Fans Efficiancy

Fan Systems
M. Beauprs Mise jour D. Dumont avril 2004

+A.Godichon Flaktwoods - Mai 2004
Content
System resistance
Performance curves
Fan types and terminology
Fan laws
Flow control
Fan audit
Process Engineering Program Gas Handling Fan Systems
June 2009
System Resistance
Concepts of Pressure
TP
SP
VP
Air flow
TP = SP + VP VP = TP - SP
Static pressure:
pressure exerted in all directions by a fluid at rest
Velocity pressure:
pressure exerted by the velocity of a fluid VP = v2
Total pressure:
the sum of static and velocity pressures
June 2009
Airflow System
k = Constant characteristic
= Gas density
Q = Volume flow
P1
P2
P = k Q2
June 2009
System Resistance
Each component in a system offers resistance to air flow
System resistance: the total of these resistances to flow,

before and after the fan
The system resistance varies with air flow rate
System curve: the relation between system resistance and

flow rate
June 2009
Completely laminar flow

airflow through filter
bag
P k
Airflow rate Q
Syste m re sistance
P
Constant static head

airflow through a liquid
pool
Syste m re sistance
P
Different Types of System Curves
P kQ
Airflow rate Q
June 2009
Completely turbulent flow

most fan systems
P kQ1.5
Airflow rate Q
Syste m re sistance
P
Slightly turbulent flow

airflow through a grain
bin
Syste m re sistance
P
Different Types of System Curves
P kQ 2
Airflow rate Q
June 2009
System Curve
Limit discussion to the completely turbulent system curve

Same principles apply to other types
P kQ 2
12
P (mm H2O)
10
8
6
4
2
0
0
20
40
60
80
100
Q (m/s)
June 2009
Fan Performance Curve
Fan Pressures
Fan Total Pressure (FTP)

The European way
FTP
= TP2 - TP1
= SP2 + VP2 - SP1 - VP1
Fan Static Pressure (FSP)

The American way
FSP
= TP2 - TP1 - VP2
= SP2 - SP1 - VP1
Fan Static Rise
SP Rise = SP2 - SP1

June 2009
11
Fan Performance Curves
Pressure
Pressure vs Volumetric flow rate given by the fan

Applicable for fixed specific operating conditions:
gas density
fan speed
Usually, power curve is given
Sometimes, efficiency curve
Power/Efficiency
Flow rate
June 2009
12
800
160
700
140
600
120
500
100
400
80
PS
PO = P x Q
300
60
200
40
100
20
0
0
100
200
300
400
500
600
700
800
900
Power (W)
Fan Static Pressure (Pa)
Fan Efficiency
0
1000
Flow Rate (m/s)
F V
F S W
P Q A t
P
t
t t O
PS
PS
PS
PS PS
June 2009
Ps: shaft power

Po: theoretical air power
13
Fan Efficiency
Total efficiency t (mechanical efficiency):
metric units
US units
Q FTP
t
PS
Q FTP
t
6362 PS
Static efficiency s
FSP Q FSP
s t
FTP
PS
Q:
FTP, FSP :
PS :
FSP Q FSP
s t
FTP 6362 PS
m/s
Pa
W
Q:
FTP, FSP :
PS :
June 2009
ft/s
in. H2O
HP
14
Typical Fan Curves

Performance Curve for IE 250 Fan
Operating conditions
1518 RPM
90F, 600 ft elev.
25
140
BHP
20
120
100
15
80
60
10
Operating point:
13091 cfm
18,0 in. H2O SP
59,4 BHP
5
0
0
5000
10000
15000
20000
Efficiency FSP
40
20
25000
30000
0
35000
Flow Rate (cfm)
June 2009
15
FSP vs FTP
25
140
120
BHP
20
100
15
80
Total
Efficiency
10
FTP
FSP
Static
Efficiency
5000
10000
15000
20000
25000
40
20
0
0
60
30000
0
35000
Flow Rate (cfm)
June 2009
16
Fan Performance and System Curves

20
140
18
BHP
16
120
100
14
12
80
10
8
Efficiency
FSP
60
40
20
2
0
0
5000
10000
15000
20000
25000
30000
0
35000
Flow Rate (cfm)
June 2009
17
Fan Types and Terminology
Types of Fans
Two large classes:
Centrifugal Fans
Extensively used in cement plants:
Clinker cooler fans
ID fan
Mill ventilation fans
Dust collector fans
Axial Fans
Kiln shell cooling fans
Hair blower
Airplanes propeller
June 2009
19
Exploded View of a Centrifugal Fan

Inlet
Outlet
Cutoff
Hub
Flange
Side Sheet
Scroll
Inlet Guide Vanes

Backplate
Inlet Bell
Blades
Impeller
June 2009
Stationary Inlet
20
Centrifugal Fan Principles

Vr
Vt : tangential velocity
Vt
Vr : radial velocity
V : fluid velocity
June 2009
21
Centrifugal Fan
June 2009
22
Centrifugal Fan
June 2009
23
Centrifugal Fan
June 2009
24
Cutaway View of a Vaneaxial Fan

Inlet
Discharge Vanes
Inner Cylinder
Belt Fairing
Outlet
Tailpiece
(sometimes omitted)
Blades
Impeller
Hub
Inlet Bell
Outer Cylinder
June 2009
Diffuser
25
Centrifugal Fan Principles
June 2009
26
Fan Blade Types
Different types of fans characterized by their blade type:

Straight radial
Forward curve
Radial tip
Backward inclined - flat blade
Airfoil
Different applications require different blade type
Each type has different fan performance curves
June 2009
27
Radial Blade Fan (RB)
The simplest of all centrifugal fans

Low efficiency (60 to 63%)
Very common due to simple design
High mechanical strength and easy maintenance
Power curve increases continually with volume
Suitable for high temperatures and very abrasive environment
June 2009
28
Radial Blade Fan (RB)

100
80
70
Efciency
Fan Static Pressure
90
60
50
40
30
20
10
0
0
12
Volume
June 2009
16
20
24
28
29
Radial Tip Impeller (RT)
Mainly used in large sizes for process exhaust and hot gases
The maximum efficiency moved slightly to the right of peak pressure
Power still rise continuously
Inherent self-cleaning capability
Static efficiency up to 71%
June 2009
30
Radial Tip Impeller (RT)

110
80
Efciency
Fan Static Pressure
100
90
70
60
50
40
30
20
10
0
Volume
June 2009
31
Forward Curved Impeller (FC)
High pressure and volume capabilities

Lower speed required for same volume and pressure
Used for furnaces and HVAC applications
Maximum efficiency almost at peak pressure
Power increases constantly with volume
Blade configuration inherently weak
Not recommended with high dust loading
June 2009
32
Forward Curved Impeller (FC)

90
70
60
Efciency
Fan Static Pressure
80
50
40
30
20
10
0
Volume
June 2009
33
Backward Inclined Blades (BI)
Non-OverLoading power (N.O.L.)

Air leaves the impeller at a velocity lower than tip speed
High efficiency: 75-80%
Peak efficiency in useable portion of pressure curve
Lowest pressure capability
Limited tip speed
June 2009
34
Backward Inclined Blades (BI)
90
80
Efciency
Fan Static Pressure
100
70
60
50
40
30
20
10
0
0
10
12
14
16
18
20
22
24
Volume
June 2009
35
Backward Inclined Airfoil (AF)
Most efficient centrifugal fan: 85-90% and more

Two-skin airfoil blade design (usually hollow)
Full Non-OverLoading power curve
High speed or large size for given duty
For clean gas applications and general ventilation
Most expensive design
June 2009
36
Backward Inclined Airfoil (AF)
Efciency
Fan Static Pressure
120
110
100
90
80
70
60
50
40
30
20
10
0
0
10
12
14
16
18
20
22
24
26
28
30
Volume
June 2009
37
Types of Blades - Summary

Airfoil (AF)
90%
Backward-curved (BC)
85%
Backward-inclined (BI)
78%
Radial-tip (RT)
70%
Forward-curved (FC)
65%
Radial blade (RB)
60%
June 2009
38
Unstable Range
Unstable
P
Stable
peak
Flow Rate
June 2009
39
Fan Laws
Fan Laws
N2 D2 3
Q 2 Q1
3
N1 D1
Volume :
Pr essure :
Power :
p 2 p1
N2 2 D2 2 2 k p1
N 2 D 2 k
1
1
p2
1
N2 3 D2 5 2
Pu2 Pu1
3
5
D
1 1
1
June 2009
41
Fan Laws
Fan performance curve made for specific conditions:

fan speed
air density (temperature, pressure)
What happen in other conditions?

What if I change the speed of the fan? (N)
What if the gas density changes? ()
What if I change the size of the fan? (D)
June 2009
42
Fan Laws - Change in Speed
Volume is directly proportional to fan speed

Q2 N 2
Q1 N1
Pressure is proportional to the square of the velocity

TP2 SP2 VP2 N 2
TP1 SP1 VP1 N1
Power is the product of volume by energy

N2
P2

P1
N1
June 2009
43
Example - Change in Fan Speed

A fan running at 1305 RPM delivering 7.1 m/s with a total pressure of 57
mm Hg consumes 66.5 kW. What should be the fan speed to increase the
flow rate to 8.5 m/s if the system curve does not change?
Q2 N1
8.5 1305
N2
1562 RPM
Q1
7.1
What would be the impact on the total pressure?
N2
TP2 TP1
N1
1562
57
1305
1562
66.5
1305
81.7 mmHg
What is the impact on power?
N2
P2 P1
N1
June 2009
114.0 kW
44
Change in Speed
30
250
25
1822 RPM
1670 RPM
1518 RPM
20
200
150
15
100
10
50
5
0
0
5000
10000
15000
20000
25000
30000
35000
0
40000
Flow Rate (cfm)
June 2009
45
Fans Laws - Change in Gas Density
Fans are constant volume machines

Affects the pressure generated and power consumed
A change in density also affects the system curve
TP2
SP2
VP2
2
TP1
SP1
VP1
1
P2
2
P1
1
June 2009
46
Change in Gas Density

Operating conditions
1518 RPM
90F, 600 ft elev.
20
160
18
140
16
120
1.13 kg/m
14
12
100
10
80
60
0.56 kg/m
40
20
2
0
0
5000
10000
15000
20000
25000
30000
0
35000
Flow Rate (cfm)
June 2009
47
Effect of Density on Fan Selection

Dust collector on inlet side of fan
total pressure drop: 20 mm Hg
inlet of fan: -20 mm Hg
Clinker cooler fan

total pressure drop: 20 mm Hg
inlet of fan: atmosphere
For same air flow, fan selection would be different

due to density change at fan inlet
June 2009
48
Fans Laws - Change in Size
Used mostly to compare two similar fans of same type

Some examples of tipping out fans
Casing often has to be redesigned
3
D2
Q2

D1
Q1
D
TP2
SP2
VP2
2
TP1
SP1
VP1
D1
D
P2
2
P1
D1
June 2009
49
Change in Size
16
100
14
90
80
12
70
10
60
+10% D
40
30
50
20
10
0
0
5000
10000
15000
20000
25000
30000
0
35000
Flow Rate (cfm)
June 2009
50
Flow Control
Flow Control
Requirement to control the air flow from a fan
The system resistance curve governs the fan output
Air flow can be changed by changing:
the fan curve
the system resistance curve
Available methods:
Outlet louvre dampers
Variable inlet vanes
Inlet louvre dampers
Variable speed drives
June 2009
52
Outlet Louvre Dampers
Opposed Blades
Parallel Blades
More flow on one side of duct

Not very linear response
Yields more uniform profile

More linear response
The outlet louvre dampers change the

system resistance curve
Power wasting devices
June 2009
53
Outlet Louvre Dampers

120
20% open
40% open
100
80
60% open
60
80% open
40
Wide open
20
0
0
10000
20000
30000
40000
50000
June 2009
60000
70000
80000
54
Variable Inlet Vanes
Installed at the inlet of the fan

Controls volume and direction of air flow
Designed to give a spin to the air in direction of impeller
Pre-spin unload the impeller reducing the pressure
Less pressure implies less power
Closed Position
Open Position
June 2009
55
Variable Inlet Vanes

100
100
90
90
80
80
70
70
60
60
50
50
40
40
30
30
20
20
10
25% open
0
0
10000
20000
30000
40000
50%
50000
June 2009
75% 100%
60000
70000
10
0
80000
56
Inlet Louvre Dampers
Similar to inlet vanes: pre-spin effect
Blades always parallel
Must be used with an inlet box
Power efficiency: a little less than inlet vanes.
Easier to maintain than inlet vanes (hot and

dusty applications)
June 2009
57
Variable Speed Fans
Direct application of the fan laws:

Q2 N2
Q1 N1
TP2 SP2 VP2 N2
TP1 SP1 VP1 N1
Maintain same efficiency at different speeds
The most efficient method of controlling fans
Higher initial cost
June 2009
P2 N2
P1 N1
58
Speed Change - Constant Efficiency

Efficiency:
Q1 TP1
P1
Fan laws:
N
Q2 Q1 2
N1
Q2 TP2
P2
N2
TP2 TP1
N1
N2
Q1
N1
N2
TP1
N1
N2
P1
N1
June 2009
N2
P2 P1
N1
Q1 TP1
P1
59
Impact of Flow Control on Power

100
90
80
% Power
70
Inlet damper
Outlet
damper
60
Inlet vanes
50
40
30
Variable
speed
20
10
0
0
10
20
30
40
50
60
70
80
90
100
110
% Flow
June 2009
60
Drive Arrangements
Belt drive
Direct drive
Standard speed motors can be

used
no need for slow speed
motors (expensive )
Reduces initial cost if standard

speed motor could be used
no extra supports, pulleys,
bearings, shafts
Exact fan speed for required air

and volume can be obtained
Elimination of power loss by belt

drive (5 to 10%)
Speed can be adjusted by simply

changing pulley ratio
No maintenance required from

stretching belts
No possible change to fan speed

unless variable speed drive
June 2009
61
Fan Selection
Lafarge preferred specifications:
Safety margin:
10% on volume
21% on pressure
maximum fan speed
1800 RPM for motors < 300 HP
1200 RPM for motors > 300 HP
1200 RPM for dusty and/or hot conditions
Variable inlet vane dampers or variable speed
V-belt drive
Often specified:
Piezometer or anubar
Silencer
June 2009
62
Fan Curves in the Real Life
Measured operating point may not fall on the fan curve

Due to measurement errors and fan system effects
In FanCurves spreadsheet, the flow rate is assumed correct
Actual fan curve (XYZ-200)
888 RPM
300F, sea level
600
12
Operating
point
500
10
400
8
300
6
200
Operating point:
129,500 cfm
11.5 "H2O
339.5 HP
2
0
0
50000
100000
150000
200000
Power (HP)
Fan Static Pressure ("H2O )
14
100
0
250000
300000
Flow Rate (cfm)
June 2009
63
System Effect
Elbows
Good
Bad
June 2009
65
Fan Inlet
June 2009
66
Duct Branches
June 2009
67
Turning Vanes
June 2009
68
Fan Audit
Gas Handling / TYTP Power
Fan Audit Program
Many fans dont operate at optimal point

Operating conditions has changed since installation
Bad initial selection at installation
Energy is wasted
Audits every five years or more frequently

To check operating conditions of the fan
Identify improvements to bring it to optimal performance
(efficiency)
Identify solutions if fan is a process bottleneck
Coordination between Maintenance, Production and Process
departments
June 2009
70
Objective
Reduce energy consumption
Indicators:
kWh absorbed by the motor
Fan efficiency
Fan reliability factor
June 2009
71
Preparation
List fans that make up for 80% of power consumption
Operating conditions, new and future, adapted to Process

requirements
Maintenance history of the fans
Fan curves
Ducting arrangement / flowsheet
Adequate position of measuring points
Creation of a common (Maintenance, Process) file
June 2009
72
Measurements
Flow rate
For one operating point
More could be required for fans with wide ranges of operating
point
Static pressure at fan inlet
after damper if any
before variable inlet vane if any
Static pressure at fan outlet
before damper if any
Static pressure on other side of damper
to determine pressure drop through damper
Damper opening
June 2009
73
Measurements
Gas temperature and composition

for density
moisture content if significant
correction for dust load if significant
Fan speed
Absorbed power
Fan elevation
Atmospheric pressure
Ambient air temperature
June 2009
74
Measurements for Fan Static Pressure
June 2009
75
Mechanical Evaluation
External inspection (fan running):

Bearings temperature
Vibrations of bearings and housing
Noise level
Leakage (holes in housing, ducting,)
Even air flow distribution at fan inlet
Pressure drop through dust collector (if any)
June 2009
76
Mechanical Evaluation
Internal inspection (fan stopped):

Fan impeller alignment
Impeller and housing: wear and material accumulation
Dampers: proper opening / closing, damages and material
accumulation
Louvers: configuration of blades, functioning of individual blade
Turning vanes condition
Belt drive: tension and wear
Coupling alignment
Internal cone adjustment (too large a gap?)
Accumulation of material in the duct
Type of fan wheel: to confirm drawings / fan curve
Validation of existing drawings
June 2009
77
Additional Information
Fan system diagram showing:

fan
damper (position and type)
position in relation with its environment
elbows
duct expansions, contractions
turning vanes
Statistics on flow, pressures and damper opening
Aspen / IP21
Fan curve
Correct to actual conditions (elevation, temperature, density, RPM)
Fan and motor nameplate information
June 2009
78
Evaluation
Position operating point on fan curve

Does it match? Why?
Calculate efficiency
Is it good?
How can we improve the efficiency?
How can we increase flow or pressure, if required?
June 2009
79
Fan Design
Poor efficiency fan design costs all the time
Many pre-1985 fans are straight radial:

60-75% efficiency
Current technology:
Curve radial (dirty air): to 82% efficiency
Airfoil (clean air):
to 85% efficiency
June 2009
80
Low Cost Solutions
Is Hermit Crab solution possible?

Can shaft & bearing be retained?
Can you take advantage of the need to replace an impeller
for maintenance reason?
Is there a retired fan that could do the job?
Inlet turning vanes can improve efficiency by 2%
Is there a way to modify ducting configuration to reduce

system effect?
June 2009
81
Report
Summary
Measurements
Mechanical observations
Other information
Findings
Fan curve
Original
Corrected to actual conditions with operating point and duty cycle
Recommendations
Follow up of actions
Include action plan in PPP
June 2009
82

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Fan Systems

M. Beauprs Mise jour D. Dumont avril 2004

Fan types and terminology

Process Engineering Program Gas Handling Fan Systems

Process Engineering Program Gas Handling Fan Systems

Each component in a system offers resistance to air flow

System resistance: the total of these resistances to flow,

The system resistance varies with air flow rate

System curve: the relation between system resistance and

Process Engineering Program Gas Handling Fan Systems

Completely laminar flow

Constant static head

Different Types of System Curves

Process Engineering Program Gas Handling Fan Systems

Completely turbulent flow

Slightly turbulent flow

Different Types of System Curves

Process Engineering Program Gas Handling Fan Systems

Limit discussion to the completely turbulent system curve

Process Engineering Program Gas Handling Fan Systems

Fan Performance Curve

Fan Total Pressure (FTP)

Fan Static Pressure (FSP)

Fan Static Rise

SP Rise = SP2 - SP1

Fan Performance Curves

Pressure vs Volumetric flow rate given by the fan

Process Engineering Program Gas Handling Fan Systems

Fan Static Pressure (Pa)

Flow Rate (m/s)

Process Engineering Program Gas Handling Fan Systems

Ps: shaft power

Process Engineering Program Gas Handling Fan Systems

Typical Fan Curves

Flow Rate (cfm)

Process Engineering Program Gas Handling Fan Systems

Flow Rate (cfm)

Process Engineering Program Gas Handling Fan Systems

Fan Performance and System Curves

Flow Rate (cfm)

Process Engineering Program Gas Handling Fan Systems

Fan Types and Terminology

Process Engineering Program Gas Handling Fan Systems

Exploded View of a Centrifugal Fan

Process Engineering Program Gas Handling Fan Systems

Inlet Guide Vanes

Centrifugal Fan Principles

Process Engineering Program Gas Handling Fan Systems

Process Engineering Program Gas Handling Fan Systems

Process Engineering Program Gas Handling Fan Systems

Process Engineering Program Gas Handling Fan Systems

Cutaway View of a Vaneaxial Fan

Process Engineering Program Gas Handling Fan Systems

Centrifugal Fan Principles

Process Engineering Program Gas Handling Fan Systems

Fan Blade Types

Different types of fans characterized by their blade type:

Different applications require different blade type

Each type has different fan performance curves

Process Engineering Program Gas Handling Fan Systems

Radial Blade Fan (RB)

The simplest of all centrifugal fans