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
gy efficiency
y opportunities
pp

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Introduction

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

Baffles
Filter

Heat
Exchanger

Inlet
Vanes
Motor
Controller

(US DOE, 1989)

Centrifugal
Belt Drive
Fan

Variable Frequency
Motor
Drive

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Introduction
S stem Resistance
System
Sum of static pressure losses in
system
Configuration of ducts
ducts, pickups
pickups, elbows
Pressure drop across equipment

Increases with square of air volume

Long narrow ducts
ducts, many bends: more
resistance
ducts, few bends: less resistance
Large ducts
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Introduction
S stem Resistance
System
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
l i
damper
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
gy efficiency
y opportunities
pp

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Types of Fans & Blowers

Types of fans
Centrifugal
Axial
A i l
Types of blowers
Centrifugal
Positive displacement
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Types of Fans & Blowers

Centrif gal Fans
Centrifugal
Rotating
g impeller
p
increases air velocity
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

C t if
Centrifugal
l Fans
F
Radial
R di l fans
f
Advantages

High pressure and temp

Simple design
High durability
Efficiency up to 75%
Large running clearances

Disadvantages
Suited for low/medium
airflow rates only

(Canadian Blower)

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Types of Fans & Blowers

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

Disadvantages
Not high pressure / harsh
service
Difficult to adjust fan output
Careful
C
f l driver
di
selection
l ti
Low energy efficiency 55-65%

(C
Canadian
di Bl
Blower))

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Types of Fans & Blowers

C t if
Centrifugal
l Fans
F
- Backward-inclined
B k
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

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

Popular with industry: compact,

compact low
cost and light weight
Applications
Ventilation (requires reverse airflow)
Exhausts (dust, smoke, steam)
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Types of Fans & Blowers

A i l Fans
Axial
F
Propeller
P
ll fans
f
Advantages
High airflow at low pressure
Little ductwork
Inexpensive
Suited for rooftop
ventilation
Reverse flow

Disadvantages
Low
Lo energy
energ efficienc
efficiency
Noisy

(Fan air Company)

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Types of Fans & Blowers

A i l Fans
Axial
F
Tube
T b axial
i l fans
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

(C
(Canadian
di Bl
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

C t if
Centrifugal
l Blowers
Bl
Gear
Gear-driven
driven impeller
that accelerates air
Single and multi-stage
blowers
Operate at 0.35-0.70
kg/cm2 pressure
Airflow drops
p if system
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
gy efficiency
y opportunities
pp

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Assessment of fans and blowers

F Efficiency
Fan
Effi i
and
d Performance
P 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
efficiency or Best Efficienc
Efficiency
Point (BEP)
Airfoil

Efficiency

Backward

Type of Fan

Peak
Efficiency
Range

Centrifugal fans:

Radial

Tubular

Airfoil, Backward
curved/inclined

79-83

Modified radial

72-79

Radial

69-75

Pressure blower

58-68

Forward curved

60-65

Axial fans:

Forward

Flow rate

Vane axial

78-85

Tube axial

67-72

Propeller

45-50

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(BEE India, 2004)

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2005

Assessment of fans and blowers

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

Ensure that
Fan
F is
i operating
ti
att rated
t d speed
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

M th d l
Methodology
fan
f efficiency
ffi i
Step
p 1: Calculate air/gas
g density
y
t = Temperature of air/gas
at site condition

C = Pitot
Cp
Pit t tube
t b 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

M th d l
Methodology
fan
f efficiency
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
gy efficiency
y opportunities
pp

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Energy Efficiency Opportunities

1 Choose the right fan

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

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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
constraints and system
y
layout
y
Space
Purchase/operating costs and operating life

Systems
Systems approach
approach most important!
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Energy Efficiency Opportunities

1. Choose the Right Fan
Avoid buying oversized fans
Do not operate
p
at Best Efficiency
y Point
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
IIncreased
d system
t
resistance
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 Control the Fan Air flo
5.
flow
a))
b)
c)
d)
e)
f))
g)
h)
i)

Pulley
y change
g
Dampers
Inlet guide vanes
Variable pitch fans
Variable speed drives (VSD)
Multiple
p speed
p
drive
Disc throttle
Operating fans in parallel
Operating fans in series

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Energy Efficiency Opportunities

5 Control the Fan Air flo
5.
flow
a)) Pulley
y change:
g reduce motor/drive
pulley size
Advantages
Permanent speed
decrease
Real energy reduction

Disadvantages
Di d
t

((BEE India, 2004))

Fan must handle capacity change

Only
O l applicable
li bl if V-belt
V b lt system
t
or motor
t
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Energy Efficiency Opportunities

5 Control the Fan Air flo
5.
flow
b)) Dampers:
p
reduce flow and increase
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 Control the Fan Air flo
5.
flow
c)) Inlet guide
g
vanes
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% of full air flow
Cost effective at 80-100%

Disadvantage
Less efficient at <80% of full air flow
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Energy Efficiency Opportunities

5 Control the Fan Air flo
5.
flow
d)) Variable p
pitch fans: changes
g angle
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 Control the Fan Air flo
5.
flow
e)) Variable speed
p
drives (VSDs):
(
) reduce
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 Control the Fan Air flo
5.
flow
e)) Variable frequency
q
y drives
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
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Reduced energy losses and costs
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Energy Efficiency Opportunities

5 Control the Fan Air flo
5.
flow
f)) Multiple
p speed
p
drive
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 Control the Fan Air flo
5.
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 Control the Fan Air flo
5.
flow
h)) Operate
p
more fans in parallel
p
(instead
(
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 Control the Fan Air flo
5.
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 Controlling the Fan Air Flow
5.
Flo
Comparing
Fans in
Parallel
and Series

(BEE India, 2004)

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Energy Efficiency Opportunities

5 Controlling the Fan Air Flow
5.
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
This PowerPoint
P
P i t training
t i i session
i was preparedd as partt off
the project Greenhouse Gas Emission Reduction from
Industryy in Asia and the Pacific
f (GERIAP).
(
) While
reasonable efforts have been made to ensure that the
contents of this publication are factually correct and
properly referenced,
referenced UNEP does not accept responsibility for
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