Januar y

2 011 1
R&D-F.K

Industrial Fans
01

FANS

GENERAL INFORMATION

The following information will be helpful for the correct selection of the
fans. Fans can be selected by three different methods. In the planning
CONTENT:
stage a quick overview is achieved using the quick selection tables PAGE -SUBJECT
combined with the overview charts in the chapters "Axial Flow Fans" and 1-FANS –General Information
"Centrifugal Fans". In the following, we would like to give some practical 2-Fan Types
guidelines. 3-4-Performance Characteristics
5-Fan Laws
6-Noise Generation
7-12-Corrections in Fan Performance
Values
13-Energy Efficiency Of Fans
14-Energy Efficient In Fan Operation
15-24-Technical Guidelines
25-27-Application Areas Of
Industrial Centrifugal Fans
2

Centrifugal Fans

FAN TYPES

Fans can be classified by various ways.

The classification used here based on the
following;
Axial fans
Centrifugal fans
Axial-centrifugal fans
Roof type fans
Cross flow blowers
Vortex or regenerative fans
Others

AXIAL FANS CENTRIFUGAL FANS

Axial fans have the following advantages.
(Here vaneaxial fans are taken for
comparison).
Great compactness,
Lower first cost,
Straight line installation resulting
lower installation lost,
Lower sound level at the same tip
speed,
Usage for high and low flow rate,
low pressure ventilation,
Direct-drive and V-belt drive,
Centrifugal fans, on the other hand, have
following advantages,
Wide range of application: high
temperature, corrosive and abrasive
applications,
Better accessibility of motor compared
direct drive axial fans,
Greater assurance for operation in
efficent and quite performance range,
particularly for system with fluctuating
flow resistance,
High structural stability,
Extremely high pressure or flow rate.
3

Performans Characteristics

The function of fans is to transfer the air in the flow rate of V(m 3/s or m3/h) from one place to
another, increasing its pressure to H (mmWC). Forexample the outside air is heated or cooled in an
air handling device and delivered to entire building via fans in high pressure; or in an industrial plant
waste gasses are filtered and exhausted to the atmosphere. In thes processes and in the fan, the
movement of the air can be described in accordance with the general principles of fluid flows.

These principles can be summerized as follow:

Equation Of Continuity: If it is assumed that there is no leakage of air alongside the flow path, the
whole air quantity is constant during the fluid flow and the flow rate can be written as:

Flow Rate (Q)=Velocity (V) x Cross Section Of Flow Conduit (S)

In a fan, the propeller diameter is smaller in the entrence region, and greater in the end region.
Since the flow rate of the air is constant, the velocity is higher in the entrence(where the cross
section of the flow path is lower) and lower in the exit (where the cross section of the flow path is
greater).
4

Performans Characteristics

Pressure Increase

The pressure rise of a centrifugal fan can be expressed as;

Pth u22 u12 v12 v22 c22 c12

2g

P= The first term of the equation is the pressure rise caused by centrifugal force. (mm of water column )(mmWC)
3
γ= specific weight of air (kg/m ),

u= u =πxDxn/60 (m/s)

u1= Velocity of the air at the entrence u1=πxD1xn/60,

u2= Velocity of the air at the exit u2=πxD2xn/60

v and c = velocities (m/s)

2
g= Acceleration of gravity (m/s )

D= Impeller diameter of the fan, (m)

n= Rotation speed of the fan , (rev/min)

NOTE:

Since D2>D1 the exit velocity will be higher. The second term is the pressure rise resulted from flow delay and the
examples are given in the explanation of Bernoulli equation and the equation of continuity (resulting from the fact that
the velocity is higher at entrence and lower at the exit).
The third term is kinetic energy rise.
Here, c is the resultant velocity and the the impeller angle β (β 1 at the entrence, and β2 at the exit), can be calculated
using the velocities of u and v.

REQUIRED POWER
3
For a fan having flow rate of V (m /h) and the pressure of ∆Pth (Pa); the required motor power can be found
from the equation below:

N (kW) = V x ∆Pth /(3600x1000)

Nm (kW) = Vx∆Pth /(3600x 102xηt)

In the equation , ∆Pth is in mm water column .(1 mmWC=9.81 Pa)

Fan pressure is a function of fluid density , rotation speed of the fan and rotor diameter.

(V) : The flow rate of the fan is depended on the rotor diameter and rotation speed.
5

Fan Laws

Fan Laws

AIR FLOW
1). V1=V2x(D1/D2)3x(n1/n2)x1

AIR PRESSURE
2). P1=P2x(D1/D2)2x(n1/n2)2x(ρ1/ρ2)

POWER
3). N1=N2x(D1/D2)5x(n1/n2)3x(ρ1/ρ2)

NOISE
4). L2-L1= 50Log10(D2/D1)+50 Log10(n2/n1)

NOTE: Above equations are valid for incompressible flow.

Where;
D= Impeller’s diameter (m)
n = Rotation speed (rpm),

ρ =Air density (kg/m3),

L= Noise level (dBA);

Suscrit1 and 2 denotes the condition 1 and 2, respectively.

6

Noise Generation

Noise energy generated by the fan rotation is very much dependent on the diameter and the rotational speed
of the fan, typically proportional to the fifth or sixth power of the linear velocity at the type of the fan blades.

The other parameters influencing the noise are construction characteristics, friction, arrangement of flow
paths.

In addition, selected bearing type, and lubrication methods also have remarkable influences on the fan noise.

Generally a large diameter fan at low rotational speed produces low frequency and comparatively low noise
level.

The same volume flow rate can be achieved by increasing the rotational speed and reducing the diameter. In
this case the frequency and the level of the noise are higher but the higher frequency noise can be more
effectively attenuated by lining the duct with sound absorbing materials. In general the SWL of fans varies
greatly with types, sizes, and speeds. It should be chosen carefully to ensure low noise levels.
The fan noise can be calculated using frequency which, in itself, is a function of rotation speed and number of
blades. The frequency can be expressed as;

BF (Hz) =n (d / d) x nblade (number of blades) / 60.

The frequency is given in the tables in standardized form as 63, 125, 250, 500, 1000, 2000, 4000, 8000 Hz. Considering
the rotation speeds and the number of blades frequently seen in the fans, it can be stated that the frequency of fans
varies between 100~500 Hz. During the calculation processes, the nearest values from the tables can be used. The
approximate noise level of the fan can be formulated as;
[Lfan (dBA)],

Lfan = Kw + 10 log10 ( V / V1) + 20 log10 ( ∆Pt / P1 ) + C

Where;
Kw = Specific Sound Level Of The Fan
V = Fan Output ( Flow Rate) ( L / s),
V1 = Correction Factor For The Flow Rate = 0.472 L/s
∆Pt = Total Fan Pressure (Pa),
P1 = Pressure Correction Factor, (249 P)
C = Correction factor for the deviation from the most efficient operation region.

Example:

The main characteristics of a fan are as follow:

3
Flow rate=50000 m /h (=13.889 L/S),
Pressure: 200 mmWaterColumn (=2000 Pa)
Rotation speed= 1000 rpm
Number of blades= 10
Find the approximate noise level .
Frequency BF =1000x10/60=166
From the number 6-3.1 reference table kW=47 dBA is read out. Forexample from the same reference table C=6 dBA can
be extracted. Then the approximate noise level of the fan can be calculated as;
Lfan= 47 + 10log10 (13889/0.472) + 20log10 (20007249) + 6 = 47 + 44.7 + 18.0 + 6 = 116 dBA
7

Corrections in Fan Performance Values

The Air Density Depending On The

Altitude
The Air Density On The Altitude
Altitude Atmospheric Atmospheric Air Density
3
(m) Temperature (°C) Pressure (Pa) (kg/m )
0 15 101325 1.205
300 13 97740 1.169
600 11 94218 1.135
900 9,10 90797 1.101
1200 7,10 87512 1.069
1500 5,60 84295 1.037
1800 3,10 81213 1.006
2100 1,10 78820 0.975
2400 0,8 75252 0.946
2700 -2,8 72407 0.918
3000 -4,7 69698 0.889
3300 -6,7 67023 0.861
3600 -8,8 64449 0.834
3900 -10,8 61943 0.807
4200 -12,7 59504 0.782
4500 -14,7 57167 0.757
6000 -24,6 46567 0.640
7500 -34,5 37592 0.539

NOTE:
Fan performance curves are produced for the standard atmospheric conditions which
are the atmospheric pressure (1 Bar) in the sea-level and 15°C temperature.
The air densitiy in these conditions is taken as ρ=1.205 kg/m3 (reference density).
However, the fans are frequently operated in different conditions deviating reference
conditions.
Forexample high altitude places, in sea-level regions but having high temperatures, or
both in high altitudes and having high temperature.
To operate the fan in these conditions, density corrections (altitude an temperature)
are required in according to the Fan Laws.
To do this, the equation for ideal gasses (PV=mRT) can be used.
Arranging this equation for the density; it is obtained the formula expressed below;
m/V=ρ=P/(RT)
8

Corrections in Fan Performance Values

ALTITUDE CORRECTION

The interpolation can be made for the intermediate values in the table.

Example:
In a place having an altitude of 1800 m (Patm=81213 Pa)
The air density will be;
ρ=81213/(287x276.1)
= 1.021 kg/m3

TEMPERATURE CORRECTION

Example:
The air density in sea-level and 15ºC is
Patm =101330, R= 287, T= (150+273) ρ= 101330/(287x423) = 0.834 kg/m3.
The correction factor is then, calculated as

actual
0.834 /1.205 0.692
s tan dard

ALTITUDE AND TEMPERATURE CORRECTION

Example: The density of the air in 1800 m of altitude and 15ºC is;
Patm=101330, R=287, T=150+273 ρ=81213/(287x423=0.669 kg/m3,
And then, the correction factor is;
actual 0.669
0.55
s tan dard 1.205

NOTE: The correction factors calculated above will be used below as examples in fan laws and fan selection charts.
9
Corrections in Fan Performance Values

DENSITY CORRECTION

Example: From the fan requirement below are stated:

Flow rate =50.000 m3/h
Pressure= 200 mm Water Column
Wit the asumption of no change in impeller’s diameter and rotation speed(rpm) the use
of the charts in relation to the density will be as follow;
(The power in the operating conditions is:
Nm=50.000x200/(3600x102x0.8)=34 kW .

NOTE: The constatnt 0.8 denotes the approximate overall efficiency)

1) Operation in standart conditions: For this case, since

actual
1.00
s tan dard

There will be no correction. (density correction factor for flow rate is 1.00 in according
to the fan laws)

2) Sea-level and 150°C operation: Here the correction factor is;

actual
0.692
s tan dard

The pressure in standard conditions is; P=200/0.692=289 mm Water Column,

And the power is; N=50.000x289/(3600x102x0.8)= 49 kW

3) Operation in 1800 m altitude and 150°C. For this case, the correction factor will be;
actual
0.555
s tan dard

And the pressure in standard conditions is P=200/0.55=360 mm Water Column ,

This, the power is Nm=50.000x360/(3600x102x0.8)= 61 kW
10

Corrections in Fan Performance Values

THE ROLE OF ROTATION SPEED

Let the fan outlined above runs in 1000 rpm.

Let the problem is to inrease the pressure in a level of 230 mmwater, changing the V-
belt drive. (it has been assumed that the impeller’s dameter and operating conditions
don’t change)

In this case, the rotation speed can be defined using the pressure relationship;
230=200x(n2/1000)2 → n2/n1= (230/200)1/2 = 1.07 → n2=1.07x1000=1070 rpm

Thus, the flow rate is;

V2=V1x(n2/n1)= 50.000x1.07=53.500 m3/h

And the motor power will be;

Nm2=34x(1.07)3 = 42 kW obtained.

Let’s assume that this fan has a noise level of L1=100 dBA ,in 1000 rpm.

The noise level for the new situation will be;

L2-L1= (50 log10(1.07)=1.47 → L2=100+1.47=101.47 dBA ( Here, it is assumed that the

impeller’s diameter and other paramaters don’t change).

11

Corrections in Fan Performance Values

NOTE:

Note 1 :
Let’s assume that this fan has cold start up conditions although it will operate normally in high
temperatures. Then, the easiest way is to select a over sized motor. (During the running, it can be
thought that the current drawn by the motor can be reduced by the devices such as variable
blade damper). However in this case, there will be some other in conveniencies that increase the
first cost remarkably, such as high current draw during start-up, inefficient operation in normal
running conditions (unnecessary oversized motor, a larger shaft for an oversized motor, larger
bearings, and excessive number of belts etc). Instead of this, selecting the motor for the
operating conditions (34 kW, in the above example) and using a frequency inverter will probably
be more convenient option. In case of variable flow rate in the operation, a frequency converter
can provide a substantial energy saving when it is used together with an automotic control
system (It is never overlooked that a frequency inverter has also a cost, and it is recommended
that an analysis should be carried out to define which option is more profitable)

Note 2 :

As in the fan laws, the volumetric flow rate of a fan is not depended on the air density. However,
when it is given in terms of the mass flow rate, in conversion of this to the volumetric flow rate,
the density in the operating conditions should be used. The mass flow rate is calculated as
m=ρxV. If the mass flow rate was given( e.g 60000 kg/h), instead of volumetric flow rate, then
the volumetric volumes would necessarily be calculated using densities for each of theseperate
situations and then, the other calculations( power etc) would have to be carried out. In the
above cases the volumetric flowrates would be;
V=60.000/1.205=49.792 m3/h, (for the case 1)
V=60.000/0.834=71.942 m3/h, (for the case 2)
V=60.000/0.664=90.361 m3/h (for the case 3)
When entering the table and charts prepared in standard conditions, these values should be
based on.
12

Characteristic Curves For The System

Characteristic Curves For The System

The fans are not devices operating stand alone. They operate as a part of a ductwork or a process.
Forexample a fan operating for the purpose of air conditioning of a building, has to overcome the
pressure losses and bring the air to the place intended.

This is a similar situation as with the filtration system of a factory’s flue gasses. (The fan has to
overcome the pressure losses in the ductwork, exchangers and other equipments, if any).

Overlapping the fan and system characteristic curves the operation point of the fan is established.

More to the point, the dynamic behaviour and suitable control strategies that will be implemented
on the system in according to the operating mode of the system, can also been studied overlapping
them on these curves.

Forexample operating of the fan in the efficient region of the curve can be studied for both
operating modes of constant (e.g. a stairway pressurizing fan) and variable(e.g. a VAV box) flow
rates; contamination levels of the filters etc, all can be investigated on these curves. Various
examples are given in proceeding sections .

The performance curves of axial fans have a more or less pronounced is stability range, because of
its shape often called saddle.

A small increase of the flow resistance coeffcient will cause a considerable decrease of the flow
combined with a simultaneous decrease of the fan.

The working point of a fan should if possible, be placed in its normal working range, where it has
the highest efficiency.
13

Energy Efficiency Of Fans

Energy Efficiency Of Fans

Most of the economical, political and social problems is caused by the constraints in the resources
and the high levels of energy prices.

In addition, the fuel such as fuel-oil, natural gas and coal leads to atmospheric contamination and
global warming.

Because of the global warming, the lakes loose thier water and global drought is turn in serious day
by day. Climate changes cause glacier melting.

For this reasons, the fans should be selected as, economical, environmentally friendly, less energy
consuming types.

If it is assumed that the life span of a fan is 40 000 working hours, the energy consumed by the fan
within the life span of it, is ten times higher than the initial cost of the fan.

So, it is very improtant to increase the energy efficiency for such systems.

Despite that the initial cost increases, this has to be done. The following, is the briefed information
on this issue.

Energy Efficiency Considerations In Selecting Fans

The main target here, is to increase the efficiency of fans and rendered these devices less energy
consuming.
To do these, correct fan selection procedure and enhencing fan manufacturing technologies are
required. At this connection, more attention should be spent for the issues outlined below:

During the selection of fan, the characteristics of the system inwhich the fan will be used, should has
to be taken into account (suitable flow rate, material selection, and operating modes)

The closed coupled fans should be used as far as possible, (However, the considerations kept in mind
that lower speed electric motors are expensive and the fans operating with V-belt draives has an
extended flexibility in selection.

The electric motors should be selected as high efficiency types (EFF1).

When operating mode allows, frequency inverters should be used in variable air volume systems,
In high temperature applications, variable vanes should be used in the entrence of the fan.
14

Energy Efficient In Fan Operation

Energy Efficient In Fan Operation

The fan design should be made in according to the operating mode (continual or intermittent
working) .

Meeting the purposes of the establishment, automatic control systems should be used in a way
by which the makximum energy enomomics could be provided,

The series and parallel operating alternatives should be taken into consideration in the systems
inwhich very high power fans are used.

Forexample in parallel operation, since the smaller and multiple fans will be operated, low
starting torks, less expensive installation cost, and back up can be considered in variable flow
rates. (And what’s more, a single and high power fan can’t be suitable for the operation with a
frequency inverter. (The cost analiysis should be carred out in these cases)

If the aerofoil blades are not used, the larger diameter fans can easily eenter the unstable
region of the fan curve, ( in contrast to the low current expectations, the electric motor can
draw higher currents).
So, for these cases, multiple and lower pwered fans should be selected, instead of single and
high powered fan.

The multiple fans selected in this way can be operated in series or parallel and with this
applications there will be a back-up possibility for the fans.

Our firm, provides services desired for the clients, on the issues outlined above and other similar
topics.
15
Technical Guidelines

STARTING TIME

The starting time is determined by both the accelerating torque, being equal to the
difference between the motor torque and counter torque of the load and by the inertia of
the impeller.

The motor torque curve may vary considerably from case to case, in spite of existing rules.
For the guaranteed starting torque, for instance, VDE 0530 rules allow a tolerance form -15
% to +25 %.
For motors having the rotor class 16 the starting time is roughly:

0.7 M D 2 .n 2
t
106 N
where n is the fan speed in rpm, Nm the rated motor power in kW, M die mass of the fan in
kg and D the impeller diameter.

For belt drive fans n2 is to be substituted by nvent · nmot the product of the blower and motor
speeds.

If motor with lower starting torque's are employed, the calculated time is to be multiplied by
1,2 for rotor class 13 and 1,9 for class 10,
where ;
n is the number of fan rotations per minute, (rev/min)
N the motor power in kW,
M the impeller mass in kg and
D the impeller diameter in m.
By nature the radial fan is a machine with a high inertia.

This is especially the case for large impellers with low speed, i. e. a motor with a relatively
low power and a small torque.
Therefore a check of starting time is to be made at least for all fans having a lower number
of rotations than the motor and for all motors above 10 kW.
The short relay times generally in use today will in many cases still make it necessary,
however, to use relays for extra heavy start or centrifugal couplings.

Special attention is necessary when single phase motors are employed, as these motors
generally have an extremely unfavourable torque curve.
16

Technical Guidelines

Material And Surface Treatment

Material And Surface Treatment

Fans of our normal design are made from structural steel, free from grease and oil and
surface oxidation, and painted with an environmentally tolerable ground coat. All screws
and nuts are galvanised. Fans of this design can be employed in the temperature range -25
degrees to +115 degrees Celsius.

Outside this range special grease, special surface treatments, cooling discs etc. may be
required. Please inform us about service conditions.

Galvanised design means that casing and impeller are coated by hot dipping, all screws and
nuts are galvanised, the conical inlet generally being made of a corrosion resisting
aluminium alloy which is compatible with zinc or also steel hot dip galvanized. The motor
support is made of structural steel with a high quality ground coat.

On request the fans receive an epoxy finish with or special paints. When fans are made
from aluminium, stainless steel or other special materials, this applies normally only to
impeller, casing and inlet. Motor support and foundations will, if not specified otherwise,
be made of normal mild steel.

Explosion Proof

On request the fans are delivered with a spark protection of naval brass which in
connection with mild steel does not give rise to friction or impact arcs. For high safety
requirements - especially in order to avoid dust explosions, the lining can be made of tin.
Its melting point is so low, that even ignition due to hot surfaces becomes unlikely.

The casing of our explosion prof designs is lined with a spark protection plate of naval
brass,which will cause no sparking due to friction pr impact with the impeller.
The motor will of course comply with pertinent rules.

The Installation

When centrifugal fans are installed, care should be taken to avoid rotational velocity
components in the air entering the fan, as this may highly impair its output. The inlet should
be free from obstructions in order to prevent output reductions. Contracted elastic
connections on the inlet side or sharp bends should be avoided, especially in connection
with cylindrical inlets. The exhaust should be connected to a duct having a length of at least
3D (D = inlet diameter).
17

Technical Guidelines

Performance Tests Of The Fans

Performance Tests Of The Fans

Performance testing of our Industrial fans are performed according to DIN 24163 test
codes. Performance of a fan can be presented in a curve sheet in which all of the folowing
seven variables are plotted against air volume (m3/h). These are;
Static pressure (Pa),
Total pressure (Pa),
Fan power (kW),
Motor input (kW),
Mechanical efficiency (%)
Sound level (dBA).

The size and speed may be noted on top of the graph. These performance curves are
obtained from tests. But some curves may be developed by using fan laws.

The use of smoke and heat exhaust ventilation systems is to create smoke free areas
before a buoyant smoke layer has become widespread. Their value in assisting in the
evacuation of people from construction works, reducing fire damage and financial loss by
preventing smoke logging, facilitating fire fighting, reducing roof temperatures and
retarding the lateral spread of fire is firmly established. In addition above performance test
these fansa re tested according to EN 12 101-3 for heat withstand.

For these benefits to be obtained it is essential that smoke and heat exhaust fans operate
fully and reliably whenever called upon to do so during their installed life. A heat and
smoke exhaust ventilation system is a scheme of safety equipment intended to perform a
positive role in a fire emergency.

The axial fans have been tested already in the following classes:

Class F200 (200°C, 120 minutes)

Class F300 (300°C, 60 minutes)
Class F300, 120 minutes (special class)
Class F400 (400°C, 120 minutes)
Class F500 (500°C, 90 minutes plus 700°C, 90 minutes (special class).
18

Technical Guidelines

Controls Of Fans

In many installations, the fan is selected for maximum output requirements, and means are
provided so that the airflow can be reduced at times, either manually or automatically. A
discussion of the three most common methods to accomplish this follows.

Variable Running Speed

This method can be applied to any type of fan. In this method, each point on the curve follows
the fan laws and moves along a parabolic system characteristic.

Advantages of this methods are as follows;

1) The fan effiency remains unchanged, and there is no risk of any shifting into an unstable
performance range (in the case of an forward curved blade fan).
2) Another advantage is that this method of flow reduction results in the greatest power
ecoonomy, since the brake horsepower of a fan varies asthe third power of the speed.
3) While speed is reduced, the noise level is correspondingly reduced.
4) It may also eliminate need of belt drive system.

The disadvantage of this method is that the first cost may be high, especcially if continuous
variation is desired.

Variable Inlet Vanes

Variable inlet vanes can be used advantageously whenever considerable operation at

less than design capacity is required or cool start up.
In the case gradual closure of the vanes should direct the flow more and more direction
of rotation.
The resultant changes in inlet whirl will reduce both power and head. No reduction of
efficiency at small flow rates in this method.
They can be used with forward curwed (FC), bacward curwed (BC) or radial type (RT) of
Teknik Bilgiler
blades impellers to achive power reduction at reduced flow rate beter than dampers ,
which don’t produce inlet whirl.
Greatest reducion can be obtained BC blades and least with FC blades.
19

Technical Guidelines

Adjustable Inlet Vanes

Not only do adjustable inlet vanes throttle the airflow, they also important to the
entering air stream a spiral motion in the direction of the fan rotation that results
in a reduction in air volume, static pressure and brake horsepower.
As to both power savings this method is is less efficien ovet the variable running
speed, bu it may be cheaper.
Inlet vanes have the additional advantage of acting as air guides and thereby
creating predetermined inlet flow conditions so that disturbances due to inlet are
minimized.
Inlet vanes also can be used for boosting instead of reducing the output of a
centrifugal fan. In this case, they have to produce an inlet spin opposite to the fan
rotation.
However, this will result in a larger motor horsepower and in a reduced fan
efficiency. This method has been used occasionally on large units for mine
ventilation if the running speed cannot be increased or for structural or other
reasons.

DAMPERS

A shutterlike mechanism is mounted on the fan outlet. The effect of such a throttle on the
perssure-volume curve of a fan.
Compared with the other methods, the savings in power consumption are smaller, but this
method is the simplest in construction and the lowest in first cost. It therefore is the one
generally used for flow reduction in small sizes, where the power savings are small at any
rate. For medium and large sizes inlet box damper can be used.
In this metdos;

Pressure drop caused by resistance

Flow drop caused by closing
Effects flow at impeller
If significant spin effect exist, performance will be stable.
This metdos is inefficient compared to other methods.
20

Technical Guidelines

Frequency Converter Control

When an axial fan is controlled by a frequency converter care has to be taken, that the fan
is not for any length of time in one of its resonance frequencies.The vibration amplitude
must be measured on the motor itself and not on the casing.The resonance frequencies
must be blocked, so that they are passed quickly. At low rotational speeds,i.e.at low motor
torque care must be taken,that the fan can not be stopped by a reverse air current,
otherwise the motor may be overheated.

Electric Current Pulse

Especially sudden reversion of the direction of as well as wind milling of axial impellers
may cause large current pulses.This may cause distubances in the electric supply net and
unacceptable wear of the contacts.The high torque pulses may also harm impellers and
electric motors. Before the direction of rotation is reserved a sufficient run-out period
must be allowed for. Wind milling may become so pronounced, that the installation of a
motor brake may be recommendable, which only is released briefly before the motor is
energised.When star-delta start is employed the swiching over must be done too early in
order to large current pulses.
21

Technical Guidelines

Drive Types

Direct drive or belt-pulley drive may be used. Advantages of direct drive are as follows;
There are three ways that can be used for an electric motor to drive a fan:
Belt drive
Direct drive (coupling or direct drive)
Here are the pros and cons of these three methods:

1. Belt drive is prevalent in large sizes, for two reasons:

Flexibility: Any speed can be obtained (while direct drive is confined to a few
speeds, such as 3450,1740, 1150, and 860 rpm). But, if variable speed contyrol
is applied to the electric motor, this adwantage will distinguis.
Expensive low-speed motorsa are avoided.

2. Direct drive is prevalent in small sizes, for four reasons:

Small sizes normally run at higher speeds, so there is no need for expensive low-
speed motors.
Direct drive results in lower cost, since no extra shafts, bearings, bearing
supports, and sheaves are needed.
Direct drive results in better fan efficiencies, since belt losses are avoided.
Direct drive requires minimum maintenance
22

Technical Guidelines

TYPES OF ELECTRIC MOTORS USED TO DRIVE FANS

There are seven types of electic motors used to drive fans. The first two ypes ar efor three-
phase power;the other five types ar efor single – phase power.

1. There-phase squirrel-cage motors are used most of he time whenever the fan requires
1 hp or more. These are the most frequently used fan motors. They have the
advantages of high effiency and low cost. Sometimes they are built as two - speed
motors. The second speed requires a separate winding. It can be 50 or 67 percent of
the top speed.
2. Three-phase wound-rotor motors are sometimes used for adjustable-speed
arrangements, but they are more expensive.
3. Single-phase, split-phase industion motors, with an auxiliary for starting only, are used
for requirements up to 0.35 kW. They are somewhat less efficient but the best we can
get for single-phase power. They have the disadvantage of a high starting cvurrent.

4. Single-phase, permanent-split-capacitor motors are for requirements up to hp. They

use a capacitor instead of the auxiliary winding to star the motor. They are less
efficient but have the advantage of a low starting current. They are often used for
direct drive.

5. Singel-phase, shaded-pole motors are used for small fan sup to hp. They have the
advantage of low cost but the disadvantages of low effiency (about 30 percent) and of
high slip resulting in a high starting current. At full load, they run at 1500 rpm (instead
of 1740 rpm) and at 1000 rpm (instead of 1150 rpm).

6. Single-phase universal motors are used for requirements up to 1 hp, for vacuum
cleaners and other high-speed applications. They have the advantage of high speed
with direct drive but the disadvantages of slightly lower efficiencies and of
commutator brushes that have to be adjusted and replaced at times.

7. Single-phase, inside-out induction motors are different in taht the rotating part is
onthe outside instead of on the inside. These motors occasionally are used in propeller
fans and in axial-centrifugal fans.
23

Technical Guidelines

SOUND AND VIBRATION

Sound
We offer a complete range of silencers and sound reduction equipment. The product
programme is modular and can be adapted to suit most needs. It can be assembled quickly
and to competitive prices.

The follow gives a brief description of our sound reduction / silencers product programme and
the various insertion loss tables and dimension sheets.

Sound reduction can become necessary in order to reduce the airborne noise from or through
ducts. In those case round or rectangular silencers are often used close to noise source. To
minimise airborne noise in enclosed spaces complete or partial sound enclosures are being
used.

Many times a combination is necessary, since unless an enclosure is combined with inlet and
outlet silencers, the sound will travel through the ducts. To reduce structure borne noise
vibration attenuator may be necessary which we also manufacture.

As a standard we offer cylindrical silencers. The "D" denominates the nominal length and the
internal diameter of the silencers (the 2D silencers have length of double the diameter).

Other dimensions are manufactured can also be accommodated. The insertion losses for
other dimensions can be found by interpolating the tables. As a standard different modules of
rectangular attenuators. The width of a module is varied between 250 mm and 400 mm and
the length from 600 to 2400 mm.

The modules are varied by the relationship between the silencer wall and the channel to
achieve a continuos range of insertion loss values. A complete attenuator consist of a number
of the same modules combined to match the desired flow rate and duct size.
24

Technical Guidelines

Vibration
Fans and other rotating machines not only generate airborne noise, but also vibrations which
need to be dampened. Otherwise these vibrations can lead to structural damages due to
material fatigue.

Also increased wear and tear and structural noise is increased. The vibration isolators selected
by Alfer can prevent or at least minimize the effects of these kind of vibrations. They are
selected to fit with the weights and frequencies involved. Just as is the case with silencers to
minimize airborne noise it is recommended to purchase the fan and the vibration isolators
together to minimize co-ordination problems. For smaller fans rubber isolators are used, while
larger fans normally are mounted with totally enclosed metal vibration isolators. For special
applications we offer a range of open, metal spring vibration mounts.

In addition we can supply vibration isolation matts etc. For the elastic mounting of light to
medium heavy devices we offer rubber mounts.

The series consists of 6 types with a maximum load of max. 350 kg/mount and a static
deflection of 11 mm. The unique design with the totaly encapsuled steel mounting plates
provide the mounts with a very high stability and resistance to mechanical damage. For
medium heavy to heavy devices up to 1600 kg per damper.

Using different attachments weights up to 125 kg per spring with a maximum deflection of 25
mm can be isolated.
25

Application Areas Of Industrial Centrifugal Fans

Application Areas Of Industrial Centrifugal Fans

Alfer Engineering Inc. has extensive experience in a multitude of different fan applications. The
main areas to which fans have been supplied in the past 20 years and were experience have
been gained are:

BUILDING MATERIAL AND CEMENT INDUSTRIE

CERAMICS INDUSTRY
CHEMICAL INDUSTRY
COOLING TOWERS
DRYING TECHNOLOGY
DUST COLLECTION TECHNOLOGY
ELECTRICAL INDUSTRY
ENERGY SUPPLY
EXHAUST VENTILATION
FIRE EXHAUST HANDLING
FLUE-GAS CLEANERS
GLASS INDUSTRY
INDUSTRIAL FURNACE CONSTRUCTION
IRON AND STEEL INDUSTRY
MACHINE TOOLS
METALLURGY AND IRON INDUSTRY
MILL CONSTRUCTION
MINING INDUSTRY
PAPER INDUSTRY AND PAPER MACHINES
PNEUMATIC HANDLING TECHNOLOGY
POWER PLANTS
PRINTING SHOPS
ROOF FANS
RUBBER INDUSTRY
SUGAR INDUSTRY
SURFACE TREATMENT TECHNOLOGY
TEXTILE INDUSTRY
THERMAL WASTE RECOVERY
TUNNEL VENTILATION
WIND-TUNNELS
WOOD AND PAPER INDUSTRY.
26

Application Areas Of Industrial Centrifugal Fans

Tunnel Ventilation
Vehicle tunnels and metros require ventilation systems that supply a varying air
flow to meet changing traffic conditions and which can remain in operation during
emergency situations. Alfer tunnel ventilation fans perform this task efficiently,
reliably and quietly and are designed to remain.

Iron and Steel

Some of today's most arduous applications for fans and compressors are to be
found in the iron and steel industry. The need to move large volumes of air or gas,
in many cases at high pressures and high dust burdens, places stringent demands
on the mechanical design of the impeller.

Mining
Whilst the normal operational demands placed on mine fans may not be as severe
as in other heavy industrial processes, the consequences of malfunction are acute.
Alfer axial and centrifugal mine ventilation fans are designed first and foremost
with safety in mind.
We provide fans for all the major ore preparation and steel making applications
that include:

sintered fans
pelletising fans
electric arc furnace fans
other fans including coke oven fans and cooling fans

Our fans are high efficient designs, so reducing power consumption in an energy
intensive industry. Our extensive experience in each application enables us to
provide equipment of great reliability with the consequent reduction of unplanned
outages.

Environmental Industries

As environmental protection becomes increasingly important, Alfer equipment

plays a significant part in many applications that are of direct environmental
benefit on land, air and water.

Glass Industry

Fans for furnaces and for cooling/tempering.

27

Application Areas Of Industrial Centrifugal Fans

Cement

Modern cement making processes impose a wide range of demands on process fans, including high abrasion, excessive
dust build-up, and high temperatures. Alfer supplies the many and varied fan types required by the cement industry,
ranging from large custom built fans for process critical applications.

We supply all the fans for a complete cement plant. These include the process critical fans, mainly centrifugal, for the
pre-heater exhaust, kiln induced draught, raw mill exhaust, final exhaust, cooler forced draught and cement mill exhaust
applications. We also supply all the other associated centrifugal and axial fans. In the UK we supply rotary positive
displacement blowers for cement conveying systems. Our experience in the cement industry goes back many years and
we have supplied equipment in many parts of the world.

As the ever increasing demand for cement puts pressure on plant capacity, our extensive experience in the industry
enables us to assist cement manufacturers to increase output by undertake the revamping and upgrading of fans and
allied plant. From the knowledge we have acquired we offer impeller designs that minimize the build up of dust and so
reduce maintenance while at the same time boosting performance. We have undertaken the upgrading of many fan
installations, enabling plants to increase output and to operate more efficiently and reliably.

Mine Ventilation

Our mining fans include variable and non-variable pitch axial flow main ventilation fans centrifugal surface ventilation
fans with radial vanes for complete air volume control mixed flow underground booster fans – compact and robust
adjustable/fixed pitch axial fans for underground auxiliary ventilation fans.

Whilst the normal operational demands placed on mine fans may not be as severe as in other heavy industrial
processes, the consequences of malfunction are acute.

Alfer axial and centrifugal mine ventilation fans are designed first and foremost with safety in mind. We supply the
largest surface mine ventilation fans as well as smaller fans for underground mine ventilation and booster applications.

Chemical

The demands placed on equipment in the chemical industry are particularly high. Toxic, corrosive and unstable gases are
frequently a part of chemical production processes. Maintaining the purity of gases being handled is a priority in the
pharmaceutical and biological industries.
28

ALFER ENGINEERING CO.

We aim to understand the markets in which our customers need to succed . ALFER products
evolce and new products are developed as a direct result of changes in the market place. These
are the innovaticve products that demonstrate our continuous drive for improvement through
novel and paented features.
The cornerstone of our approach to customer satisfaction is to provide you with prompt service
and first-class product support. That is from initial fan selection at the Project design stage
through installation , commissioning and operational maintenance. Experienced and qualified
ALFER sales and service staff working partnership with you to provide technical advice and
world-wide service support.

ALFER ENGINEERING CO.

General Directorate and Factory
Ankara 1.Organize Sanayi Bölgesi
Oğuz Cad. No:15 06930
Sincan/Ankara-TÜRKİYE
Phone:+90 312 267 01 42(Pbx)
Fax : +90 312 267 19 40
Istanbul Department
Sahrayıcedit Mahallesi Atatürk Caddesi No:3 Onur İşhanı B Blok
Kat:4 Daire:12 Kadıköy/İSTANBUL-TÜRKİYE
Phone:+90 216 355 74 24(Pbx)
Fax : +90 216 355 74 23

www.alfer.com.tr
alfer@alfer.com.tr