to our extensive experience in fan engineering.

The results

After the successful completion of the project, the fan is now running with minimal vibrations and with increased performance. These improvements allowed the boiler to run on full capacity and meet the required supply to the grid. High technical knowledge and proven advisory expertise allowed Howden to finally solve a problem that the competitors had tried to fix for over 30 years.

The technical project management worked very well. Even with a very complex installation situation and a very tight schedule, everything went fine. The installed fan works excellent and will help us secure our availability."

Stefanie Pfriem, Uniper
 

The solution

After our initial investigation we established that the root of the problem were the movements of the fan housing originating from a weak steel foundation, and so, we conducted a supplementary torsion analysis to demonstrate this to the client. We considered the pros and cons of repair versus a complete replacement and, after some deliberation, we finally recommended to change the steel foundation as well as the fan to prevent future vibrations. The solution entailed new fan housing and Variax rotor, a steel foundation and vibration springs, a combined oil unit, two hubs and oil-filled blade bearings, a high pressure blade profile in aluminium material, coupling and a stall warning and alarm system.

When we, at Howden, take on a project, we strive for the best possible outcome. Therefore, we will only offer a lasting solution and thus eliminate the inheritance of problems from quick fixes. This is one of the main factors that led the client to trust Howden over the OEM despite entailing a larger investment at the time.

Even though there was a tight schedule to deliver this service, we were certain that this was the best solution for the client and, therefore, we put it at the top of our priority list. Moreover, the FD fan was located on a foundation at 71m above the boiler, making the project much more challenging than normal.

Howden not only demonstrated an ability to plan and execute a full operation efficiently, but the exercise restored confidence in the reliability of the fan. Despite all odds, we exceeded Uniper's expectations by delivering the project in six months instead of the usual ten.

 

Full Case Study

Please complete the fields below to get your copy.

Email Address
First Name
Last Name
Company
 

Full List of Case Study pages

The introduction of Howden's VN seal system to the air preheaters brought an immediate drop in leakage level from 26% to 5%.


Howden completed a retrofit of VARIAX ID fans on the 640MW unit 5 at Asnaes Power Station, Denmark.


The Howden Free Floating Piston is a proven unique technolgy that turns the weakest point to one of the strongest, which removes rider bands wear at a stroke


Berre Petrochemical Cluster, which includes polypropylene and polyethylene plants, trusted Howden to reduce its power costs by 7% within a 3 year return on investment.


VentSim CONTROL technologies result in impressive cost and energy savings while also raising productivity at Goldcorp Eleonore gold mine.


Fresnillo mine is one of the most technologically advanced deep mines in the world, and incorporates VentSim CONTROL ventilation management.


UPTIME provides advanced compressor performance analysis at Gunvor Petroleum in the Netherlands


Howden worked with a North American hard rock mine to introduce a Ventilation on Demand system using VentSim CONTROL technology.


Installing a bigger hub at Herningvaerket, reducing installation costs and future service expenses.


The understanding and knowledge provided by Howden is an essential factor when installing additional equipment on your compressors.


New integrally geared compressor (IGC) results in power savings up to 31MW/h a day


Replacement of primary plate heaters with Howden custom designed rotary air preheaters.


200 bar to 300 bar hybrid compressor retrofit for helium capacity filling


At Millmerran Power Station, Howden provides a tailored service that supports their needs of the plant to prepare for their upcoming major outage.


New boiler and FGD processes called for a total change of the ID booster fan at a power plant in Plzen


Howden develop method to drastically reduce the cylinder repair time of reciprocating compressors.


Upgrade your reciprocating compressor with our innovative coated liner solution.


The introduction of Howden's HC element to the air preheater resulted in extended operational times.


Huge savings were realised by using Howden's turnkey service to reduce heater leakage and running costs.


A large chemical plant on the east coast of the United States contacted Howden to perform a full Turnkey project on their critical path air preheaters.


Howden expertise solves long lasting problems with an axial fan at Uniper's Franken plant.


During the first few months after the deployment of Uptime, VEAS experienced two distinct challenges where the benefits of Uptime were clearly demonstrated.


VentSim CONTROL case study for three typical mining projects.


Replacement of existing blades at the Wangqu Thermal Power Station


Efficient engineering solves impeller failures at the Wibank coalfield.


Centrifugal Fan

At Tarmac (Dunbar cement plant, UK), their existing Raw Mill fan was replaced with an enhanced Howden design in 2007.


Reciprocating Compressor

Building the world's biggest reciprocating compressor - a white paper and video.


If you would like to submit an enquiry please get in touch.

Your local Howden contact

The below contact(s) are the representatives for your country. You can change country below.