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1. INTRODUCTION
This section describes the main features of fans and blowers.
1.1 What are fans and blowers?
Most manufacturing plants use fans and blowers for ventilation and for industrial processes
that need an air flow. Fan systems are essential to keep manufacturing processes working,
and consist of a fan, an electric motor, a drive system, ducts or piping, flow control devices,
and air conditioning equipment (filters, cooling coils, heat exchangers, etc.). An example
system is illustrated in Figure 1. The US Department of Energy estimates that 15 percent of
electricity in the US manufacturing industry is used by motors. Similarly, in the commercial
sector, electricity needed to operate fan motors composes a large portion of the energy costs
for space conditioning (US DOE, 1989).
Fans, blowers and compressors are differentiated by the method used to move the air, and by
the system pressure they must operate against. The American Society of Mechanical
Engineers (ASME) uses the specific ratio, which is the ratio of the discharge pressure over
the suction pressure, to define fans, blowers and compressors (see Table 1).
Table 1: Difference between Fans, Blowers and Compressors (Ganasean)
Equipment
Specific Ratio
Pressure rise (mmWg)
Fans
up to 1.11
1136
Blowers
1.11 to 1.20
1136 2066
Compressors
more than 1.20
-
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Figure 2. System Curve of a Fan and Effect of System Resistance (US DOE, 1989)
1.2.2 Fan characteristics
Fan characteristics can be represented in form of fan curve(s). The fan curve is a performance
curve for the particular fan under a specific set of conditions. The fan curve is a graphical
representation of a number of inter-related parameters. Typically a curve will be developed
for a given set of conditions usually including: fan volume, system static pressure, fan speed,
and brake horsepower required to drive the fan under the stated conditions. Some fan curves
will also include an efficiency curve so that a system designer will know where on that curve
the fan will be operating under the chosen conditions (see Figure 3). Of the many curves
shown in the figure, the curve static pressure (SP) versus flow is especially important.
The intersection of the system curve and the static pressure curve defines the operating point.
When the system resistance changes, the operating point also changes. Once the operating
point is fixed, the power required can be determined by following a vertical line that passes
through the operating point to an intersection with the power (BHP) curve. A horizontal line
drawn through the intersection with the power curve will lead to the required power on the
right vertical axis. In the depicted curves, the fan efficiency curve is also presented.
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Forward curved
fans, with
forward curved
blades (Figure 8)
Backward
inclined fan,
with blades that
tilt away from
the direction of
rotation: flat,
curved, and
airfoil (Figure 9)
Advantages
Disadvantages
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Fig
ure
7.
Ra
dia
l
Bla
de
Centrifugal Fan (Canadian Blower)
Figure 6. Centrifugal Fan
(FanAir Company)
Tube-axial fan,
essentially a
propeller fan
Advantages
Generate high airflow rates at low pressures
Not combined with extensive ductwork (because the
generate little pressure)
Inexpensive because of their simple construction
Achieve maximum efficiency, near-free delivery, and are
often used in rooftop ventilation applications
Can generate flow in reverse direction, which is helpful in
ventilation applications
Higher pressures and better operating efficiencies than
propeller fans
Suited for medium-pressure, high airflow rate
Disadvantages
Relative low
energy
efficiency
Comparatively
noisy
Relatively
expensive
Moderate
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Vane-axial fan
(Figure 13)
Advantages
applications, e.g. ducted HVAC installations
Can quickly accelerate to rated speed (because of their
low rotating mass) and generate flow in reverse direction,
which is useful in many ventilation applications
Create sufficient pressure to overcome duct losses and are
relatively space efficient, which is useful for exhaust
applications
Suited for medium- to high-pressure applications (up to
500 mmWC), such as induced draft service for a boiler
exhaust
Can quickly accelerate to rated speech (because of their
low rotating mass) and generate flow in reverse
directions, which is useful in many ventilation
applications
Suited for direct connection to motor shafts
Most energy efficient (up to 85% if equipped with airfoil
fans and small clearances)
Disadvantages
airflow noise
Relatively low
energy
efficiency
(65%)
Relatively
expensive
compared to
propeller fans
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Section 2.2 is based on Energy Efficiency Guide Book (2004), Chapter 5, p 93-112, with permission from the Bureau of
Energy Efficiency, Government of India
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Fan performance is typically estimated by using a graph that shows the different pressures
developed by the fan and the corresponding required power. The manufacturers normally
provide these fan performance curves. Understanding this relationship is essential to
designing, sourcing, and operating a fan system and is the key to optimum fan selection.
Section 3 is based on Energy Efficiency Guide Book (2004), Chapter 5, p 93-112, with permission from the Bureau of
Energy Efficiency, Government of India
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Where:
Cp = Pitot tube constant, 0.85 (or) as given by the manufacturer
p = Average differential pressure measured by pitot tube by taking measurement
at number of points over the entire cross section of the duct.
= Density of air or gas at test condition
Step 3: calculate the volumetric flow
The third step is to calculate the volumetric flow as follows:
Take the duct diameter (or the circumference from which the diameter can be estimated).
Calculate the volume of air/gas in the duct by following relation
b) Static efficiency, which is the same except that the outlet velocity pressure is not added to
the fan static pressure:
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Non-availability of fan specification data: Fan specification data (see Worksheet 1) are
essential to assess the fan performance. Most of the industries do not keep these data
systematically or have none of these data available at all. In these cases, the percentage of
fan loading with respect to flow or pressure can not be estimated satisfactorily. Fan
specification data should be collected from the original equipment manufacturer (OEM)
and kept on record.
Difficulty in velocity measurement: Actual velocity measurement becomes a difficult
task in fan performance assessment. In most cases the location of duct makes it difficult
to take measurements and in other cases it becomes impossible to traverse the duct in
both directions. If this is the case, then the velocity pressure can be measured in the
center of the duct and corrected by multiplying it with a factor 0.9.
Improper calibration of the pitot tube, manometer, anemometer & measuring
instruments: All instruments and other power measuring instruments should be calibrated
correctly to avoid an incorrect assessment of fans and blowers. Assessments should not
be carried out by applying correction factors to compensate for this.
Variation of process parameters during tests: If there is a large variation of process
parameters measured during test periods, then the performance assessment becomes
unreliable.
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Figure 17. Relative Power Consumption among Flow Control Options (US DOE, 1989)
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Advantages
Permanent speed decrease
Real energy reduction (see Figure 18:
a 2 inch reduction in pulley results in
12 kW savings)
Inexpensive
Easy to install
Disadvantages
Fan must be able to
handle capacity change
Fan must be driven by
V-belt system or motor
Provide a limited
amount of adjustment
Reduce the flow but not
the energy consumption
Higher operating and
maintenance costs
Less efficient at airflows
lower than 80% of full
flow
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Advantages
Efficient control of flow
Suitable if only two fixed speeds are
required
Simple design
Disadvantages
Need to jump from
speed to speed
Investment costs can be
a barrier
Feasible in some
applications only
Figure 19. Fans Operating in Series and in Parallel (BEE India, 2004)
Energy Efficiency Guide for Industry in Aisa www.energyefficiencyasia.org
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5. OPTION CHECKLIST
This section lists the most important energy efficiency options.
Use smooth, well-rounded air inlet cones for fan air intake
Avoid poor flow distribution at the fan inlet
Minimize fan inlet and outlet obstructions
Clean screens, filters and fan blades regularly
Minimize fan speed
Use low slip or flat belts for power transmission
Check belt tension regularly
Eliminate variable pitch pulleys
Use variable speed drives for large variable fan loads
Use energy-efficient motors for continuous or near continuous operation
Eliminate leaks in duct works
Minimize bends in duct works
Turn fans and blowers off when not needed
Reduce the fan speed by pulley diameter modifications incase of oversized motors
Adopt inlet guide vanes in place of discharge damper control
Change metallic / Glass reinforced plastic (GRP) impeller by more energy efficient
hollow FRP impeller with aerofoil design
Try to operate the fan near its best operating point (BEP)
Reduce transmission losses by using energy efficient flat belts or cogged raw-edged Vbelts instead of conventional V-belt systems
Minimizing system resistance and pressure drops by improving the duct system
Ensure proper alignment between drive and driven system
Ensure proper power supply quality to the motor drive
Regularly check for vibration trend to predict any incipient failures like bearing damage,
misalignments, unbalance, foundation looseness etc.
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6. WORKSHEETS
This section includes following worksheets:
Fans and Blowers Specification Data
Fans and Blowers Efficiency Calculation
Worksheet #1: FANS AND BLOWERS SPECIFICATION DATA
No.
Parameter
1
2
Make
Type
(Axial/Centrifugal)
Discharge Flow
Head Developed
Fluid Handlled
Density of Fluid
Dust Concentration
Temperature of Fluid
Flow Control Type
Flow Control Range
Fan Input Power
Fan Speed
Fan Rated Efficiency
Specific Power
Consumption
Fan Motor
Rated Power
Full Load Current
Rated Speed
Supply Voltage
Rated Efficiency
Rated Power Factor
Supply Frequency
Bearing Type
Fan (Driving End)
Fan (Non-Driving End)
Motor (Driving End)
Motor (Non-Driving
End)
Lubricant Grade
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Units
Fan/Blower number
1
2
m3/hr
mmWC
kg/m3
kg/m3
0
C
%
kW
RPM
%
kW/(m3/hr)
kW
Amp
RPM
Volts
%
Hz
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Parameter
Units
m3/sec
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
Fan/Blower reference
1
2
3
mmWC
mmWC
mmWC
mmWC
m2
0
C
kg/m3
kW
%
Hz
kW
m/sec
m3/sec
%
kW/(m3/sec)
%
%
%
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7. REFERENCES
The following sources were used to prepare this chapter:
Bureau of Energy Efficiency (BEE), Government of India. Energy Efficiency Guide Book,
chapter 5, p 93-112. 2004
Canadian Blower. Industrial Fans and Blowers,
www.canadianblower.com/blowers/index.html
FanAir Company, product presentation. www.fanair.com/products.pdf
Ganasean, Indian Institute of Technology. Fans, Pumps and Compressors
Northern Industrial Supply Company (NISCO), Products Fans and Blowers, New York
Blowers. www.nisco.net/nyb.html
US Department of Energy (US DOE), Energy Efficiency and Renewable Energy, 1989.
Improving Fan System Performance a sourcebook for industry
www1.eere.energy.gov/industry/bestpractices/pdfs/fan_sourcebook.pdf
Copyright:
Copyright United Nations Environment Programme (year 2006)
This publication may be reproduced in whole or in part and in any form for educational or non-profit purposes without
special permission from the copyright holder, provided acknowledgement of the source is made. UNEP would appreciate
receiving a copy of any publication that uses this publication as a source. No use of this publication may be made for resale
or any other commercial purpose whatsoever without prior permission from the United Nations Environment Programme.
Disclaimer:
This energy equipment module was prepared as part of the project Greenhouse Gas Emission Reduction from Industry in
Asia and the Pacific (GERIAP) by the National Productivity Council, India. While 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 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.
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