Dynamic Response of Large ACC Fan Systems

Dynamic
Response
Dynamic response of large ACC fan systems
2017 ACCUG A C L V
Background
On-site measurements:
Blade loading
Full-scale measurements
Wind effects
Vibra on frequencies
Excita on reconstruc on
algorithm
Laboratory
measurements: Analysis
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment
Simula on of fan system

dynamics
Adams model
Jacques Muiyser, Ochse Lombard, System response
Johan van der Spuy, Danie Els Albert Zapke System design
Stellenbosch University Enexio

1 of 42
Dynamic
Outline Response
1 Background
2 On-site measurements: Blade loading
Full-scale measurements Background
Wind effects On-site measurements:

Blade loading
Vibra on frequencies Full-scale measurements
Excita on reconstruc on algorithm Wind effects

3 Laboratory measurements: Analysis of vibra on sources algorithm
Fan bridge Laboratory

Pla orm height of vibra on sources
Fan bridge
4 On-site measurements: Sha loads Pla orm height
Site setup Sha loads
Start/Stop Site setup

Start/Stop
Bending moment Bending moment

5 Simula on of fan system dynamics dynamics
Adams model
Adams model System response
System response System design
System design
2 of 42
Dynamic
Response
Background
Blade loading
Wind effects
Background Vibra on frequencies

algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
3 of 42
Background
Test Case A air-cooled condenser (ACC) fans
At the Test Case A coal-fired power sta ons, steam is condensed in

an air-cooled condenser (ACC) by forcing ambient air through
inclined heat exchangers with an array (288) of large Ø9 m, 270 kW
axial flow fans situated at a height of 50 m.
Dynamic
Background Response
Fan blade loading
Each fan is suspended from a fan bridge.

Distorted inlet air flow condi ons due to winds and other Background
fans1 as well as the downstream flow obstruc on (bridge) cause On-site measurements:
Blade loading
varying aerodynamic loads. Full-scale measurements
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
1 Van der Spuy, S.J., Von Backström, T.W. and Kröger, D.G. (2009). An evalua on of simplified methods to model the perormance of
axial flow fan arrays. R & D Journal of the South African Ins tu on of Mechanical Engineering, vol. 26, pp. 12–20. 6 of 42
Dynamic
Response
Blade loading Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
7 of 42
Dynamic
Full-scale measurements2 Response
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
2Muiyser, J., Els, D.N.J., Van der Spuy, S.J. and Zapke. A. (2014). Measurement of air flow and blade loading at a large-scale cooling
system fan. R & D Journal of the South African Ins tu on of Mechanical Engineering, vol 30, pp 30–38 8 of 42
Dynamic
Full-scale measurements Response
Site setup Test Case A
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
9 of 42
Dynamic
Wind effects
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
10 of 42
Dynamic
Fast Fourier transform (FFT) showed peaks at 𝛺, 2𝛺 and Background
3𝛺 ≈ 𝑓 . On-site measurements:
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
11 of 42
Dynamic
Excita on reconstruc on algorithm Response
The response of a single degree of freedom system to periodic
excita on
Consider single degree of freedom
system in the figure 𝑘𝑓(𝑡) Background
𝑚𝑥(𝑡)
̈ + 𝑐 𝑥(𝑡)
̇ + 𝑘𝑥(𝑡) = 𝑘𝑓(𝑡) On-site measurements:
Blade loading
with periodic func on 𝑥(𝑡) Full-scale measurements
𝑚 Wind effects
𝑓(𝑡) = 𝑎 + Re 𝐴 𝑒 algorithm
𝑘 𝑐 Laboratory
of vibra on sources
where 𝐴 = ∫ 𝑓(𝑡)𝑒 𝑑𝑡 Fan bridge

Pla orm height
The steady state response is then On-site measurements:

Sha loads
Site setup
Start/Stop
𝑥(𝑡) = 𝑎 + Re 𝐴 𝐺 𝑒 Bending moment

dynamics
with Adams model

System response
1 𝑐 System design
𝐺 = , 𝜔 = 𝑘/𝑚, 𝜁=
2𝑚𝜔
1− 𝑝 + 𝑖2𝜁𝑝
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Dynamic
Formula on
Non-linear least-squares op miza on is used to fit a Fourier series

to a periodic measured response, 𝑟(𝑡), using 𝑃 harmonic terms
where the variables are: 𝑎 , 𝑎 , 𝑏 , 𝑎 , 𝑏 , … 𝑎 , 𝑏 , 𝜔 . Background
Blade loading
Wind effects
𝑄(𝑡) = 𝑟(𝑡) − 𝑎 + Re 𝑎 + 𝑖𝑏 𝑒 (1) Vibra on frequencies
algorithm
Laboratory
Then for the op mum curve fit of vibra on sources
Fan bridge
𝑎∗ + 𝑖𝑏∗
Pla orm height
𝑎∗ + 𝑖𝑏∗ ≈ 𝐴∗ 𝐺 or 𝐴∗ ≈ (2) On-site measurements:

Sha loads
𝐺 Site setup
Start/Stop
The reconstructed excita on, 𝑓 (𝑡), is then given by Bending moment

dynamics
Adams model
System response
𝑓 (𝑡) = 𝑎 + Re 𝐴∗ 𝑒 (3) System design
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Dynamic
Test Case A: Full scale flapwise bending force results
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
14 of 42
Excita on reconstruc on algorithm
Full scale results
Results show similar excita on for both cases with a lower peak on
the windward side during decreased winds.
Higher wind speed Lower wind speed
12 12
Bending load [kN.m]

Bending load [kN.m]
10 10
8 8
6 6
4 4
2 2
0 0
Reconstructed excitation [kN.m]

Reconstructed excitation [kN.m]
9 9
8 8
7 7
6 6
5 5
4 4
3 3
0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180
Rotational position [degrees] Rotational position [degrees]
Analysis of vibra on sources
Test Case X – No resonance!
Measurements recorded at a different plant, Test Case X, where

𝑓 ≠ 3𝛺 did not include large blade vibra ons.
Higher wind speed Lower wind speed
Flapwise bending moment [kN.m]

Flapwise bending moment [kN.m]
8 8
7 7
6 6
5 5
4 4
3 3
0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180 0 180 0
Azimuth angle [degrees] Azimuth angle [degrees]
800 800
700 Amplitude [N.m] 700
Amplitude [N.m]
600 600
500 500
400 400
300 300
200 200
100 100
0 0
0 2 4 6 8 10 12 0 2 4 6 8 10 12
Frequency [Hz] Frequency [Hz]
Dynamic
Test Case X – Effect of surrounding fans
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
17 of 42
Dynamic
Response
Background
Blade loading
Laboratory measurements:
Wind effects
Analysis of vibra on sources algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
18 of 42
Analysis of vibra on source
The effect of the fan bridge on fan blade vibra on3
Strain gauges were a ached to a flat plate fan blade to determine

the effect of bridge solidity and distance from the rotor.
MicroStrain SG-Link
Strain gauges
3 Work performed in conjunc on with the final-year project of Nico R. Basson.

Dynamic
Analysis of vibra on source Response
The effect of the fan bridge on fan blade vibra on
It was found that the amplitude of vibra on increases with:

Increasing flow rate Background
Decreased distance between fan rotor and bridge On-site measurements:

Blade loading
Increasing bridge solidity Full-scale measurements

Wind effects
algorithm
0.14
Reference curve Laboratory
0.12 Grid at 150 mm of vibra on sources
Plate at 150 mm Fan bridge
0.10
Plate at 250 mm Pla orm height
Load amplitude
0.08 Sha loads
Site setup
0.06 Start/Stop
Bending moment
0.04 Simula on of fan system

dynamics
0.02 Adams model
System response
System design
0.00
0 2 4 6 8 10 12 14 16
Flow rate [m3 /s]
20 of 42
Dynamic
The effect of the pla orm height
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
21 of 42
Dynamic
The effect of the pla orm height
Increase of the measured vibra on as the pla orm height is Background

reduced from 4.5𝐷 to 2.5𝐷 On-site measurements:
Blade loading
A slight decrease 1.5𝐷 , change in excita on mode Full-scale measurements
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
22 of 42
Dynamic
Response
Background
Blade loading
Wind effects
Sha loads
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
23 of 42
Dynamic
Sha loads Response
Site setup Test Case A
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
24 of 42
Dynamic
Sha loads Response
Instrumenta on
Full bridge torque strain gauge

Full bridge bending moment strain gauge ×2
Speed sensor Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
Low speed sha

25 of 42
Dynamic
Sha loads Response
Startup Torque
70
60
Shaft torque [N.m]
Background
50
40 Blade loading
30 Wind effects
20 Excita on reconstruc on
algorithm
10
Laboratory
0 measurements: Analysis
of vibra on sources
160 Fan bridge
Pla orm height
Shaft speed [rpm]
120 Sha loads
Site setup
Start/Stop
80 Bending moment

40 dynamics
Adams model
System response
0 System design
0 1 2 3 4 5
Time [s]
26 of 42
Dynamic
Sha loads Response
Startup torque low iner a fan blade comparison: Test Case B
Test Case B
Background
New genera on low iner a fan blade that was tested under full
scale condi ons. Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
27 of 42
Dynamic
Sha loads Response
Startup Power
Background
2500
Electric Blade loading
Fan shaft
2000 Wind effects
Power [kW]
1500 algorithm
Laboratory
1000 of vibra on sources
Fan bridge
Pla orm height
500 On-site measurements:

Sha loads
Site setup
0 Start/Stop
0 1 2 3 4 5 6 Bending moment

Time [s] dynamics
Adams model
System response
System design
28 of 42
Dynamic
Sha loads Response
Shutdown
20
15
Staft torque [kN.m]
Background
10
Blade loading
5
0 Wind effects
-5 algorithm
Laboratory
-15 measurements: Analysis
of vibra on sources
130
Fan bridge
Pla orm height
120
Staft speed [rpm]
Sha loads
90 Site setup
Start/Stop
Bending moment
60
dynamics
30 Adams model
System response
System design
0
80 85 90 95 100 105
Time [s]
29 of 42
Dynamic
Sha loads Response
Shutdown Spectogram
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
30 of 42
Dynamic
Sha loads Response
Low speed sha bending
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Total force × length (moment) on output sha rela ve to gearbox Start/Stop
Wind speed 25 m/s Bending moment

(a) wind direc on 66° dynamics
Adams model
(b) wind direc on 92° System response
System design
(c) wind direc on 115°
31 of 42
Dynamic
Sha loads Response
FFT
100
80 Background
1ω On-site measurements:
60
Magnitude [dB]
2ω Blade loading
3ω Full-scale measurements
40 Wind effects
20 Excita on reconstruc on
algorithm
0 Laboratory
-20 of vibra on sources
Fan bridge
-40 Pla orm height
-80 Sha loads
0 5 10 15 20 25 30 Site setup
Frequency [Hz] Start/Stop
Bending moment
Rota on speed 1𝜔 (2.11 Hz) Simula on of fan system

dynamics
Walkway load pulse 2𝜔 (4.23 Hz) Adams model

System response
Blade first bending mode ≈ 3𝜔 (6.35 Hz) System design
32 of 42
Dynamic
Sha loads Response
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
wind direc on 66°

33 of 42
Dynamic
Sha loads Response
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
wind direc on 92°

34 of 42
Dynamic
Sha loads Response
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
wind direc on 115° 35 of 42

Dynamic
Response
Background
Blade loading

Wind effects
dynamics algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
36 of 42
Dynamic
Simula on of fan system dynamics Response
Adams model
MSC ADAMS used for the dynamic simula on of the fan system
Flexible bodies used Background
Fan blade proper es selected to be the same as the finite Blade loading
element fan blade to provide a blade with similar vibra onal Wind effects
characteris cs as the full-scale fan blade. Vibra on frequencies

algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
37 of 42
Dynamic
Vibra on characteris cs
Imprac cal to solve eigenvalue problem Background
Virtual experiment by applying a force to a model with sweep On-site measurements:

Blade loading
or a chirp force func on and measuring the response at a point. Full-scale measurements
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
Linear sweep
38 of 42
Dynamic
ADAMS vibra on characteris cs
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
39 of 42
Dynamic
System vibra on characteris cs
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
40 of 42
Dynamic
System design recommenda ons Response
Background
Blade loading
Wind effects
algorithm
Laboratory
of vibra on sources
Fan bridge
Pla orm height
Sha loads
Site setup
Start/Stop
Bending moment

dynamics
Adams model
System response
System design
41 of 42

Dynamic Response of Large ACC Fan Systems

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Dynamic Response of Large ACC Fan Systems

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Dynamic

Simula on of fan system

Stellenbosch University Enexio

Wind eﬀects On-site measurements:

Excita on reconstruc on algorithm Wind eﬀects

Fan bridge Laboratory

4 On-site measurements: Sha loads Pla orm height

Start/Stop Site setup

Bending moment Bending moment

Simula on of fan system

System response System design

Background Vibra on frequencies

Simula on of fan system

At the Test Case A coal-ﬁred power sta ons, steam is condensed in

Each fan is suspended from a fan bridge.

Simula on of fan system

Simula on of fan system

Simula on of fan system

Simula on of fan system

Simula on of fan system

Fast Fourier transform (FFT) showed peaks at 𝛺, 2𝛺 and Background

Simula on of fan system

where 𝐴 = ∫ 𝑓(𝑡)𝑒 𝑑𝑡 Fan bridge

The steady state response is then On-site measurements:

𝑥(𝑡) = 𝑎 + Re 𝐴 𝐺 𝑒 Bending moment

Simula on of fan system

with Adams model

Non-linear least-squares op miza on is used to ﬁt a Fourier series

𝑎∗ + 𝑖𝑏∗ ≈ 𝐴∗ 𝐺 or 𝐴∗ ≈ (2) On-site measurements:

The reconstructed excita on, 𝑓 (𝑡), is then given by Bending moment

Simula on of fan system

Simula on of fan system

Bending load [kN.m]

Reconstructed excitation [kN.m]

Measurements recorded at a diﬀerent plant, Test Case X, where

Higher wind speed Lower wind speed

Flapwise bending moment [kN.m]

Simula on of fan system

Analysis of vibra on sources algorithm

Simula on of fan system

Strain gauges were a ached to a ﬂat plate fan blade to determine

3 Work performed in conjunc on with the ﬁnal-year project of Nico R. Basson.

It was found that the amplitude of vibra on increases with:

Decreased distance between fan rotor and bridge On-site measurements:

Increasing bridge solidity Full-scale measurements

0.04 Simula on of fan system

Simula on of fan system

Increase of the measured vibra on as the pla orm height is Background

Simula on of fan system

Simula on of fan system

Simula on of fan system

Full bridge torque strain gauge

Simula on of fan system

Low speed sha

Simula on of fan system

Simula on of fan system

500 On-site measurements:

Simula on of fan system

Simula on of fan system

Wind speed 25 m/s Bending moment

Simula on of fan system

Rota on speed 1𝜔 (2.11 Hz) Simula on of fan system