Professional Documents
Culture Documents
Surge Stall and Instabilities in Fans FE 600
Surge Stall and Instabilities in Fans FE 600
time.
FLOW
600
Figure 1 shows the flow for an ideal system. Figures
2 through 5 show a variety of conditions for time 400
variation of flow.
200
Figure 1. Ideal Flow
0
1200
0 5 10 15 20 25 30
1000 TIME
800
Figure 3. Stall Condition
FLOW
600 1200
400 1000
200 800
FLOW
0 600
0 5 10 15 20 25 30
TIME 400
and reverse (flow exiting the inlet) many times per 900
500
more difficult to measure the flow, they can create a 300
variety of problems:
100
1. Dramatic increases in noise. -100
2. Increases in vibration.
-300
3. Structural fatigue damage to the fan due to continuous 0 5 10 15 20 25 30
loading and unloading of components. TIME
4. Damage to the ductwork and other system
components.
5. A fan system that does not perform properly due to Figure 5. Bi-Stable Flow Condition
unsteady flow and/or transmitted vibration. 1200
TRIGGERING EVENT
600
agreement in the conclusions as to what the exact
causes are. From their research we can learn the 400
used and misused. The result is that there are few TIME
authoritative reference materials to use as diagnostic There is a time-varying nature for the flow of a fan
guides. We will discuss some of the more common in stall. However, this is normally not the major cause
terms and issues. of concern. The increased noise being generated can be
a problem, but this too can often be dealt with. The
Stall major concern for a fan operating in stall is the potential
for mechanical damage. Those who have had a “bumpy”
Elongated objects (such as fan blades) when passing
airplane ride have a feel for how severe aerodynamic
through the airstream will deflect the air. If we change
shock impacts can be.
the orientation of the object relative to the flow direction,
A fan continuously operating in stall can sustain
we can increase or decrease the amount that the air is
structural metal fatigue. This is especially true for axial
deflected. If we progressively increase the attack angle
flow fans having long slender blades, or blades
of the fan blade, it will increase the amount of deflection.
fabricated from sheet metal. Centrifugal fans are less
It is this change of direction (and relative velocities) that
prone to damage. Centrifugal fans designed for relatively
allows the fan to generate pressure. If the attack angle
high pressures but operating at very low pressures (less
becomes too severe, the air will no longer follow the
than 1" SP) have been known to operate continuously
blade surface in a uniform manner. The amount of
in stall for many years without damage.
deflection and the pressure being generated stops
There is another downside to having a fan operate in
increasing and normally will fall off. This is called the
stall. It means the efficiency of the fan is less than
stall point. Figure 6 shows a fan curve of a fan with a
optimum. A smaller size fan costs less and has a lower
significant dip in the stall region.
operating cost. It will also likely outlast a larger fan.
In a fan, the blades are normally rotating at constant
velocity. Therefore, to change the angle of attack, the
system to which the fan is attached must be changed.
Rotating Stall
Higher flow rates through the inlet increase the attack This is a special case of stall that normally only occurs
angle, and lower flow rates decrease it. Therefore, if a in backwardly inclined and airfoil centrifugal fans. Most
fan is operating in stall, it is because the CFM is too observers also report that inlet box dampers are
low for it. On a given system, this is caused by selecting involved. Variable inlet vanes do a good job of preventing
a fan which is too large (making the air velocities too rotating stall because they provide a more stable flow
low in the fan). path for the air through the wheel. These fans are
encased in a scroll type housing that helps generate the
Figure 6. Curve Showing a Dip in the Stall Region fan’s pressure. The pressure around the periphery of the
fan wheel varies relative to how near it is to the fan
4
outlet (where it is highest). These fans have several
3.5
STALL REGION blades, typically 9 to12.
STATIC PRESSURE (inWC)
2
FAN ENGINEERING – FE-600
1. There must be a relatively large volume of air which Figure 7. Bi-Stable Flow
is pressurized (such as the grain bins or a large 3
plenum).
2. There must be a section of ductwork with relatively
7.5
to reduce by over 15%. This fan continued to operate
at the lower flow rate until the test was restarted.
We can determine the stability of a fan by performing 6
two air tests. On one test, we start at full flow (free
delivery) and measure the flow and pressure as we 4.5 B
progressively add more resistance. In the second test, D C
we start at shut-off and progressively reduce the
3
resistance. We now have two flow vs. pressure fan E A
curves. If they do not overlay, we have a region of
instability. Figure 7 shows a sample fan curve with this 1.5
property. Since there are only two possible conditions
on any system, this is called bi-stable flow. 0
Although the noise changes between the two flow 0 1000 2000 3000 4000 5000 6000
conditions, neither is particularly objectionable. If the fan
is rated in the high flow condition and it “trips” to the CFM
lower condition, the loss of flow can be a problem.
Bi-stable flow has been observed in backwardly
inclined centrifugal fans, usually at performances close
to free delivery and almost always at flow rates higher
than that where the best efficiency occurs.
3
WWW.AEROVENT.COM
Those familiar with the system will recognize the • The system is happy because the flow (total of both
system curve as a parabola with the equation: fans) and pressure readings are on the system
curve.
SP = CFM2 ÷ Constant
• Fan #1 is happy because point “C” is on the fan
For this system we get: curve.
• Fan #2 has mixed emotions. It is happy that point
4 = 70002 ÷ Constant
“C” is on the fan curve, but unhappy about being
or
trapped in stall.
Constant = 49,000,000 ÷ 4 = 12,250,000
If these were your fans you would probably be
We can determine what this system will do with one unhappy because:
fan running by plotting this parabola on our fan curve. 1. The total CFM is only 6550, not 7000 as expected.
With fan #1 running we can see that we will get about 2. Fan #2 is probably noisy.
4750 CFM at 1.8" SP (A). 3. Fan #2 is prone to damage due to operation in
At this point, flow would be going backwards through stall.
fan #2 unless we stop the leak. Commonly, heavy duty
This example shows that it is possible to have two
backdraft dampers are used for this. When starting fan
identical fans not sharing the load equally. A more
#2, it will contribute no flow until it reaches a speed
severe condition can exist if non-identical fans are
such that the pressure (at shut-off) exceeds the back
operating in parallel. Some years ago a complaint
pressure it sees from fan #1. As the speed continues
regarding a system with two fans in parallel was
to increase, the flow will eventually reach point “D”.
received from a customer. After installing a second
Meanwhile, the pressure fan #1 sees continues to
larger fan in parallel with a smaller fan that had been
increase until it reaches point “C”.
in operation, the combined flow wasn’t what was
We then have the final condition:
expected. Measurements revealed that the second fan
Fan #1 is delivering 3800 CFM @ 3.50" SP
by itself was generating more pressure than the first fan
Fan #2 is delivering 2750 CFM @ 3.50" SP
was capable of at any point on its fan curve. The
From the system curve equation: original fan was completely overpowered, and flow was
(2750 + 3800)2 ÷ 12,250,000 = 3.50" blowing back out of its inlet. The customer was advised
to shut off the original fan (saving the power) and block
Figure 9. Normal Width Fan RPM=1282, BHP=13.14 Figure 10. Reduced Width Fan RPM=1342, BHP=12.56
12 32 12 32
OPERATING POINT CLOSE TO STALL REDUCED WIDTH SELECTION
10.5 28 10.5 28
STATIC PRESSURE (inWC)
BRAKE HORSEPOWER
9 24 9 24
7.5 20 7.5 20
6 16 6 16
4.5 12 4.5 12
3 8 3 8
1.5 4 1.5 4
0 0 0 0
0 4 8 12 16 20 24 0 2 4 6 8 10 12 14 16
CFM in (1,000s) CFM in (1,000s)
Figure 11. Blade Angle=45° RPM=1388, BHP=15.64 Figure 12. Blade Angle=35° RPM=1663, BHP=14.67
6 24 9 18
8 16
5 20
STATIC PRESSURE (inWC)
7 14
BRAKE HORSEPOWER
BRAKE HORSEPOWER
4 16 6 12
5 10
3 12
4 8
2 8 3 6
2 4
1 4
1 2
0 0 0 0
0 5 10 15 20 25 30 35 40 0 4 8 12 16 20 24 28 32
CFM in (1,000s) CFM in (1,000s)
4
FAN ENGINEERING – FE-600
solid the duct branch to the original fan (plugging the 8. For fans in parallel, there are four suggestions:
leak). There were two lessons learned here: a. Make sure fans start simultaneously.
b. Select fans so that the operating static pressure is
1. Don’t mix two different fans (or operate two identical
lower than the lowest point of the dip in the curve.
fans at different speeds) for parallel operation.
(Below the pressure at point E on Figure 8.)
2. If more flow is required on a constant system, boost
c. Select identical fans.
the pressure capability of the fan or add a second
d. Operate fans at identical speeds.
fan in series.
5
WWW.AEROVENT.COM
WWW.AEROVENT.COM
5959 Trenton Lane N. | Minneapolis, MN 55442 | Phone: 763-551-7500 | Fax: 763-551-7501