Training Session on Energy Equipment E i t

Fans & Blowers

Presentation from the Energy Efficiency Guide for Industry in Asia www.energyefficiencyasia.org

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Training Agenda: Fans & Blowers

Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities gy y pp

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Introduction

1. Fan components p 2. System resistance 3. Fan curve 4. 4 Operating point 5. Fan laws

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Introduction Fan Components

Provide air for ventilation and industrial processes that need air flow
Turning Vanes (typically used on short radius elbows) Outlet Diffusers Heat Exchanger

Baffles Filter

Inlet Vanes Motor Controller

(US DOE, 1989)

Centrifugal Belt Drive Fan

Variable Frequency Motor Drive

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Introduction System S stem Resistance

Sum of static pressure losses in system
Configuration of ducts pickups elbows ducts, pickups, Pressure drop across equipment

Increases with square of air volume

Long narrow ducts many bends: more ducts, resistance ducts, Large ducts few bends: less resistance
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Introduction System S stem Resistance

System resistance curve for various flows
Actual with system resistance calculated

(US DOE, 1989)

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Introduction Fan Curve C r e

Performance curve of fan under specific conditions
Fan volume System static pressure Fan speed Brake horsepower
(US DOE, 1989)
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Introduction Operating Point

Fan curve and system curve intersect
Flow Q1 at pressure P1 and fan speed N1

Move to flow Q2 by closing damper l i d (increase system resistance) )

(BEE India, 2004)

Move to flow Q2 by reducing fan speed

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Introduction Fan Laws La s

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(BEE India, 2004)

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Training Agenda: Fans & Blowers

Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities gy y pp

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Types of Fans & Blowers

Types of fans Centrifugal A i l Axial Types of blowers Centrifugal Positive displacement

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Types of Fans & Blowers Centrifugal Centrif gal Fans

Rotating impeller increases air velocity g p y Air speed is converted to pressure High pressures for harsh conditions
High temperatures Moist/dirty air streams Material handling

Categorized by blade shapes

Radial Forward curved Backward inclined
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Types of Fans & Blowers Centrifugal Fans R di l fans C t if lF Radial f

Advantages
High pressure and temp Simple design High durability Efficiency up to 75% Large running clearances
(Canadian Blower)

Disadvantages
Suited for low/medium airflow rates only

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Types of Fans & Blowers Centrifugal Centrif gal Fans For ard c r ed Forward curved
Advantages
Large air volumes against low pressure R l ti small size Relative ll i Low noise level

Disadvantages
Not high pressure / harsh service Difficult to adjust fan output C Careful driver selection f ld i l ti Low energy efficiency 55-65%
(C Canadian Bl di Blower) )

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Types of Fans & Blowers Centrifugal Fans - B k C t if lF Backward-inclined d i li d

Advantages
Operates with changing static pressure Suited for high flow and forced draft services Efficiency >85%

Disadvantages
Not suited for dirty airstreams Instability and erosion risk

( Canadian Blower)

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Types of Fans & Blowers Axial A ial Fans

Work like airplane propeller:
Blades create aerodynamic lift Air is pressurized Air moves along fan axis

Popular with industry: compact, low compact cost and light weight Applications
Ventilation (requires reverse airflow) Exhausts (dust, smoke, steam)
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Types of Fans & Blowers Axial F A i l Fans P Propeller fans ll f

Advantages
High airflow at low pressure Little ductwork Inexpensive Suited for rooftop ventilation Reverse flow

Disadvantages
Lo energy efficienc Low energ efficiency Noisy
(Fan air Company)
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Types of Fans & Blowers Axial F A i l Fans T b axial fans Tube i l f

Advantages g
High pressures to overcome duct losses Suited for medium-pressure, high airflow rates Quick acceleration Space efficient

Disadvantages
Expensive Moderate noise Low energy efficiency 65%
(Canadian Blower)
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Types of Fans & Blowers Axial Fans Vane axial fans

Advantages
Suited for medium/high g pressures Quick acceleration Suited for direct motor shaft connection Most energy efficient 85%

Disadvantages
Expensive
(Canadian Bl (C di Blower) )
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Types of Fans & Blowers Blowers

Difference with fans
Much higher pressures <1.20 kg/cm2 Used to produce negative pressures for industrial vacuum systems y

Types
Centrifugal blower Positive displacement
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Types of Fans & Blowers Centrifugal Blowers C t if l Bl

Gear driven impeller Gear-driven that accelerates air Single and multi-stage blowers Operate at 0.35-0.70 kg/cm2 pressure Airflow drops if system p y pressure rises
(Fan air Company)

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Types of Fans & Blowers Positive Displacement Blowers

Rotors trap air and push it through housing Constant air volume regardless of system pressure Suited for applications prone to clogging Turn slower than centrifugal blowers Belt-driven for speed changes
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Training Agenda: Fans & Blowers

Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities gy y pp

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Assessment of fans and blowers Fan Effi i F Efficiency and Performance dP f

Fan efficiency:
Ratio of the power conveyed to air stream and power delivered by the motor to the fan Depends on type of fan and impeller

Fan performance curve

Graph of different pressures and corresponding required power Supplier by manufacturers
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Assessment of fans and blowers Peak efficienc or Best Efficienc efficiency Efficiency Point (BEP)
Airfoil Backward Type of Fan
Centrifugal fans: Airfoil, Backward curved/inclined Modified radial Radial 79-83 72-79 69-75 58-68 60-65

Peak Efficiency Range

Efficiency

Radial

Tubular

Pressure blower Forward curved

Forward

Axial fans: Vane axial 78-85 67-72 45-50

Flow rate

Tube axial Propeller

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(BEE India, 2004)

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Assessment of fans and blowers Methodology Methodolog fan efficiency efficienc

Before calculating fan efficiency Measure operating parameters
Air velocity, pressure head, air stream temp, electrical motor input

Ensure that
F is operating at rated speed Fan i ti t t d d Operations are at stable condition
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Forced Draft Operation

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Suction Draft Operation

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Assessment of fans and blowers Methodology f efficiency M th d l fan ffi i

Step 1: Calculate air/gas density p g y
t = Temperature of air/gas
at site condition

Cp Pitot t b C = Pit t tube constant, t t

Step 2: Measure air velocity and calculate average

0.85 (or) as given by the manufacturer

p = Average differential
pressure

= Density of air or gas at

test condition

Step 3: Calculate the volumetric flow in the duct

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Assessment of fans and blowers Methodology f efficiency M th d l fan ffi i

Step 4: Measure the power drive of the motor Step 5: Calculate fan efficiency Fan mechanical efficiency

Fan static efficiency

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Assessment of fans and blowers Difficulties in Performance ssess e t Assessment

Non-availability of fan specification data Difficulty in velocity measurement Improper calibration of instruments Variation of process parameters during tests
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Training Agenda: Fans & Blowers

Introduction Types of fans and blowers Assessment of fans and blowers Energy efficiency opportunities gy y pp

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Energy Efficiency Opportunities

1. 1 Choose the right fan 2. Reduce the system resistance 3. Operate close to BEP 4. Maintain fans regularly 5. 5 Control the fan air flow

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Energy Efficiency Opportunities 1. Choose the Right Fan

Considerations for fan selection
Noise Rotational speed Air stream characteristics Temperature range Variations in operating conditions p y y Space constraints and system layout Purchase/operating costs and operating life

Systems approach most important! Systems approach

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Energy Efficiency Opportunities 1. Choose the Right Fan

Avoid buying oversized fans
Do not operate at Best Efficiency Point p y Risk of unstable operation Excess flow energy High airflow noise Stress on fan and system

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Energy Efficiency Opportunities 2. Reduce the System Resistance

I Increased system resistance d t i t reduces fan efficiency
Check periodically Check after system modifications Reduce where possible
(BEE India, 2004)
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Energy Efficiency Opportunities 3. Operate Close to BEP

Best Efficiency Point = maximum efficiency Normally close to rated fan capacity Deviation from BEP results in inefficiency and energy loss

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Energy Efficiency Opportunities 4. Maintain Fans Regularly

Periodic inspection of all system components Bearing lubrication and replacement Belt tightening and replacement Motor repair or replacement Fan cleaning
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

a) ) b) c) d) e) ) f) g) h) i) Pulley change y g Dampers Inlet guide vanes Variable pitch fans Variable speed drives (VSD) Multiple speed drive p p Disc throttle Operating fans in parallel Operating fans in series

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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

a) Pulley change: reduce motor/drive ) y g pulley size Advantages
Permanent speed decrease Real energy reduction

Di d Disadvantages t

( (BEE India, 2004) )

Fan must handle capacity change O l applicable if V-belt system or motor Only li bl V b lt t t
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

b) Dampers: reduce flow and increase ) p upstream pressure Advantages
Inexpensive Easy to install

Disadvantages
Limited adjustment Reduce flow but not energy consumption Higher operating and maintenance costs
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

c) Inlet guide vanes ) g
Create swirls in fan direction Reduce angle air and fan blades Lowering fan load, pressure, air flow

Advantages
Improve efficiency: reduced load and airflow 80 100% Cost effective at 80-100% of full air flow

Disadvantage
Less efficient at <80% of full air flow
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

d) Variable p ) pitch fans: changes angle g g incoming airflow and blades Advantages
High efficiency at range of operating conditions No resonance problems No stall problems at different flows

Disadvantages
Applicable to axial fans only Risk of fouling problems Reduced efficiency at low loads
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

e) Variable speed drives (VSDs): reduce ) p ( ) fan speed and air flow Two types
Mechanical VSDs Electrical VSDs (including VFDs)

Advantages
Most improved and efficient speed control Speed adjustments over continuous range

Disadvantage: high costs

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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

e) Variable frequency drives ) q y Change motors rotational speed by adjusting electrical frequency of power Advantages g
Effective and easy flow control Improved efficiency over wide operating range Can be retrofitted to existing motors Compactness No fouling problems 94 Reduced energy losses and costs UNEP 2006

Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

f) Multiple speed drive ) p p Changes fan speed from one speed to other speed Advantages g
Efficient control of flow Suitable if only 2 speeds required

Disadvantages
Need to jump from speed to speed High investment costs
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

g) Disc throttle: Sliding throttle that changes width of impeller exposed to air stream Advantages g
Simple design

Disadvantages
Feasible in some applications only
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

h) Operate more fans in parallel (instead ) p p ( of one large fan) Advantages
High efficiencies at varying demand Risk of downtime avoided Less expensive and better performance than one large fan Can be equipped with other flow controls

Disadvantages
Only suited for low resistance system
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Energy Efficiency Opportunities 5. 5 Control the Fan Air flo flow

i) Operate fans in series Advantages g
Lower average duct pressure Less noise Lower structural / electrical support required

Disadvantages
Not suited for low resistance systems
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Energy Efficiency Opportunities 5. 5 Controlling the Fan Air Flow Flo

Comparing Fans in Parallel and Series

(BEE India, 2004)

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Energy Efficiency Opportunities 5. 5 Controlling the Fan Air Flow Flo

Comparing the impact of different types of flow control on power use

(BEE India, 2004)

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Training Session on Energy Equipment E i t

Fans & Blowers

THANK YOU FOR YOUR ATTENTION

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Disclaimer and References

Thi PowerPoint training session was prepared as part of This P P i tt i i i d t f the project Greenhouse Gas Emission Reduction from Industry in Asia and the Pacific (GERIAP). While y f ( ) reasonable efforts have been made to ensure that the contents of this publication are factually correct and properly referenced, UNEP does not accept responsibility for referenced the accuracy or completeness of the contents, and shall not be liable for any loss or damage that may be occasioned directly or indirectly through the use of, or reliance on, the contents of this publication. UNEP, 2006. The GERIAP project was funded by the Swedish International Development Cooperation Agency (Sida) Full references are included in the textbook chapter that is 129 available on www.energyefficiencyasia.org
UNEP 2006