Fans and Blowers

1
 Session Objectives
This session is intended to discuss the following:
• Types and working principle of fans and blowers
• Applications of various fans and blowers
• Pressure rise, flow coefficient and efficiency
• Velocity triangles
• Performance characteristics
• Fan laws

2
 What is a Fan?

Any device that produces a current of air by the movement of

broad surfaces can be called a fan.
Fans fall under the general classification of “turbomachinery”
and have a rotating impeller at least partially encased in a
stationary housing.
Fans are similar in many respects to pumps. Both are
turbomachines that transfer energy to a flowing fluid. It is easy to
distinguish between fans and pumps: pumps handle liquids; fans
handle gasses.
Broadly speaking, the function of a fan is to propel, displace, or
move air or gas.

3
 .

Fans, Blowers and Compressors

Fans, blowers and compressors are differentiated by the method used to
move the air, and by the system pressure they must operate against.
Difference Between Fans, Blower and Compressors
Equipment Specific Ratio Pressure Rise (mmWC)
Fans Up to 1.11 1136
Blowers 1.11 to 1.20 1136 to 2066
Compressors More than
1.20

As per American Society of Mechanical Engineers

(ASME) the specific ratio – the ratio of the
discharge pressure to the suction pressure – is used
for defining the fans and blowers

. 4
 .

Components of Fan/Blower System

Turning Vanes
(typically used on
short radius elbows)

Outlet Diffusers

Provide air for

ventilation and
Heat
industrial Exchanger
processes that
need air flow Baffles

Filter Inlet
Vanes

Motor
Controller

Centrifugal Fan/Blower
Variable Frequency Drive
Belt Drive
Motor

. 5
 .

Parts of a Fan / Blower

1. Impeller
2. Blade
3. Shroud
4. Hub
5. Housing
6. Inlet
7. Outlet
8. Guide Vanes

• Centrifugal housing
include side plate and
scroll sheets.
• Axial housing includes
the outer and inner
cylinder, belt tube

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 .

Fan Types
Fans are classified according to the direction of flow through the
impeller:

Axial Flow: Air flows through the impeller parallel to, and at a
constant distance from the axis. The pressure rise is provided by the
direct action of the blades
Centrifugal or radial flow: Air enters parallel to the axis of the fan
and turns through 900 and is discharged radially through the blades. The
blade force is tangential causing the air to spin with the blades and the
main pressure is attributed to this centrifugal force
Mixed flow: Air enters parallel to the axis of the fan and turns through
an angle which may range from 300 to 900. The pressure rise is partially
by direct blade action and partially by centrifugal action
Cross Flow: air enters the impeller at one part of the outer periphery
flows inward and exits at another part of the outer periphery.

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 .

Centrifugal Fans
 Rotating impeller increases air velocity
 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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 .

Centrifugal Fan Impeller Types

Backward inclined Open Type
Radial tip Blades Backward inclined
Radial Tip Blades

Airfoil
Blades
with
Higher
Efficiency

Open Type Forward

Backward Backward Curved
inclined inclined Radial Blades Type
radial Tip Blades
blade

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 .

Centrifugal Fans
Forward-curved fans are used
in clean environments and
operate at lower
temperatures. Well suited for
low tip speed and high-
airflow at lower pressures

Paddle blade or
radial fan
Radial fans have high static
pressures (up to 1400 mm
WC) and can handle heavily
contaminated airstreams.
Well suited for high
temperatures and medium
blade tip speeds
Backward curved
Backward-inclined fans are
more efficient than forward-
curved fans. Also known as
"non-overloading" because
Forward curved or
changes in static pressure do
multi-vane radial fan not overload the motor

. ©©
M.M
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Raaim
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 .

Applications of Centrifugal Fans

• Augmenting Air Fan
• Scanner Air Fan
• BoosterAir Fan
• BurnerAir Fan
• Degasser Blower
• Combustion Air Fan
• Oil Vapour Exhaust
Fan
• Purge Gas Blowers
• Inline Fans
• Supply Air Fan
• Exhaust Air Fan
• Ventilation Fan
• Radial Blowers
• Turbo Blowers
(Centrifugal)
• FD Fan
• ID Fan
• In-series Blowers
• IgniterAir Fan
• Seal Air Fan
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 .

Centrifugal Fans
Type Characteristics Typical Applications
High pressure, medium flow, Various industrial applications,
Radial efficiency close to tube axial fans, suitable for dust laden, moist
power increases continuously air/gases

Medium pressure, high flow, dip Low pressure HVAC, packaged

Forward curved in pressure curve, efficiency
units, suitable for clean and
blades higher than radial fans, power rises
dust laden air/gases
continuously

High pressure, high flow, high

HVAC, vaious industrial
Backward efficiency, power reduces as flow
applications forced draft fans
curved blades increases beyond the point of
etc
highest efficiency
Same as backward curve type, Same as backward curved, but
Airfoil type
highest efficiency for clean air application

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 .

Fan/Blower Blade Types

 Impeller blades are manufactured either laminar (flat, constant
thickness) or aerofoil shape and generally hollow
 Aerofoil blades have greater efficiencies (up to 90%) compared
to constant thickness blades, with the advantages of efficiency
spread over the characteristic and lower noise generation
 However with careful attention to design of blade curvature,
inlet eye detail and impeller shrouding, comparable efficiencies
can be achieved with constant thickness blades
 Aerofoil blades are freely used particularly when blade stresses
are high and extra stiffening is required

constant thickness blades Aerofoil blades

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 .

Axial Flow Fans

Less efficient, large airflow
and low speeds

Vane axial fan

Tube axial fan

Propeller fan

Higher speeds than

propeller fans, high- Pressures upto 500
pressures 250 – 400 mm mmWC and are highly
WC and efficiency up to energy-efficient
65%.

. . 14
 .

Axial Flow Fans – Applications

• Ventilation Fan
• Airscrew Fan
• Wall mounted Supply Fan
• Wall mounted Exhaust Fan
• Bifurcated Fan
• Roof Exhaust Fan
• Inline Fan
• Spark proof Fans
• Inline Fans
• Fresh Air Unit
• Ventilation Unit
• Air washer Unit
• Smoke Exhaust Unit
• Toilet Exhaust Fans
• CPU Fans

. . 15
 .

Propeller Fan
Propeller fan also known as panel fan is commonly used to exhaust hot or
contaminated air or corrosive gases from factories, welding shops, foundries,
furnace rooms, laboratories, laundries, stores or residential attics or windows

24”propeller fan with belt drive

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 .

Axial Fans
Type Characteristics Typical Applications
low pressure, high flow, low Air circulation,
efficiency, peak efficiency ventilation,
Propeller close to point of free air exhaust
delivery (zero static pressure)
Tube Axial Medium pressure, high flow, HVAC,
higher efficiency than drying ovens,
propeller type, dip in pressure exhaust systems
flow curve before peak
pressure point
Vane Axial High pressure, medium flow, High pressure
dip in pressure-flow curve, applications including
use of guide vanes improves HVAC systems
efficiency exhausts
. . 17
 .

Mixed Flow Fan

Mixed flow fan with barrel shaped spun housing for small
diameters of inlet and outlet ducts. Direct drive, the fan wheel
has a conical back plate. Outlet guide vanes prevent excessive
air spin at the small outlet diameter.

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 .

Axial-Centrifugal Fan Types

Single inlet single
width impeller

Double inlet
double width
impeller Single inlet single width
fan wheel with six radial
blades welded to a back
plate

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Belt Drive versus Direct Drive
Belt drive
•Flexibility in operating
speeds
•The air stream passing over
the motor cools it
•Large size fans can be
operated at low speeds while
motor is operated at higher
speeds resulting in
economical operation
A 30 increase in blade angle will
result in 10-15% increase in flow
. .
.
Direct drive
•Lower number of components
resulting in lower costs
•Requires no regular checkups for
adjustment of belt
•Higher fan efficiency since no
slippage due to belt drive
•Results in more flow since motor
does not obstruct flow
•Performance flexibility of belt
drive can be obtained by adjustable
pitch blades and increasing number
of blades
20
 .

Blower Types
 Centrifugal blowers typically operate against pressures of 0.35 to 0.70
kg/cm2, but can achieve much higher pressures
 Also used to produce negative pressures for industrial vacuum systems
 Major types are; centrifugal blower and positive-displacement blower
 The impeller is typically gear-driven and rotates as fast as 15,000 rpm
 Efficiency drops with multi-staging due to the path taken from stage to stage
 One characteristic is that airflow tends to drop drastically as system pressure
increases
 Positive-displacement blowers have rotors, which "trap " air and push it
through housing.
 Positive-displacement blowers provide a constant volume of air even if the
system pressure varies. They are especially suitable for applications prone to
clogging,
 They turn much slower than centrifugal blowers (e.g. 3,600 rpm), and are
often belt driven to facilitate speed changes.

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 .

Fan Laws
Fan data for geometrically similar fans can be collapsed onto a
single curve using dimensionless numbers
Q = volumetric flow rate
D = fan diameter
N = fan rotational speed
W = fan power
 = fluid density
P = fan pressure rise

N  10% Q  10% or N  10% Ps  19% N  10% HP  27% or

N  10% Q  10% or N  10% Ps 21% N  10% HP 33%

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 .

Fan Laws
Law 1 – relates to effect of changing size, speed, or
density on volume flow, pressure, and power level

Law 2 – relates to effect of changing size, pressure,

or density on volume flow rate, speed, and power

Subscript 1 and 2 denotes the variable for the fan

under consideration and for the tested fan respectively

For all fan laws (t)1 = (t)2 and (point of rating)1 =

(point of rating)2

Law 3 – shows effect of changing size, volume P equals either pt or ps

flow, or density on speed, pressure, and power

. . 23
 .

Fan Laws
Operating Point: Fan curve and system curve intersect

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

Flow Q1 at pressure
P1 and fan speed
N1

Move to flow Q2 by
reducing fan speed

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 .

Efficiency or BEP
Peak
Type of Fan Efficiency
Range
Centrifugal fans:
Airfoil, 79-83
Backward
curved/inclined
Modified radial 72-79
Radial 69-75
Pressure blower 58-68
Forward curved 60-65
Deviation from BEP results in inefficiency Axial fans:
and energy loss Vane axial 78-85
Increased system resistance reduces fan
efficiency Tube axial 67-72
Propeller 45-50
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 .

Fan Efficiency Calculation

• Before calculating fan efficiency measure operating parameters
 Air velocity, pressure head, air stream temp, electrical motor
input, etc.,
• Ensure that Is efficiency
 Fan is operating at rated speed the only
 Operations are at stable condition criteria for fan
• Methodology selection?
1. Calculate air/gas density
2. Measure air velocity and calculate average
3. Calculate the volumetric flow in the duct
4. Measure the power drive of the motor
5. Calculate fan efficiency (Mechanical and Static efficiency)

. . 26
 .

Performance Characteristics

The theoretical pressure-quantity curve of an ideal fan (no

losses) is a straight line between zero volume and zero pressure

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 .

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

Increases with
square of air volume
• Long narrow ducts,
many bends: more
resistance
• Large ducts, few bends:
less resistance

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 .

System Resistance Curve

. . 29
 .

Fan Characteristic Curve

The fan curve is a graphical representation of a number of inter-related
parameters under a specific set of conditions

Typically a curve
will be developed
for a given set of
conditions usually
including: fan
volume, system
static pressure, fan
speed, efficiency
and BHP required
to drive the fan
under the stated
conditions

. . 30
 .

Impeller Types and Performance

Non
overloading
Efficiency power
limited to 60% characteristic.
to 70% at most. (i.e. power
Steeply rising input does not
power peak at either
characteristic free flow or
no flow)

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 .

Centrifugal Fans
Schematic sketch of a typical centrifugal fan wheel with ten backward-curved airfoil blades

d1 = blade inner diameter  = blade angle

d2 = blade outer diameter U = blade velocity
b = blade width W = relative air velocity
l = blade length V = Absolute air velocity

1 is usually
10o to 30o

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 .

Scroll Casing

Schematic sketch of typical scroll housing assembly for

a 36.5 inch centrifugal fan with airfoil, backward curved
blades for general ventilation

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 .

Airflow versus Blade Width

Airflow versus blade width for a centrifugal fan with airfoil blades

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 .

Blade Angles and Diameter Ratios

Tip angles 2, as a function of the inlet blade angle 1 and of the
diameter ratio d1/d2 for straight blades
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 .

Control of Fan/Blower Airflow

 Speed change by pulley change

 Dampers
 Inlet guide vanes
 Variable pitch fans Flow control Pulley Driven
dampers
 Variable speed drives (VSD)
 Multiple speed drive
 Disc throttle
 Operating fans in parallel
 Operating fans in series

Inlet vane dampers Inlet guide vanes

. . 36
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Control of Fan/Blower Airflow

• Pulley change: reduce motor/drive pulley
size Speed Change
Permanent speed decrease
Real energy reduction
Fan must handle capacity change
Only applicable if V-belt system or motor
• Dampers: reduce flow and increase
upstream pressure
Inexpensive
Easy to install
Limited adjustment
Reduce flow but not energy consumption
Higher operating and maintenance costs Dampers
. . 37
 .

Control of Fan/Blower Airflow

• Inlet guide vanes
 Create swirls in fan direction
 Reduce angle air and fan blades
 Lowering fan load, pressure, air flow
Improve efficiency: reduced load and airflow
Cost effective at 80-100% of full air flow
Less efficient at <80% of full air flow
• Variable pitch fans: changes angle incoming
airflow and blades – Axial fan only Lets look at this
High efficiency at range of operating conditions in detail in
No resonance problems subsequent
slides
No stall problems at different flows
Applicable to axial fans only
Risk of fouling problems
Reduced efficiency at low loads
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 .

Control of Fan/Blower Airflow

• Variable speed drives (VSDs): reduce fan speed and air flow
– Two types; Mechanical VSDs and Electrical VSDs
(including VFDs)
Most improved and efficient speed control
Speed adjustments over continuous range
high costs
• Variable frequency drives (Change motor’s rotational speed
by adjusting electrical frequency of power)
Effective and easy flow control
Improved efficiency over wide operating range
Can be retrofitted to existing motors
Compactness
No fouling problems
Reduced energy losses and costs
. ©©
M.M
S..R
S.am
Raaim
ahaSiachhoS
olcohfoA
odl voafnA
ceddvSatn
udcieeds, SBtaundgiaelsore 3399
 .

Control of Fan/Blower Airflow

• Multiple speed drive (Changes fan speed from one to other)
Efficient control of flow
Suitable if only 2 speeds required
Need to jump from speed to speed
High investment costs
• Disc throttle (Sliding throttle that changes width of impeller
exposed to air stream)
Simple design
Feasible in some applications only
• Operate fans in series
Lower average duct pressure
red
Less noise
Lower structural / electrical support requi

Not suited for low resistance systems Fans in series

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 .

Control of Fan/Blower Airflow

• Operate more fans in parallel (instead of one large fan)
High efficiencies at varying demand
Less expensive and better performance than one large fan
Risk of downtime avoided
Can be equipped with other flow controls
Only suited for low resistance system
Comparing Fans in
Parallel and Series

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

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Solidity – Axial Flow Fans

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Blade Pitch (angle) Setting

Adjustment using pitch plates Adjustment using pitch markings

• Performance control is achieved by altering speed, adjusting

impeller blade pitch angle or adjusting variable inlet guide vanes
• Performance is enhanced by installation of inlet cone, inlet or outlet
guide vanes, tail fairings, and diffusers
• On-load or off load blade pitch adjustment is possible

. . 43
 .

Blade Pitch (angle) Setting

Adjustment using a protractor Variable pitch blades

Each setting has a different performance

Impellers without markings require the use
characteristic
of a protractor to set the appropriate angle

Some manufacturers specify the blade pitch angle in terms of the “tip chord”. Those
who refurbish fans often incorrectly set these angles as the at the blade root rather
than the tip of the blade. Depending upon the twist of the blade this could be as
much as 30 resulting with the fan performance less than expectations

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 PEMP

Start Up  Single Fan – Variable Speed RMD 2501

 On start up the fan goes

from standstill to full speed
 Will follow path 1,2,3,4 if
equilibrium is reached
instantaneously
 Will follow path 1 ’, 2 ’, 2 ’,
4 if equilibrium is not
established instantaneously
 In any case all points are
on the negative part of the
curve and therefore stable

Single fan - variable speed

. . 45
 .

Start Up  Single Fan – Damper Control

 Dampers set to open when a
predetermined pressure is
reached (i.e no flow until
operating pressure is reached)
 Fan must follow the parabola
over the hump and the fan may
become unstable during this
stage
 It is found by experience that
fans with long lengths of lay-flat
duct reduces excessive power
draw and prevents the fan from
shaking violently Single fan – Damper Control

. . 46
 .

Start Up  Two Fan in Series

 If started simultaneously they will
act in the same manner as a single
fan
 If one fan is started the operating
fan sees a higher resistance
caused by the non-operating fan
 At the start-up of the second fan
the system resistance is lowered
and the first fan comes down the
curve whilst the second fan
moves from a free flow (air from
the first fan) situation until both
fans are at the same speed and
contributing to the combined fan
Two fans in series
curve

. . 47
 .

Start Up  Two Fan in Parallel

 If started simultaneously they will act
in the same manner as a single fan
 When one fan is started it will run up
and settle on the system
 The second fan (no flow) will start
and when acceleration is sufficient it
will move to the right at the same
time that the first fan is moves up its
curve until both fans are at the same
speed and contributing to the
combined fan curve
 Note that the second fan must move
over the hump and could cause
serious instability if the curve has a Two fans in parallel
dip as well as a hump

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 .

Merits of Axial and Centrifugal Fans

 Axial fans offer better efficiency over a wider range of duties whereas
the centrifugal fans can have a higher efficiency, albeit over a smaller
range, on a single performance curve.
 The performance of a single speed axial fan can be altered simply by
adjustment to the impeller blade pitch angle.
 The performance of a single speed centrifugal fan requires the
installation of variable inlet vanes.
 Axial fans are generally considered to be more easily accessible for
maintenance.
 Axial fans generally run faster than centrifugal as a consequence are
much noisier.
 Axial fan impellers are generally manufactured from aluminum in an
effort to keep weight to a minimum. As a consequence the potential for
erosion is greater, particularly if there is water in the shaft.
. . 49
 .

Merits of Axial and Centrifugal Fans

 The light material used in the blades along with the high rotational speed
of axial fans make them prone to erosion, and even in good (dry)
conditions it is reasonably expected that this erosion will have
significantly reduced the fan performance within five years.
 Centrifugal fan impellers are fabricated from plate and are generally
hollow. As a consequence when there is water in the shaft the nose of the
blade is prone to pitting allowing water to enter the hollow section.
Sufficient water in this section will cause the impeller to become
unbalanced, and if allowed to continue it will result in high vibration and
eventual failure of the impeller shaft.
 Centrifugal fans traditionally require the construction of large concrete
foundations for the motor and ductwork. The cost of these foundations
significantly increases the capital cost of the fan.

. . 50
 .

Merits of Single and Multiple Fans

 Single fan installations are generally less expensive than multiple fan
installations.
 Multiple fan installations have the advantage of airflow redundancy,
i.e. a percentage of airflow will always be available whilst a fan is off
line for maintenance or component change out.
 Single fan options do not provide any capacity for redundancy
airflow. The purchase of spares (motor, impeller, shafts, bearings,
blades etc) is good management and should be included as upfront
capital expenditure.

. . 51
 .

Session Summary

• Various types of axial and centrifugal fans and blowers have

been described.
• Fans and blowers are low speed machines with low pressure
rise, and the flow through them is treated as incompressible.
• Fan / blower characteristics have been discussed.
• Fan starting characteristics have been explained.
• Fans and blowers follow affinity laws which help in scaling of
the machines.

. . 52