2 - Fan Assessment - Presentation

Fan performance, what’s that?
CTS-TPT/Jan Kaminsky
Power consumption – some definitions
 Shaft power (as calculated process-wise)
pV
Pshaft 
p = diff. Pressure over fan [mbar]
 fan V
fan
= gas flow through fan [Am3/s]
= efficiency of impeller/casing
trans = efficiency of transmission
 Total power (as measured electrically) motor = efficiency of motor
Ptot 
Pshaft
transmotor
....but how and where to measure?

2
Holcim Group Support Fan Workshop Dec. 2004 09.07.2019/JK
Fan performance, what’s that.ppt
Measurement
Inlet: Tin, pin, Vin, O2in
Outlet: Tout, pout, Vout , O2out
 Pin < Pout on purpose 
 Tin ? Tout = f(heat loss, compression, false air)
 Vout = Vin * (273+Tout)/(273+Tin) * pin/pout + False air term

 O2,in < O2,out = f(false air)
Reference for fan curve  Inlet conditions
3
Differential pressure
0 mbar-Line Static pressure
Measured p is acceptable
0 mbar-Line
Turbulence
Measured p is lower than the performance relevant one

 calculation of low fan efficiency
4
Gas flow
Gas flow
Not measurable
relevant for fan
performance
Gas flow
measured
Gas flow for

fan curve
5
Contradiction in pressures after fan (Hon Chong)
Pst = -2 mbar
Pst = +2 mbar
Bernoulli:
p  const  pstatic  2  v 2
Example: =0.8 kg/m3, v1=25 m/s, v2=40 m/s  63% of cross section
pdyn1 = 2.5 mbar, pdyn1 = 6.4 mbar
Further internal gas flow increase and pressure loss 6
Heat loss – energy dissipation
M motor: convection
trans: convection
fan: compression
Very small portion of fan: convection
 You can feel energy dissipation

 Quantitative measurement is difficult
7
Compression
 Temperature increase due to isentropic compression
 1
 pout  
Tout  Tin    …with T in [K] and ~1.41
 pin 
 Heat loss
H = Vnwet * cp(Tavg) * T
…with cp [kJ/Nm3K] from 100 – 500°C
1.30 - 1.35 for air
1.40 - 1.45 for combustion gas
1.45 – 1.55 kiln exhaust @ 3%O2
8
Back to Fan Efficiency
Where? Fan or system efficiency?
Where? Fan or system efficiency?
pV
 fan  Ptot trans motor Hot?
Hot?
Help from electricians
Impeller/Casing – or flow resistance/circulation loss

9
Using the fan assessment spreadsheet (1)
Step 1: Step 2:
Take readings from the suppliers fan The temperature and static
curve (flow rate and diff. Pressure). Use pressure are important for further
the density for which the suppliers curve calculations. Put in the measured
is valid (here 0.725 kg/Am3). Use your data - NOT suppliers data. The
measured density for correcting the fan resulting gas densities are
curve (here 0.75 kg/Am3). estimates for kiln exhaust gas -
NOT for air or combustion gas.
Remark:
p across fan – NOT
across fan and control
damper
10
Step 3:
Put in the data from
actual measurement.
Step 4:
Adjust n_equiv. until the line for
measured fan speed crosses the
measured operating point. The
n_equiv. indicates the quality of the
fan compared to suppliers
specification.
11
Step 5:
Put in the data for a new
expected operating point.
Step 6:
Adjust the fan speed until the line for
this speed crosses the new
operating point.
12
Step 7:
Take readings from suppliers
power curve. Step 9:
Adjust this factor until the red
line crosses the red mark. This
figure represents the quality of
the suppliers specification for
the fan efficiency.
Step 10:
Adjust the efficiency for the
new operating point until the
Step 8: green/red mark is laying on the
Put in your measured power red line. This figure is the
consumption. expected fan efficiency for the
new operating point.
13
Remark:
If you want to see the motor
limit curve on the fan
characteristic diagram set 1,
otherwise set 0.
Remark:
Put in an estimate for the
motor/transmission efficiency.
14
Step 3*:
Use here the diff. Pressure
across control damper and
fan.
Step 4*:
Adjust until curve for actual damper position crosses the
measured operating point. The n_equiv. indicates the
quality of the fan compared to suppliers specification.
15

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Fan performance, what’s that?

 Total power (as measured electrically) motor = efficiency of motor

....but how and where to measure?

 Pin < Pout on purpose 

 Tin ? Tout = f(heat loss, compression, false air)

 Vout = Vin * (273+Tout)/(273+Tin) * pin/pout + False air term

Reference for fan curve  Inlet conditions

Measured p is lower than the performance relevant one

Gas flow for

Very small portion of fan: convection

 You can feel energy dissipation

Where? Fan or system efficiency?

Where? Fan or system efficiency?

Impeller/Casing – or flow resistance/circulation loss

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