Fans, Ductwork, & Air

Handling Components:
Design, Performance, & Commissioning Issues

Fans

Instructor:
David Sellers
Senior Engineer
Facility Dynamics Engineering
November 6, 2012
Fan Fundamentals;
(Very Similar to Pump Fundamentals)

FANS 2
Centrifugal Fan Operation

Spin the wheel …

… and air is thrown

from the center to the
perimeter

FANS 3
 Centrifugal Fan Operation

Adding a scroll …

… collects and
distributes the air
and recovers
some of the
velocity pressure

FANS 4
Common HVAC Fan Types

Centrifugal
• Pressure created by:
‒ Centrifugal force
‒ Velocity added at the
impeller
• Single Width/Single Inlet
(SWSI)

FANS 5
Common HVAC Fan Types

Centrifugal
• Pressure created by:
‒ Centrifugal force
‒ Velocity added at the
impeller
• Single Width/Single Inlet
(SWSI)
• Double Width/Double Inlet
(DWDI)

FANS 6
Common HVAC Fan Types

Centrifugal
• Pressure created by:
‒ Centrifugal force
‒ Velocity added at the
impeller
• Single Width/Single Inlet
(SWSI)
• Double Width/Double Inlet
(DWDI)
• Plenum or Plug

FANS 7
Common HVAC Fan Types

Centrifugal
• Pressure created by:
‒ Centrifugal force
‒ Velocity added at the
impeller
• Single Width/Single Inlet
(SWSI)
• Double Width/Double Inlet
(DWDI)
• Plenum or Plug
• Axial

FANS 8
Common HVAC Fan Types

Centrifugal
• Pressure created by:
‒ Centrifugal force
‒ Velocity added at the
impeller
• Single Width/Single Inlet
(SWSI)
• Double Width/Double Inlet
(DWDI)
• Plenum or Plug
• Axial

FANS 9
Fan Terminology Frame

Wheel
Drive
System

Motor
Inlet Cone

Isolator

FANS 10
Outlet Terminology
Cut-off

Blast Area

Hub Area

Outlet Area
Outlet Area
Hub Area
Swept Area Ratio =
Outlet Area

FANS 11
 Airfoil Fan Wheel
Characteristics:

Total Pressure
Increasing Static, Efficiency and Power

Static Pressure
Total Efficiency

Static
Efficiency

Power

Increasing Flow

FANS 12
 Backward Inclined Fan Wheel
Characteristics:

Total Pressure
Increasing Static, Efficiency and Power

Static Pressure

Total Efficiency

Static
Efficiency
Power

Increasing Flow

FANS 13
 Forward Curved Wheel
Characteristics:
Increasing Static, Efficiency and Power

Total Pressure

Total Efficiency

Static Pressure

Power
Static
Efficiency

Increasing Flow

FANS 14
 Forward Curved Wheel
Characteristics:
Increasing Static, Efficiency and Power

Total Pressure
Total Efficiency

Static Efficiency
Power

Static Pressure
Increasing Flow

FANS 15
 See the ASHRAE Systems and Equipment Vane Axial Fan Characteristics:
Handbook Table 1 and the ASHRAE Pocket
Guide pages 12 and 13 and the Buffalo Fan
Engineering Manual for more information
Total Pressure
Increasing Static, Efficiency and Power

Total Efficiency

Static Pressure
Static
Efficiency Power

Increasing Flow
Images courtesy of NASA; http://www.nasa.gov/centers/langley/images/content/221601main_image-0222-2008_full.jpg

FANS 16
 Fan Efficiency
Mechanical and
Fluid Dynamics
Air Horse Losses
Power Out
(Mass in
Motion)
Drive
System
Losses
Motor
Losses

Leakage
Losses

Electrical
Power In

FANS 17
A Field Issue Affecting Fan Efficiency

Imagess courtesy of Greenheck (left) and ASHRAE 2008 Handbook of Systems and Equipment, Chapter 20 (right)

FANS 18
Image courtesy Bill Michell – DOE – NY Marriott Marque

Inlet Cones, Inlet Vanes, and VFD Retrofits

FANS 19
Image courtesy Bill Michell – DOE – NY Marriott Marque

Inlet Vanes are Supported by Inlet Cones

Image courtesy Bill Michell – DOE – NY Marraiott Marque

FANS 20
Image courtesy Bill Michell – DOE – NY Marriott Marque

Adding VFDs?
Remove the Vanes, Leave the Cone!

FANS 21
Fan Performance Presentation

Flow vs. static

for a given speed
with a given
impeller size
System curve

Surge line

FANS 22
 Horsepower tends to drop
off as speed drops off

Reducing speeds with a

fixed impeller size moves
up and down the system
curve
Running out the fan curve
tends to increase
horsepower for a while,
then maintain a fairly
steady horsepower

FANS 23
Fan Performance Presentation

There is a difference between the applied fan curve and

the fan curve
Some manufacturers document this

10,000 cfm 10,000 cfm

4 in.w.c. 4 in.w.c.
1,499 rpm 1,512 rpm
9.05 bhp 9.11 bhp

FANS 24
System Flow Rates are Generally Set by
the Loads Served
FANS 25
System Flow Rates are Generally Set by
the Loads Served
FANS 26
System Flow Rates are Generally Set by
the Loads Served
FANS 27
 Pacific Energy Center Main Classroom - Design Load
Baseline; Full Class, Scheduled, Medium Construction, Light Walls, SE Exposure; Shades
Open, 2% Cooling Design Condition (High 74°F, Low 57°F), Space - 70°F
The Loads Can Be Quite Variable
60,000
91.0 Solar, Transimission, Return Gains
50,000 (Cooling) Btu/hr

40,000 86.0
People, Internal, Lights to Return, No

Outside Temperature, °F
30,000 Fan (Cooling) Btu/hr
81.0
Cooling Load, Btu/hr

20,000
76.0 Space Load (Solar, etc. plus People etc.)
10,000 Btu/hr

71.0
0
Infiltration, Ventilation (Cooling) Btu/hr
-10,000 66.0

-20,000
61.0 Total Cooling Btu/hr

-30,000
56.0
-40,000 Outdoor Temperature °F
51.0
-50,000

-60,000 46.0
1 3 5 7 9 11 13 15 17 19 21 23

Hour
FANS 28
 Static Requirements
are Set by Geometry
Fabrication details versus as
designed details can make a
difference
• Design – 25° mitered offset
‒ C0 – 0.11
‒ Loss – 0.05 in.w.c.
• Fabrication – 45° mitered
offset
‒ C0 – 0.31
‒ Loss – 0.14 in.w.c.

FANS 29
 Static Requirements
are Set by Geometry
Fabrication details versus as
designed details can make a
difference
• Design – single thickness
turning vanes
‒ C0 – 0.11
‒ Loss – 0.05 in.w.c.
• Fabrication – double thickness
turning vanes
‒ C0 – 0.25
‒ Loss – 0.10 in.w.c.

FANS 30
Design vs. Fabricated vs. Reality

FANS 31
 A
The AHU8 Supply Duct
Some Perspective B

Plotted to scale from the fan

discharge (A) to the terminal unit
inlet at the most remote terminal
unit (C)
40% of the static pressure is used
up between the discharge (A) and
the mechanical shaft point of
entry (B).

FANS 32
Given:

The fan curve in the next slide

A measured fan speed of 1,411 rpm
A measured flow rate of 30,000 cfm
Determine:
The fan static pressure
The fan class
The fan brake horsepower
The system curve
The speed required to produce 28,000 cfm and the operating
conditions at that speed
What would happen if you throttled to 28,000 cfm instead of
reducing fan speed?
Could you speed the fan up and obtain 35,000 cfm?

FANS 33
 Operating point

Fan static = 7.0 in.w.c.

FANS 34
 Operating point

Operating speed exceeds the

maximum Class I speed but is less
than the maximum Class II speed;
thus the wheel needs to be at least
Class II

FANS 35
The brake horse power is between
40 and 50 bhp; approximately 44
bhp
Operating point

FANS 36
 The system curve is plotted based
on the operating point using the
“square law”:
PNew = POld x (FlowNew/FlowOld)2

FANS 37
Discussion Point

Do VAV systems operating on a

single fan curve?
Where is the origin of the fan
curve for a VAV system.

FANS 38
 Assuming no changes in the
system, the new operating point can
be assessed by moving down the
system curve to the new flow rate
and reading the remaining
parameters from the fan curve:
• Static pressure = about 6 in.w.c.
• Speed = about 1,290 rpm
• Bhp = about 35 bhp

FANS 39
 Increasing the fan speed:
• Exceeds the Class II maximum
speed
• Requires 68 bhp; a 17% increase
in flow required a 51% increase in
power
The new bhp requirement can be
assessed using the fan affinity law
relating bhp and fan speed:
HPNew = HPOld x (RPMNew/RPMOld)3

FANS 40
Fan Operating Limits

Fan wheels have structural limits

“.. must be physically capable
of operating safely at every … Class III at or
point of rating on or below the below this limit
minimum performance limit …”
• Class I – Class IV (minimum to … Class II at or
maximum rating) below this limit
• Result in a maximum speed … Class I at or
rating for each class below this limit

FANS 41
This Is What Can Happen If You Over-speed
A Fan

Image courtesy of
Jim Bochat of Pro
Services

These blades should be straight

The fan had been

running about 1,000
rpm over the maximum
speed limit for its fan
class.

FANS 42
This Is What Can Happen If You Over-speed
A Fan

The wheel rim and backplate …

… should be here!
… should be here!

FANS 43
This Project Was Lucky

The wheel did not

disintegrate
The collapse was so
uniform the wheel
remained in balance
The problem was
discovered before
stress cracks cause
the wheel to fail

FANS 44
Given the Following Information

• Flow - 25,000 cfm

• Inlet static pressure – negative 1.9
in.w.c.
• Discharge static pressure - 4.1
in.w.c.
• Fan speed – 1,411 rpm
• Volts – 463
• Amps – 42

Where do you think the fan is

operating and why?

FANS 45
 • Flow - 25,000 cfm
• Inlet static pressure - negative1.9 in.w.c.
• Discharge static pressure - 4.1 in.w.c.
• Fan speed – 1,411 rpm
• Volts – 463
• Amps – 42

6 in.w.c. Which point is

the right point?

25,000 cfm
1,411 rpm

FANS 46
 • Flow - 25,000 cfm
• Inlet static pressure - negative1.9 in.w.c.
• Discharge static pressure - 4.1 in.w.c.
• Fan speed – 1,411 rpm
• Volts – 463
• Amps – 42
The tie-breaker
⎛Volts x Amps x Power Factor x 3 ⎞
kW = ⎜ ⎟
⎜ 1,000 ⎟
⎝ ⎠

6 in.w.c.

25,000 cfm
1,411 rpm

FANS 47
Fan Static Pressure

Ptotal = Ptotal out – Ptotal in

Pstatic = Ptotal – Pvelocity in
• Derived from the AMCA test method
‒ Gauge static at 100% effective duct length corrected to
discharge
‒ Fan draws air from surroundings through a well shaped
inlet
Pstatic = Pstatic out – Ptotal in
VAV SYSTEMS 48
 Surge Varying Fan
Line
System
Curve
Volume
Single Zone Technique
• Modulate based on zone
temperature
Increasing Static

Increasing Flow

FANS 49
 Surge Varying Fan
Line
System
Curve
Volume
Single Zone Technique
• Modulate based on zone
temperature
Multiple Zones
• Zones modulate based on
temperature
Increasing Static

• Fixed pressure may be

maintained at some point in
the system

Increasing Flow

FANS 50
 Surge Varying Fan
Line
System
Curve
Volume
Single Zone Technique
• Modulate based on zone
temperature
Multiple Zones
• Zones modulate based on
temperature
Increasing Static

• Fixed pressure may be

maintained at some point in
the system
• Fan follows the total zone
flow requirement
• Work on a family of system
curves
Increasing Flow

FANS 51
 Surge Varying Fan
Line
System
Curve
Volume
Following the system curve is
desirable in the context of
minimizing the power
requirement as the flow rate
drops off
Increasing Static

Constant brake
horse power
Lower constant brake
horse power
Even lower constant
brake horse power
Increasing Flow

FANS 52
 Surge Varying Fan
Line
System
Curve
Volume
Discharge Dampers
• Push the fan up its curve
• Approach the surge line
• Noise can be an issue
Increasing Static

Increasing Flow

FANS 53
 Surge Varying Fan
Line
System
Curve
Volume
Inlet Guide Vanes
• Direct the flow into the fan
wheel imparting “swirl”
• Changes the shape of the
Wide surge line
Open • Droops the fan curve
• Tend to follow the system
Increasing Static

Less curve
Hardly Open • May be integral to the fan’s
Open peak efficiency point
Even Less
Open

Increasing Flow

FANS 54
Inlet Guide Vanes; Directing Airflow into the
Fan Wheel

FANS 55
Inlet Guide Vanes; Directing Airflow into the
Fan Wheel

FANS 56
Inlet Guide Vanes; Directing Airflow into the
Fan Wheel

FANS 57
Inlet Guide Vanes; Directing Airflow into the
Fan Wheel

FANS 58
Inlet Guide Vanes; Should You Remove
Them if you Retrofit a VSD?

FANS 59
Inlet Guide Vanes; Should You Remove
Them if you Retrofit a VSD?

“It Depends”
Jay Santos

See Inlet Guide Vanes (IGVs) and Variable Speed Drives(VSDs)

at http://av8rdas.wordpress.com/ for more information
FANS 60
Image courtesy Bill Michell – DOE – NY Marriott Marque

Adding VFDs?
Remove the Vanes (Maybe),
Leave the Inlet Cone (For Sure)

FANS 61
 Surge Varying Fan
Line
System
Curve
Volume
Varying Speed
Traditional balancing approach
Family of similar shaped
operating curves
Tends to preserve the efficiency
Full Speed at the original operating point
Increasing Static

• Tend to follow the system

curve
Lower
Speed
Even Lower
Speed

Increasing Flow

FANS 62
 Varying Fan
Course
Pitch
Volume
System Curve
Varying Blade Pitch
Vane axial fan approach
Similar to speed variation in
terms of power reduction
Tend to follow the system curve
Mechanically complex
Increasing Static

Less
Course
Pitch

Fine Pitch

Increasing Flow

FANS 63
Image courtesy AVA HVAC Products
http://avahvacproducts.com/Joy_Fan_Service___Parts.html
FANS 64
Image courtesy AVA HVAC Products
http://avahvacproducts.com/Joy_Fan_Service___Parts.html
FANS 65
FANS 66
FANS 67
FANS 68
 Power Consumption Outlet
Comparison Damper
Source:
Howden Buffalo
Fan Engineering
9th Edition

Inlet Guide
Increasing Power

Vanes
Variable
Speed
Variable Theory (Fan Power
Pitch Equation)

Increasing Flow

FANS 69
 Would the Control Logic Outlet
Damper
Requirements Associated with
Controlling Supply Fan Flow Vary
with the Different Capacity Variation
Strategies?

Inlet Guide
Increasing Power

Vanes
Variable
Speed
Variable Theory (Fan Power
Pitch Equation)

Increasing Flow

FANS 70
Plug Fans Solve
Space Problems

FANS 71
 Two Fans Selected for Best Efficiency at
the Same Operating Point…

Plug Fan (Previous Slide) SWSI Centrifugal (Shown)

Flow – 50,000 cfm Flow – 50,000 cfm
Static – 6.0 in.w.c. Static – 6.0 in.w.c.
Speed – 855 rpm Speed – 697 rpm
Power – 65.35 bhp Power – 56.86 bhp
Static Efficiency – 72.16% Static Efficiency – 82.94%
Annual Cost* - $12,675 Annual Cost*- $11,028

Plug Fans Solve

Space Problems
But That’s Not Without a Price
* 2,600 hours per year; $0.10 per kWh

FANS 72
Fan performance optimization

Specify in terms of fundamentals

• Flow
• Fan total or static pressure
• Maximum bhp
• Minimum fan efficiency
• Minimum motor efficiency
• Minimum motor power factor
• Maximum motor speed
Allow the manufacturers to exploit their technology

FANS 73
Get What you Asked For

If you don’t need it, don’t specify it

If you do need it, enforce the specification requirement
Require shop drawings
• Standard catalog data – A good starting point
• Fan performance curves
• Motor performance curves
• Seismic qualification certification statement
• Documentation of special features and requirements
• Require O&M data upon approval of shop drawings for
commissioning support
Review shop drawings

FANS 74
Fan Efficiency Is Only Part Of The Equation

The fan’s characteristics need to be matched to the

system’s requirements
The air handling unit components need to be optimized
to the application
Distribution efficiency is critical
The air handling system needs to be tuned to the actual
operating requirements
• Flexible, robust design
• Commissioning
• Training

FANS 75
 Economizers bring in outdoor air above and
beyond the ventilation requirement, mix it
with return air as required to control set point
and thereby provide free cooling

A Quick Word about Economizers,

Return Fans, and Relief Fans
FANS 76
 The Goes Inta’s Gotta
Equal the Goes Outa’s
Dr. Albert Black

The extra outdoor air brought in for “free

cooling” needs a relief system to get it back
out of the building. Otherwise, the fan will
pressurize the building but move no air
FANS 77
Return Fans

Overcome the static pressure loss

between the zone and the air
handling system
Operate any time the supply fan runs
• Return air for recirculation
• Frequently, deliver air to the relief
louver for discharge to the exterior
when operating on an economizer
cycle
Coordinating with VAV supply
operation is tricky

FANS 78
Relief Fans

Overcome the static pressure loss

between the air handling unit location
and the relief louver
• Only operate during an economizer
cycle
• VFD operation often coordinated
with building pressure

FANS 79