Confederation of Indian Industry

Fans & Blowers

Confederation of Indian Industry
Fans & Blowers
v Simple Definition
Machines to move gases (or) gases mixed
with small solid particles
v Operation of fans & pumps similar
v Broad Classification
Centrifugal
Axial
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Difference Between Fans, Blowers
and Compressors
- > 1.20 Compressors
1136 2066 1.11 to 1.20 Blowers
1136 < 1.11 Fans
Pressure rise
(mm WG)
Specific
Pressure*
Equipment
As per ASME Definition
* Ratio of discharge pressure to suction pressure
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v Capacity (RPM)
v Head (RPM)
2
v Power (Capacity x Head)
(RPM)
3
Fans & Blowers - Formulae
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Fans & Blowers Formulae
v Capacity :
v Head :
v Power :
If the RPM is reduced by say 10%, what
will happen to the
reduce by 10%
reduce by 19%
reduce by 27%
Confederation of Indian Industry
Characteristic Curve of Fan
N1 rpm
N2 rpm
Power consumption
80%
76%
74%
Volumetric Flow
S
t
a
t
i
c

P
r
e
s
s
u
r
e
Confederation of Indian Industry
Fan Efficiency

fan
= Q (m
3
/ s) x P (mm WC)
102 x
motor
x kW (I)
Where,
Q = Volumetric Flow
P = Static Head Developed by fan
Typical Efficiencies 40 to 70%
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Factors Affecting Fan Performance
v RPM
v Diameter
v Density
v Temperature
RPM Diameter Density Temperature
Volumetric n D
3
- -
capacity
Pressure rise n
2
D
2
1/ T
Power
consumption n
3
D
5
1/ T
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Effect of Various Capacity Controls
100
80
60
40
20
20 40 60 80 100
Q in %
k
W
i
n
%
Recirculation
VFD
Damper
On/ off Ideal
VFC
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I nlet Guide-vane control
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I nlet Guide-vane control
v Different from damper
v Guide-vane gives a twist to the air in the
direction of rotation
q Different characteristic curve
q Useful for marginal capacity reductions
v Useful earlier
q VFDs were not cost economic
q VFD reliability was a question
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Throttling of a Fan
v Suction/ Delivery
v Why?
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Throttling - Suction
0 mm
-600 mm -700 mm
Average pressure of fan = (10336 - 700) + (10336 0)
2
= 9986 mm WG
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Average density higher, power consumption higher
Average pressure of fan = (10336 - 600) + (10336 + 100)
2
= 10086 mm WG
Throttling - Delivery
+100 (120) mm
-600 mm
0 mm
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Power Consumption - Oversized Fan
Fan designed
v 1,20,000 m
3
/ h
v 650 mm Wg
Actual requirement
v 90,000 m
3
/ h
v 510 mm Wg
10 mm Wg
Damper 60%
-500 mm Wg -720 mm Wg
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Potential in Oversized Fan
Energy saving potential in over sized fan
= x Power Cons.
= [(720 500)/ (10 (-720)] x 289 kW
= (220/ 730) x 289 kW
= 87 kW
P across damper
Total pressure rise
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Energy Audit in Fans & Blowers
v Is it off the correct capacity/ head?
v How is the fan controlled?
Damper throttling
Guide vane control
Speed control GRR / SPRS / VFD
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v Can the capacity/ head be further fine tuned?
v What is the efficiency of fan?
v Can it be replaced by high fan
v Is it possible to reduce system resistance
Suction / discharge side ?
v Can fan operation be interlocked with
process operation?
Energy Audit in Fans & Blowers
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Can fan be replaced by one of
lower capacity / head ?
Confederation of Indian Industry
Coal Mill Ventilation Fan Speed Reduction
v Pressure drop = (90/ 365) X 100
= 24%
v Head required = 0.76 times present head
+ 5 mm
50%
BF
-360 mm
-270 mm
38 kW
Confederation of Indian Industry
Coal Mill Ventilation Fan Speed Reduction
v Fan had belt drive
v RPM of fan reduced by 10%
Annual Savings = Rs. 1.34 Lakhs
I nvestment = Rs.0.05 Lakhs
Payback period = 1 month
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COAL MI LL VENT FAN - 2
Coal Mill Vent Fan
-11 mm
462 m
3
/min
288 mmWC
45 kW
18.3 kW
-140 mm
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Fan Characteristic Curve
50 Hz
36 Hz
Volumetric Flow
S
t
a
t
i
c

P
r
e
s
s
u
r
e
288
462
150
333
130
403
54%
Confederation of Indian Industry
v Fan Efficiency - 54%
v Install a correct size higher efficient fan
q At least 70% efficiency
v Total savings - 7.4 kW
I nstall Correct size Fan for Coal Mill
Vent Fan - 2
Confederation of Indian Industry
I nstall Correct size Fan for Coal Mill
Vent Fan - 2
v Annual Savings : Rs. 0.92 Lakhs
v Investment : Rs. 1.00 Lakh
v Payback : 13 months
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Control of fans
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I nstall VFD for Boiler I D Fan
Present Control
v Damper Based on Furnace Draught
v Energy Loss Across Damper
-60 mm -110 mm
50%
ID Fan
53 kW
VFD 29 kW
30
TPH
Boiler
ESP
PIC
VFD
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Install VFD for Boiler ID Fan
Install VFD
Control by Varying Speed
Damper - 100% Open
Power with damper = 53 kW
Power with VFD = 29 kW
Savings = 24 kW
Annual Savings - Rs. 7.76 Lakhs
I nvestment - Rs. 6.85 Lakhs
Payback period - 11 Months
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System Resistance reduction
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Suction side pressure drop
v Extensive discussions held
q Fan suppliers BHEL & ABB
q Fan experts
v Suction pressure drop
q Not more than 15-20mm
v Cooler fans invariably very high - 70-90 mm
q Intentional
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Fan inlet pressure drop
- 94 mm
v Total Pr Rise of Fan - 558 mm WC
v I nlet pressure loss - 16.8% of pr developed
v Power consumption - 210.2 kW
Cooler fan - 10
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Piezo Ring Characteristic Curve
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Suction side pressure drop
v Typically flow measurement
q using Piezometer ring
q Additional pressure difference for accuracy
v Measures to be taken
q Reduce inlet pressure drop
q Measure air flow
v For reducing the inlet pressure drop
q I nlet Air velocity - 10-12 m/ sec
q Reduction in entry loss using bell mouth
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Modification of suction side
v Radius of bell mouth
- 0.25 x effective diameter
v Flow measurements using aerofoil
r
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Flow measurement
v Aerofoil in cooler fans
q I nitial apprehension dust
q Prone for wear due to dust
v Extensively practiced in power plants FD fans
v Potential in cooler fans no. 5 and 10
v I nlet Pressure not more than 20 mm WC
v Saving potential - 6-7%
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Flow Measurement - Alternate
v Majority fitted with VFDs
v After inlet modification
q Speed & discharge pr. thro a software to
determine the flow
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Lower inlet suction pressure drop
in identified fans
Annual savings - Rs 8.58 Lakhs
Investment - Rs 2.0 Lakhs
Payback period - 3 Months
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VFD for cooling Tower fans
v Conventional control On-Off
v One fan switched Off-during favourable
condition
q Energy Saving Partial
q 50% of heat transfer area not utilised
Confederation of Indian Industry
VFD for cooling Tower Fans
v Latest Trend-I nstallation of VFD
v Operate both fans at 50% speed
q Heat transfer area fully utilised
v Pressure drop (Velocity)
2
v Reduction in Velocity by 50%
q Reduction in pressure drop 75%
v I n axial flow fans, power Pressure drop
q Power savings 75%
Confederation of Indian Industry
Case Study
v Centralized cooling tower
q 2 out of 4 fans operated
v Cooling Tower Fans Provided with TI C
q ON at 32 Deg C
q OFF at 30 Deg C
v Benefits
q Two cells not used
q 20% energy savings achieved
v I nstalled VFD for all fans after revamp
Confederation of Indian Industry
Case Study
v Operate all fans at 50% speed
q All cells area fully utilised
v 50% energy savings achieved
Annual savings = Rs 2.64 lakhs
Investment = Rs 2.50 lakhs
Payback period = 11 months
Confederation of Indian Industry
Thank You