Mill fan performance

Efficiency calculation

Detlef Blümke – Commissioning Department

Technical field service meeting LOI 2011
Dehli, 13/10/2011

Agenda

Fan Inspection
Pressures and Calculations
Measurements
Efficiency Calculation
© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 2

Fan Inspection

inlet duct(s) outlet duct

compensator(s) compensator(s)

inlet damper(s) housing bearings/sealings

Mounted according to drawings (tolerances!)? Free of foreign matter?

© by LOESCHE GmbH

Directions respected? All Sealings sealed?

No cooling devices insulated? …

Rev.1 - 13/11/2010 13/10/2011 3

1
Fan Inspection

turn direction of housing and impeller

turn direction correct or wrong?

a b c

© by LOESCHE GmbH
Rev.1 - 13/11/2010 13/10/2011 4

Fan Inspection

turn direction of inlet damper has to match

© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 5

Fan Inspection
© by LOESCHE GmbH

correct if damper above is closed or opened?

Rev.1 - 13/11/2010 13/10/2011 6

2
Fan Inspection

Lower end position

© by LOESCHE GmbH
correct if damper above is closed or opened!
Rev.1 - 13/11/2010 13/10/2011 7

Fan Inspection
Impeller
ƒ easy to turn by hand
ƒ alingment against: Inlet nozzle
ƒ circumferential gap
ƒ horizontal alignment
© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 8

Fan Inspection
Inlet nozzle Attention: different values for cold and hot condition, left and right,
top and bottom!
© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 9

3
Agenda

Fan Inspection
Pressures and Calculations
Measurements
Efficiency Calculation

© by LOESCHE GmbH
Rev.1 - 13/11/2010 13/10/2011 10

Pressures
Static, dynamic and total pressure

static pressure + dynamic pressure = total pressure

+ =

ps + (ρ/2)*v2 = total pressure

ps + pd = pt
© by LOESCHE GmbH

kg m² kg
Pa+ ⋅ = = Pa
m³ s² m⋅ s²
Rev.1 - 13/11/2010 13/10/2011 11

Pressures
Total static pressure

ambient pressure + static pressure = total static pressure

+ =

pa + ps = total static pressure

pa + ps = pst
© by LOESCHE GmbH

Ambient pressure available in decent laboratory or weather station near to plant site (internet).
Standard (DIN 1343) ambient pressure = 101325 Pa.

Pa + Pa = Pa
Rev.1 - 13/11/2010 13/10/2011 12

4
Calculations
Gas density

total static pressure / (gas constant * temperature) = density

/ (R * T) = ρ

pst / (R*T) = density

pst / (R*T) = ρ

© by LOESCHE GmbH
J
R(air)=287,1 kg ⋅ K

Pa ⋅ kg ⋅ K N ⋅ kg ⋅ K kg
= =
J ⋅K m² ⋅ N ⋅ m ⋅ K m³

Rev.1 - 13/11/2010 13/10/2011 13

Calculations
Gas velocity
As dynamic pressure = pd = (ρ/2)*v2

(2 * dynamic pressure) / density) = velocity

/ ρ = v

Sqrt ((2pd) / ρ) = velocity

© by LOESCHE GmbH

Sqrt ((2pd) / ρ) = v
Pa ⋅ m³ N ⋅ m³ kg ⋅ m ⋅ m³ m² m
= = = =
kg m² ⋅ kg m² ⋅ kg ⋅ s ² s² s

Rev.1 - 13/11/2010 13/10/2011 14

Calculations
Volume flow

velocity * cross section = volume flow

.
v * A = V

v * A = volume flow
.
v*A= V
© by LOESCHE GmbH

m ⋅m² m³
=
s s
Rev.1 - 13/11/2010 13/10/2011 15

5
Calculations
Δ p total

2 – 1 + 2 – 1 = Δpt

pst2 – pst1 + pd2 – pd1 = Δpt

Only if cross section at inlet and outlet is equal, the dynamic

pressure can be ignored (pst2 – pst1 = Δp)!

© by LOESCHE GmbH
Index 1 = fan inlet
Index 2 = fan outlet
Pa= Pa
Rev.1 - 13/11/2010 13/10/2011 16

Calculations
Hydraulic power vs. power at shaft

.
Δpt *V = hydraulic power Pel * ηmech = Power at shaft

Δpt *V
.=P
h Pel * ηmech = Pmech

Pmech / Pel = ηmech

Pmech -> name plate

U * I * sqrt(3) * cos φ = Pel

Attention: cos φ varies with load of drive.

© by LOESCHE GmbH

Conclusion: Pel can only be calculated

correct if drive is at nominal load (or FC m³⋅ Pa N ⋅ m³
= =W
does calculated/indicate actual cos φ). s m² ⋅ s
Rev.1 - 13/11/2010 13/10/2011 17

Agenda

Fan Inspection
Pressures and Calculations
Measurements
Efficiency Calculation
© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 18

6
Measurements
What and how to measure?

To be measured: By:
ƒ Ambient pressure ƒ Barometer
ƒ Static pressure ƒ Pitot static tube/Prandtl
ƒ Dynamic pressure ƒ (S-Type)
ƒ Temperature ƒ (Anemometer)
ƒ PT100

© by LOESCHE GmbH
Source: www.electro-mation.de and http://www.testo.de/view/product/de/05604160/testo-416

Rev.1 - 13/11/2010 13/10/2011 19

Agenda

Fan Inspection
Pressures and Calculations
Measurements
Efficiency Calculation
© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 20

Measurements
What and how to measure?

Location of measurement:
ƒ Laminar flow required for measurement
ƒ Strait duct portion: Tree up to five times of diameter (depending on source) up- and
down-stream of measurement location
ƒ Near inlet AND near outlet of fan

As this is practically impossible: best possible points

ƒ Inlet usual upstream (in front) of damper (damper 100 % open!)
ƒ Outlet according to platform etc. between fan and stack/recirculation damper

Other Requirements:
ƒ grid-point measurement
ƒ Fan running at/around nominal load
ƒ No changes during measurement/stable operation
© by LOESCHE GmbH

To be considered:
Preparation time around three days. + Measurement around three hours. + Calculation
and report around two days. = Minimum five days!

Rev.1 - 13/11/2010 13/10/2011 21

7
Efficiency Calculation
What to consider for calculation?

Grit-point measurement:
Two different possible arrangements –
1. variaton of measurement points
2. Calcualtion of measured cross sections
Are used to equalise the measured values for average figures.

Order of calculations:
1. total static pressure (pst) at all points
2. density at all points
3. velocity at all points
4. average velocity and density according to weight of cross section
5. Volume flow
6. Δ p total
7. Hydraulic power of fan

© by LOESCHE GmbH
Calculation of fan efficiency:
Ph
ηf =
Pmech
Rev.1 - 13/11/2010 13/10/2011 22

Efficiency Calculation
Example:
1 2 3 4 5 6 crosssection
p_d(left) 464 461 443 449 447 443 3,0728m
p_d(right) 434 458 436 433 425 410 3,0728m
p_d(out) 1792 2249 2141 1344 2239 2175 3,120356m

p_s(left) -6624 -6701 -6729 -6691 -6639 -6587

p_s(right) -6739 -6631 -6594 -6682 -6541 -6648

p_s(out) -873 -733 -530 -953 -638 -578

T_(left) 352,95 352,75 352,35 352,75 352,35 350,25

T_(right) 352,05 353,35 352,85 352,65 352,25 352,35
T_(out) 362,25 362,25 362,25 360,95 360,95 360,95

Ambient 95913
© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 23

Thank you for your attention!

© by LOESCHE GmbH

Rev.1 - 13/11/2010 13/10/2011 24