6) Fläkts FansSystem StagECC 2009

Fan Systems
M. Beauprés – Mise à 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 2

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 = ½  v2
 Total pressure:
the sum of static and velocity pressures

Airflow System
k = Constant characteristic
 = Gas density
Q = Volume flow
Q Q
P1 P P2
P = k  Q2

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

Different Types of System Curves
System resistanceP
P  k
Constant static head

 airflow through a liquid
pool
Airflow rate Q
P  kQ
Completely laminar flow
 airflow through filter bag
Airflow rate Q

Different Types of System Curves
P  kQ1.5
Slightly turbulent flow
 airflow through a grain
bin Airflow rate Q
P  kQ 2
Completely turbulent flow
 most fan systems
Airflow rate Q

System Curve
 Limit discussion to the completely turbulent system curve
 Same principles apply to other types
P  kQ 2
12
10
D P (mm H2O)
0
0 20 40 60 80 100
Q (m³/s)

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

Fan Performance Curves
 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
Pressure
Flow rate

Fan Efficiency
800 160
700 140
Fan Static Pressure (Pa) 600 120
500 100
Power (W)
400
P 80
300
PO = P x Q PS 60
200 40
100 20
Q
0 0
0 100 200 300 400 500 600 700 800 900 1000
Flow Rate (m³/s)
F V FS W
 Ps: shaft power
P  Q A t P
t    t  t  O Po: theoretical air power
PS PS PS PS PS

Fan Efficiency
Total efficiency t (mechanical efficiency):
metric units US units
Q  FTP Q  FTP
t  t 
PS 6362  PS
Static efficiency s
FSP Q  FSP FSP Q  FSP
 s  t   s  t 
FTP PS FTP 6362  PS
Q: m³/s Q: ft³/s
FTP, FSP : Pa FTP, FSP : in. H2O
PS : W PS : HP

Typical Fan Curves
P e rfo rm a n c e Cu rve fo r IE 2 5 0 F a n
Op e ra ting co nd itio ns
1518 R P M
25 90ºF, 600 ft e le v. 140
120
20 BHP
100
15
80
60
10
Efficie nc y FS P
Op e ra ting p o int: 40
5 13091 cfm
18,0 in. H2O S P 20
59,4 BHP
0 0
0 5000 10000 15000 20000 25000 30000 35000
Flo w R a te (c fm)

FSP vs FTP
25 140
120
20 BHP
100
15
80
To ta l
Efficie ncy FTP 60
10
FS P
40
5 S ta tic
Efficie ncy 20
0 0
0 5000 10000 15000 20000 25000 30000 35000
Flo w R a te (c fm)

Fan Performance and System Curves
20 140
18
120
16 BHP
14 100
12
80
10
60
8 FS P
Efficie ncy
6 40
4
20
2
0 0
0 5000 10000 15000 20000 25000 30000 35000
Flo w R a te (c fm)

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
 Airplane’s propeller

Exploded View of a Centrifugal Fan
Inlet Outlet Inlet Guide Vanes
Backplate Inlet Bell
Cutoff Blades
Hub
Flange
Side Sheet Impeller Stationary Inlet
Scroll

Centrifugal Fan Principles
Vr V Vr : radial velocity
Vt : tangential velocity
Vt
V : fluid velocity

Centrifugal Fan

Centrifugal Fan

Centrifugal Fan

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

Centrifugal Fan Principles

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

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

Radial Blade Fan (RB)
100
90
80
Fan Static Pressure
70
60
Efficiency
50
40
30
20
10
0
0 4 8 12 16 20 24 28
Volume

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%

Radial Tip Impeller (RT)
110
100
90
Fan Static Pressure
80
Efficiency
70
60
50
40
30
20
10
0
Volume

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

Forward Curved Impeller (FC)
90
80
70
Fan Static Pressure
60
Efficiency
50
40
30
20
10
0
Volume

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

Backward Inclined Blades (BI)
100
90
Fan Static Pressure
80
Efficiency
70
60
50
40
30
20
10
0
0 2 4 6 8 10 12 14 16 18 20 22 24
Volume

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

Backward Inclined Airfoil (AF)
120
110
100
Fan Static Pressure
90
80
Efficiency
70
60
50
40
30
20
10
0
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30
Volume

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%

Unstable Range
Uns table S table
P pe a k
Flo w Ra te

Fan Laws
Fan Laws
 N2  D2 3 
Volume :  Q 2  Q1   3 

 N1  D1 
 N2 2  D2 2  2  k p1 
Pr essure :  p 2  p1   2 
 N D   k 
2
 1 1 1 p2 
 N2 3  D2 5  2 
Power :  Pu2  Pu1   3 5


 N1  D1  1 

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)

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

2
TP2 SP2 VP2  N 2 
   
TP1 SP1 VP1  N1 
 Power is the product of volume by energy

3
P2  N2 
  
P1  N1 

Example - Change in Fan Speed
A fan running at 1305 RPM delivering 7.1 m³/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 m³/s if the system curve does not change?
What would be the impact on the total pressure?
Q2 N1 8.5  1305
N2    1562 RPM
What is the impact on power? Q1 7.1
2 2
N  1562 
TP2  TP1  2   57     81.7 mmHg
 N1   1305
3 3
 N2  1562 
P2  P1    66.5     114.0 kW
 N1   1305

Change in Speed
30 250
25 1 8 2 2 RPM 200
1 6 7 0 RPM
20 1 5 1 8 RPM
150
15
100
10
50
5
0 0
0 5000 10000 15000 20000 25000 30000 35000 40000
Flo w R a te (c fm)

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

Change in Gas Density
Op e ra ting c o nd itio ns
1518 RP M
20 160
90ºF, 600 ft e le v.
18 140
16
120
14 1 .1 3 kg /m³
12 100
10 80
8 60
0 .5 6 kg /m³
6
40
4
2 20
0 0
0 5000 10000 15000 20000 25000 30000 35000
Flo w R a te (c fm)

Effect of Density on Fan Selection
Dust collector on inlet side of fan Clinker cooler fan

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

due to density change at fan inlet

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
Q2  D2 
  
Q1  D1 
2
TP2 SP2 VP2 D 
    2
TP1 SP1 VP1  D1 
5
P2 D 
  2
P1  D1 

Change in Size
16 100
14 90
80
12
70
10 60
8 50
+1 0 % D
6 40
D 30
4
20
2
10
0 0
0 5000 10000 15000 20000 25000 30000 35000
Flo w R a te (c fm)

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

Outlet Louvre Dampers
Parallel Blades Opposed Blades
 More flow on one side of duct  Yields more uniform profile

 Not very linear response
 More linear response
 The outlet louvre dampers change the

system resistance curve
 Power wasting devices

Outlet Louvre Dampers
120
100 2 0 % o pe n
4 0 % o pe n
80
6 0 % o pe n
60
8 0 % o pe n
40
Wide o pe n
20
0
0 10000 20000 30000 40000 50000 60000 70000 80000

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

Variable Inlet Vanes
100 100
90 90
80 80
70 70
60 60
50 50
40 40
30 30
20 20
10 10
25% ope n 50% 75% 100%
0 0
0 10000 20000 30000 40000 50000 60000 70000 80000

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)

Variable Speed Fans
 Direct application of the fan laws:
2 3
Q2 N2 TP2 SP2 VP2  N2  P2  N2 
      
Q1 N1 TP1 SP1 VP1  N1  P1  N1 
 Maintain same efficiency at different speeds

 The most efficient method of controlling fans
 Higher initial cost

Speed Change - Constant Efficiency
Efficiency: Q1  TP1
1 
P1
Fan laws:
2 3
N   N2   N2 
Q2  Q1  2  TP2  TP1   P2  P1  
 N1   N1   N1 
2
N  N 
Q1  2   TP1  2 
Q  TP2  N1   N1  Q1  TP1
2  2  3

P2  N2  P1
P1  
 N1 

Impact of Flow Control on Power
100
90
80
70
Inlet damper
Outlet
60
damper
% Power
50
Inlet vanes
40
30
Variable
20
speed
10
0
0 10 20 30 40 50 60 70 80 90 100 110
% Flow

Drive Arrangements
Belt drive Direct drive
 Standard speed motors can be  Reduces initial cost if standard

used speed motor could be used
 no need for slow speed  no extra supports, pulleys,
motors (expensive ) bearings, shafts
 Exact fan speed for required air  Elimination of power loss by belt
and volume can be obtained drive (5 to 10%)
 Speed can be adjusted by simply  No maintenance required from

changing pulley ratio stretching belts
 No possible change to fan speed

 unless variable speed drive

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

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
14 300°F, sea level 600
Fan Static Pressure ("H2O)
12 Operating 500
point
10
400
Power (HP)
8
300
6
200
4
Operating point:
2 129,500 cfm 100
11.5 "H2O
0 339.5 HP 0
0 50000 100000 150000 200000 250000 300000
Flow Rate (cfm)

System Effect
Elbows
Good
Bad

Fan Inlet

Duct Branches

Turning Vanes

Fan Audit
Gas Handling / TYTP Power
Fan Audit Program
 Many fans don’t 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

Objective
Reduce energy consumption
Indicators:
 kWh absorbed by the motor
 Fan efficiency
 Fan reliability factor

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

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

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

Measurements for Fan Static Pressure

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)

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

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

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?

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

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?

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

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Fan Systems

M. Beauprés – Mise à jour D. Dumont avril 2004

Process Engineering Program – Gas Handling – Fan Systems June 2009 2

Process Engineering Program – Gas Handling – Fan Systems June 2009 4

Process Engineering Program – Gas Handling – Fan Systems June 2009 5

 Each component in a system offers resistance to air flow

Process Engineering Program – Gas Handling – Fan Systems June 2009 6

Constant static head

Process Engineering Program – Gas Handling – Fan Systems June 2009 7

bin Airflow rate Q

Process Engineering Program – Gas Handling – Fan Systems June 2009 8

Process Engineering Program – Gas Handling – Fan Systems June 2009 9

 Fan Static Pressure (FSP)

 Fan Static Rise

Process Engineering Program – Gas Handling – Fan Systems June 2009 11

 Usually, power curve is given

Process Engineering Program – Gas Handling – Fan Systems June 2009 12

Fan Static Pressure (Pa) 600 120

Flow Rate (m³/s)

Process Engineering Program – Gas Handling – Fan Systems June 2009 13

Process Engineering Program – Gas Handling – Fan Systems June 2009 14

Process Engineering Program – Gas Handling – Fan Systems June 2009 15

Process Engineering Program – Gas Handling – Fan Systems June 2009 16

Process Engineering Program – Gas Handling – Fan Systems June 2009 17

Two large classes:

 Clinker cooler fans

 Mill ventilation fans

 Dust collector fans

Process Engineering Program – Gas Handling – Fan Systems June 2009 19

Process Engineering Program – Gas Handling – Fan Systems June 2009 20

Process Engineering Program – Gas Handling – Fan Systems June 2009 21

Process Engineering Program – Gas Handling – Fan Systems June 2009 22

Process Engineering Program – Gas Handling – Fan Systems June 2009 23

Process Engineering Program – Gas Handling – Fan Systems June 2009 24

Inlet Bell Outer Cylinder Diffuser

Process Engineering Program – Gas Handling – Fan Systems June 2009 25

Process Engineering Program – Gas Handling – Fan Systems June 2009 26

 Backward inclined - flat blade

 Different applications require different blade type

Process Engineering Program – Gas Handling – Fan Systems June 2009 27

 The simplest of all centrifugal fans

Process Engineering Program – Gas Handling – Fan Systems June 2009 28

Process Engineering Program – Gas Handling – Fan Systems June 2009 29

Process Engineering Program – Gas Handling – Fan Systems June 2009 30

Process Engineering Program – Gas Handling – Fan Systems June 2009 31

 High pressure and volume capabilities

Process Engineering Program – Gas Handling – Fan Systems June 2009 32

Process Engineering Program – Gas Handling – Fan Systems June 2009 33

 Non-OverLoading power (N.O.L.)

Process Engineering Program – Gas Handling – Fan Systems June 2009 34

Process Engineering Program – Gas Handling – Fan Systems June 2009 35

 Most efficient centrifugal fan: 85-90% and more

Process Engineering Program – Gas Handling – Fan Systems June 2009 36

Process Engineering Program – Gas Handling – Fan Systems June 2009 37

Radial blade (RB)

Process Engineering Program – Gas Handling – Fan Systems June 2009 38

Process Engineering Program – Gas Handling – Fan Systems June 2009 39

Process Engineering Program – Gas Handling – Fan Systems June 2009 41

 air density (temperature, pressure)

 What happen in other conditions?

 What if the gas density changes? ()

 What if I change the size of the fan? (D)

Process Engineering Program – Gas Handling – Fan Systems June 2009 42