4 - Fan Systems and Audit

FAN SYSTEMS
&
FAN AUDIT
20/01/2009 - 1
Fan Systems & Fan Audit
LEARNING OBJECTIVES
At the end of the day the trainee shall be able to :
- Measure and qualify fan performance
Revise fan curves
Determine system curves
Estimate power savings potential
20/01/2009 - 2
FAN BASICS
&
FAN SYSTEMS
20/01/2009 - 3
FAN SYSTEMS - CONCEPTS OF PRESSURE

pt
TP
pSP
s
p
VP
d
Air flow
pt = ps + pd
Static pressure (ps):

pressure exerted in all directions by a fluid at rest
Dynamic pressure (pd):

pressure exerted by the velocity of a fluid : pd = v2
Total pressure (pt):

the sum of static and velocity pressures
20/01/2009 - 4
FAN SYSTEMS SYSTEM RESISTANCE
p = k Q2
k = Constant characteristic
= Gas density
Q = Volume flow
p1
p2
20/01/2009 - 5
FAN SYSTEMS SYSTEM RESISTANCE
Each component in a system offers resistance to the

gas flow.
System resistance :
The sum of all resistances to the flow
The system resistance varies with air flow rate
System curve :
The relation between system resistance and flow rate

20/01/2009 - 6
Constant static head

Airflow through a liquid pool
Fluidized bed
System resistance P
FAN SYSTEMS SYSTEM CURVES

p = k
Complete turbulent flow

Standard fan systems
System resistance P
Airflow rate Q
p = kQ 2
Airflow rate Q
20/01/2009 - 7
FAN SYSTEMS SYSTEM CURVES
Limit discussion to the completely turbulent

system curve
12
10
p = k Q
8
6
4
2
0
0
20
40
60
80
100
Q (m/s)
20/01/2009 - 8
Pressure
Pressure vs Volumetric flow

rate given by the fan
Defined for fixed specific
operating conditions :
gas density
(T, p, composition)
fan speed
Usually, power curve is given
Sometimes, efficiency curve
Power/Efficiency
FAN SYSTEMS PERFORMANCE CURVES
Flow rate
blue = pressure
red = power
green = efficiency
20/01/2009 - 9
FAN SYSTEMS FTP / FSP CONCEPT
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
Static Pressure Rise(Good way!)

=
SP2 - SP1
20/01/2009 - 10
FAN SYSTEMS FTP / FSP EFFICIENCY
Q FTP
3600 P
Total efficiency (
t)
: t =
Static efficiency (
s)
FSP Q FSP
=
: s = t
FTP 3600 P
where
fan flow (m/h)
FTP
FSP
P
:
:
:
fan total pressure (Pa)

fan static pressure (Pa)
fan power (W)
Fan Total Efficiency

Fan Static Efficiency
Fan Static Rise Efficiency
83%
80%
85%
20/01/2009 - 11
FAN SYSTEMS FTP vs FSP

Pe rformance Curve for IE 250 F an
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 R a te (cfm)
20/01/2009 - 12
FAN SYSTEMS FAN PERFORMANCE

Performance Curve for IE 250 Fan
103
62
50
r
we
BHP
Operating Point
88
74
37
60
Effic
ienc
y
25
Fa
n
To
tal
Pr
es
su
r
45
e
12
30
Power [kW] / %efficiency
Fan Total Pressure [mbar]
Po
15
0
0
2,5
7,5
10
12,5
15
0
17,5
Flow Rate [m/s]

20/01/2009 - 13
FAN SYSTEMS FAN + SYSTEM CURVES

50
103
88
74
35
30
60
25
Effi
cien
cy
20
15
45
FT
P
Fan Pressure [mbar]
40
10
30
Power [kW] / % efficiency
r
we
o
P
45
15
5
0
0
2,5
7,5
10
12,5
15
0
17,5
Flow Rate [m/s]

20/01/2009 - 14
FAN SYSTEMS REALITY
Measured operating
35
442
Fan Total Pressure [mbar]
30
Operating
point
368
25
Power [kW]
point may not fall on

the fan curve
Due to measurement
errors and fan system
effects
In Fan Curves
spreadsheet, the flow
rate is assumed
correct
Actual fan curve (XYZ-200)
295
20
221
15
10
5
0
147
Operating point :
6,12 m/s
28,62 mbar
249,9 kW
2,5
7,5
10
74
12,5
0
15
Flow Rate [m/s]
20/01/2009 - 15
FAN SYSTEMS OPERATING RANGES

Unstable
Stable
Peak
Flow Rate
20/01/2009 - 16
FAN SYSTEMS FAN TYPES

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
Airplanes propeller
20/01/2009 - 17

Exploded View of a Centrifugal Fan
Inlet
Outlet
Cutoff
Hub
Flange
Side Sheet
Scroll
Inlet Guide Vanes

Backplate
Inlet Bell
Blades
Impeller
Stationary Inlet
20/01/2009 - 18

Cutaway of a Vane-Axial Fan
Inlet
Discharge Vanes
Inner Cylinder
Outlet
Belt Fairing
Tailpiece
(sometimes omitted)
Blades
Impeller
Hub
Inlet Bell
Outer Cylinder Diffuser

20/01/2009 - 19
FAN SYSTEMS FAN PRINCIPLES

Centrifugal Fan Principles
vr : radial velocity
vr
vt
vt : tangential velocity
v : fluid velocity
20/01/2009 - 20
FAN SYSTEMS FAN BLADES
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
20/01/2009 - 21
FAN SYSTEMS FAN BLADES

Airfoil (AF) : 85 - 90 %
Backward-curved (BC) : 85 %
Backward-inclined (BI) : 75 - 80 %
Radial-tip (RT) : < 71 %
Forward-curved (FC) : 65 %
Radial blade (RB) : 60 - 63 %
20/01/2009 - 22
FAN SYSTEMS FAN LAWS
Fan performance curve made for specific

conditions:
fan speed
air density (temperature, pressure)
Always AT INLET CONDITIONS
What happens 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)
20/01/2009 - 23
FAN SYSTEMS FAN LAWS
Geometrically similar (impeller) fans

Volume is directly proportional to fan speed
Q2 N 2
=
Q1 N1
Pressure is proportional to the square of the speed
TP2
N2
=
TP1
N1
Power is proportional to the speed cubed

P2
=
P1
N2
N1
20/01/2009 - 24
Exercise 5.1 FAN LAWS

Question :
Fan Details :
n = 1305 [min-1]
v (1) = 7,1 [m/s]
dpT = 7,6 [kPa]
P = 66,5 [kW]
Increased flow (2)

v (2) = 8,5 [m/s]
n, dp , P =?
20/01/2009 - 25
Exercise 5.1 FAN LAWS

Solution :
Q 2 N1 8.5 1305
=
= 1562 min 1
N2 =
Q1
7.1
N2
TP2 = TP1
N1
P2 = P1
N2
N1
1562
= 7,6
1305
= 66.5
1562
1305
= 10.89 kPa
= 114.0 kW
20/01/2009 - 26
20/01/2009 - 27
FAN SYSTEMS FAN LAWS - SPEED

185
75
182
2m
i n -1
150
167
0m
in -1
151
8m
in -1
50
37,5
110
75
Power [kW]
Fan Pressure [mbar]
62,5
25
40
12,5
0
2,5
7,5
10
12,5
15
17,5
20
Flow Rate [m/s]

20/01/2009 - 28
FAN SYSTEMS FAN LAWS - DENSITY
Fans are constant volume machines

Affects the pressure generated and
power consumed
A change in density affects the

system curve
20/01/2009 - 29

50
120
45
105
90
1.13 kg/m
35
30
75
25
60
20
45
0.56 kg/m
15
30
10
15
5
0
Power [kW]
Fan Pressure [mbar]
40
0
0
2,5
7,5
10
12,5
15
17,5
Flow Rate [m/s]

20/01/2009 - 30

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

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

due to density change at fan inlet
20/01/2009 - 31
FAN SYSTEMS FAN LAWS (SIZE)
Used mostly to compare two similar

fans of same type
Some examples of tipping out fans

Casing often has to be redesigned
20/01/2009 - 32
FAN SYSTEMS FAN LAWS (SIZE)

40
75
35
67,5
60
30
52,5
25
45
20
37,5
+10% D
30
15
22,5
10
15
5
0
Power [kW]
Fan Pressure [mbar]
7,5
0
2,5
7,5
10
Flow Rate [m/s]
12,5
15
17,5
D = Diameter
20/01/2009 - 33
FAN SYSTEMS FAN 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:
Discharge dampers
Variable inlet vanes
Box-vane control
Variable speed drives
20/01/2009 - 34

Discharge Dampers
Parallel Blades
More flow on one side of duct

Not very linear response
Opposed Blades
Yields more uniform profile

More linear response
The discharge dampers change

the system resistance curve
Power wasting devices
20/01/2009 - 35

Discharge Dampers
90
20% open
40% open
Fan Pressure [mbar]
75
60
60% open
45
80% open
30
Wide open
15
0
10
15
20
25
30
35
40
Flow rate [m/s]

20/01/2009 - 36

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 the direction of the
impeller
Pre-spin unload the impeller
reducing the pressure
Less pressure implies less
power
Closed Position
Open Position
20/01/2009 - 37

Variable Inlet Vanes
75
90
67,5
80
60
70
52,5
60
45
50
37,5
40
30
30
22,5
20
15
10
7,5
25% open
0
10
15
20
50%
25
75% 100%
30
35
40
Power [kW]
Pressure
100
Flow rate [m/s]
20/01/2009 - 38

Box Vane Control
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)
20/01/2009 - 39

Box Vane Control
Box vane controls
20/01/2009 - 40

Box Vane Control
20/01/2009 - 41

Variable Speed Fans
Direct application of the fan laws:

Q2 N 2
=
Q1 N1
TP2
N
= 2
TP1
N1
P2
N2
=
P1
N1
Maintain same efficiency at different speeds

The most efficient method of controlling fans
Higher initial cost
20/01/2009 - 42

Variable Speed Fans
Efficiency :
1 =
Q1 TP1
P1
Fan Laws :
N
Q2 = Q1 2
N1
2 =
Q 2 TP2
=
P2
N
TP2 = TP1 2
N1
N2
Q1
N1
N2
TP1
N1
N2
P1
N1
N
P2 = P1 2
N1
Q1 TP1
P1
20/01/2009 - 43

Power Savings
100
90
80
% Power
70
Discharge
damper
60
Bo
ne
a
xv
co
e
I nl
50
ol
r
t
n
ne
a
tv
40
30
Variable
speed
20
10
0
0
10
20
30
40
50
60
70
80
90
100
110
% Flow
20/01/2009 - 44
Exercise 5.2 VARIABLE SPEED ID FAN

Question :
100%
open
Fan Inlet
P = -70mbar
T = 350C
Fan Outlet
P = -2mbar
T = 350C
Flow = 144.4m3/s
(a) Plot the operating point on the fan curve

(b) What is the speed of the fan?
(c) What is the shaft power of the fan?
(d) Is the fan selection good? Why?
20/01/2009 - 45
20/01/2009 - 46
20/01/2009 - 47

Solution :
REMEMBER ALWAYS CONVERT TO INLET
CONDITIONS !
144.4m3/s x 3600 = 519840m3/hr at the outlet
Remember Ideal Gas Law
PV = nRT or P1V1/T1 = P2V2/T2
So, Flow at inlet Conditions,
= 519840 x (1013-2)/(1013-70) = 557327m3/hr
From Performance curves,
Delta P = 68mbar => Speed is 990rpm
Shaft Power is 2025kW
20/01/2009 - 48

Drive Arrangements
Belt drive
Standard speed motors can
be used
no need for slow speed
motors (expensive )
Exact fan speed for
required air and volume
can be obtained
Speed can be adjusted by
simply changing pulley
ratio
Direct drive
Reduces initial cost if
standard speed motor
could be used
no extra supports,
pulleys, bearings, shafts
Elimination of power loss
by belt drive (5 to 10%)
No maintenance required
from stretching belts
20/01/2009 - 49
FAN SYSTEMS
LAFARGE PREFERRED SPECIFICATIONS
Important points are :

Safety margin : 10% on volume & 10% on pressure
Recommended maximum fan speed
Far enough to be from critical speed
Variable inlet vane dampers(clean gas) or variable
speed
V-belt drive
Often required :
Piezometer
Silencer
20/01/2009 - 50
FAN AUDIT
20/01/2009 - 51
FAN AUDIT
Objective :
Reduce energy consumption
Indicators:
kWh absorbed by the motor
Fan efficiency
Fan reliability factor
20/01/2009 - 52
FAN AUDIT
20/01/2009 - 53
FAN AUDIT
Hardfacing was removed
Deformation
Crack
20/01/2009 - 54
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
20/01/2009 - 55
FAN AUDIT - 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
20/01/2009 - 56
FAN AUDIT - MEASUREMENT
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
20/01/2009 - 57
FAN AUDIT - MEASUREMENT
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
20/01/2009 - 58
MEASUREMENT FOR FAN STATIC PRESSURE
20/01/2009 - 59
FAN AUDIT 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)
20/01/2009 - 60
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
20/01/2009 - 61
Internal inspection (fan stopped) :

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
20/01/2009 - 62
FAN AUDIT ADDITIONAL INFORMATION
Fan system diagram showing :

fan
damper (position and type)
position in relation with its environment
elbows
duct expansions, contractions
turning vanes
20/01/2009 - 63
FAN AUDIT ADDITIONAL INFORMATION
Statistics on flow, pressures and damper

opening
Aspen / IP21
Fan curve
Correct to actual conditions (elevation,
temperature, density, RPM)
Fan and motor name plate information
20/01/2009 - 64
FAN AUDIT 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?
20/01/2009 - 65

Duty Cycle :
For fans with highly variable flow demand

such as:
Cooler exhaust
Kiln I.D.
Some cooler fans
Variable Frequency Drive (VFD) ?
20/01/2009 - 66

Duty Cycle :
For constant duty fans such as:

Mill draught
Primary air
Find most cost effective solution to

gain efficiency
Replace belt (and motor?)
Modify impeller?
20/01/2009 - 67

What Is The Damper Saying?
If fan damper never open > 75%

then fan is oversized and wasteful
Downsizing?
Replace belts?
VFD?
20/01/2009 - 68

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
20/01/2009 - 69

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?
20/01/2009 - 70
FAN AUDIT 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 PIP
20/01/2009 - 71
20/01/2009 - 72

4 - Fan Systems and Audit

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4 - Fan Systems and Audit

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FAN SYSTEMS

Fan Systems & Fan Audit

Fan Systems & Fan Audit

Fan Systems & Fan Audit

FAN SYSTEMS - CONCEPTS OF PRESSURE

Static pressure (ps):

Dynamic pressure (pd):

Total pressure (pt):

Fan Systems & Fan Audit

FAN SYSTEMS SYSTEM RESISTANCE

Fan Systems & Fan Audit

FAN SYSTEMS SYSTEM RESISTANCE

Each component in a system offers resistance to the

The sum of all resistances to the flow

The system resistance varies with air flow rate

The relation between system resistance and flow rate

Fan Systems & Fan Audit

Constant static head

FAN SYSTEMS SYSTEM CURVES

Complete turbulent flow

Fan Systems & Fan Audit

FAN SYSTEMS SYSTEM CURVES

Limit discussion to the completely turbulent

Fan Systems & Fan Audit

Pressure vs Volumetric flow

FAN SYSTEMS PERFORMANCE CURVES

Fan Systems & Fan Audit

FAN SYSTEMS FTP / FSP CONCEPT

Fan Total Pressure (FTP)

Fan Static Pressure (FSP)

= TP2 - TP1 - VP2

Static Pressure Rise(Good way!)

Fan Systems & Fan Audit

FAN SYSTEMS FTP / FSP EFFICIENCY

fan flow (m/h)

fan total pressure (Pa)

Fan Total Efficiency

Fan Systems & Fan Audit

FAN SYSTEMS FTP vs FSP

Fan Systems & Fan Audit

FAN SYSTEMS FAN PERFORMANCE

Power [kW] / %efficiency

Fan Total Pressure [mbar]

Flow Rate [m/s]

Fan Systems & Fan Audit

FAN SYSTEMS FAN + SYSTEM CURVES

Fan Pressure [mbar]

Power [kW] / % efficiency

Flow Rate [m/s]

Fan Systems & Fan Audit

FAN SYSTEMS REALITY

Fan Total Pressure [mbar]

point may not fall on

Actual fan curve (XYZ-200)

Flow Rate [m/s]

Fan Systems & Fan Audit

FAN SYSTEMS OPERATING RANGES

Fan Systems & Fan Audit

FAN SYSTEMS FAN TYPES

Fan Systems & Fan Audit

FAN SYSTEMS FAN TYPES

Inlet Guide Vanes

Fan Systems & Fan Audit

FAN SYSTEMS FAN TYPES