(Lecture 7) Introduction to Fan, Pump and Energy Saving Opportunities

Energy Efficiency Training of Trainers in 2022
Introduction to Fan, Pump and Energy Saving Opportunity
27th October, 2022
KILHWAN KIM
(Energy Consulting Division)
Introduction to Fan, Pump and
Contents
Energy Saving Opportunity
Ⅰ Basics of Fan System & Energy Saving
Ⅱ Basics of Pump System & Energy Saving
Ⅲ Energy Audit Process

CONTENTS
Basics of Fan System & Energy Saving
01 Overview of Fan System

02 Case Study of Fan Power Saving
01 I. Basics of Fan System 4
Overview of Fan System
 FAN(BLOWER) ?
. A machine that converts energy from mechanical energy to pressure and velocity energy
 Classification by pressure
Air blower Compressor

Fan Blower Compressor
1,000mmAq under 1,000~10,000 mmAq under 10,000mmAq more than
(0.1kg/cm2 under) (0.1~1.0kg/cm2 under) (1kg/cm2 more than)
Forward curved backward curved
Sirocco Fan(multi-blade) Turbo Fan

▪ Characteristics of Sirocco fan

- Driving power requirement increases sharply as the flow is increased.
- Proper for large flow and low pressure is needed.
- Low efficiency compared to other type.
- Surging range under the low air volume flow.
▪ Characteristics of Turbo fan

- Backward inclined vane/ Pressure grows rapidly as flow increased / Proper for high pressure is needed. (Boiler Fan)
Air foil fan

Low flow(Surging range) Radial fan
Sirocco fan
< Performance of Sirocco Fan > < Performance of Turbo Fan > < Characteristics by fan type >
▪ Fan Pressure
- Fan Total Pressure : pt = pt 2 − pt1 = ps 2 − ps1 + pd 2 − pd 1
- Fan Static Pressure : ps = pt − pd 2 = ps 2 − ps1 − pd 1
 
- Fan Dynamic Pressure : pd 1 = v12 and pd 2 = v22
2g 2g
Surging Operation Overload
Total Pressure
Power
Total Pressure Static Pressure
Efficiency
Efficiency
Pressure
Dynamic
Static Pressure Pressure
ATM Efficiency
Shaft Power
Quantity
< Fan Pressure (Total, Static, Dynamic pressure) >
< Example of fan performance >
▪ Fan Power Equation
Q(㎥ / min) × H(mmAq )

FAN POWER (kW ) =
6120 × η(Fan ) × η(MOTOR )
N(revolutions per minute(RPM))  Flow(Q), N2 (RPM)  Pressure(H) ,

P(Power)  Flow(Q) x Pressure(H) ☞ P(Power)  RPM3(N)
▪ Fan Use
[Boiler system] [Dusting]
ID-Fan Stack
Boiler FD-Fan
▪ Fan Volume Control

① Regulating System Curve : Damper Control, Bypass Control
② Regulating Fan Curve: Speed Control, Inlet Vane Control, Inlet Damper Control, Pitch Control
▪ Damper Control
- Low initial investment cost, Proper for small equipment
- Surging can happen under extremely low volume operation
- Forward inclined fan is more energy efficient than backward inclined fan.
• Air Volume Changing from QA to QB

- Operating point moves form A to B
- Pressure at that point is PA and PB
- PA –PB = Damper Resistance by Damper throttling
- Required Power decreases by LA-LB
- But, Energy saving is decreased under too low volume
because of reduced efficiency.
▪ Bypass Control
• Current Air Volume Can be reduce from QA to QB and system

resistance curve is changed from RA to RB
- Fan Pressure is changed from PA to Pc and operating point
from A to C
- Bypass air volume : QC –QB
- But, power consumption increase from L A to LC, which means no
power saving.
▪ Speed Control
• Air Volume is controlled by varying fan rotating speed
- Affinity law is applied : QB/QA=N2/N1, PB/PA=(N2/N1)2, LB/LA=(N2/N1)3
- Reducing air volume leads to power reduction from L A to LB.
- How to fan speed control
☞ Inverter(VVVF) : Fan operation is stable and most energy efficient
☞ Automatic control is easily applied to fan system.
▪ Inlet Guide Vane Control

- Inlet guide vane is composed of 8~12 radial vanes and installed in the suction of fan for air volume control.
- Vane angle regulating for volume and discharge pressure control
• Operating Point moves from A to B by guide vane

throttling
• Pressure and air volume is lowered simultaneously and
shaft power curve changes also. (Power consumption
reduced from A’ to B’)
- Good controllability and low initial investment cost
- Low fan efficiency under low volume range, so saving
amount is behind the speed control.
< Inlet Guide Vane Control>

Fan power(%), Shaft Power(%)

Efficiency decreasing
by reducing vane opeining
Fan flow rate of change(%)
< Performance Curve of Suction Vane Control> < Power by flow control method>
Case Study of Fan Power Saving
▪ Current Status
- Efficiency improvement of suction vane controlled force draft fan of low load boiler
- (Current) Steam generation of current boiler(steam generation rate 80t/h) is 48t/h(60% load) / Fan load of flow rate 48%
Power consumption 220kW
※ Low efficiency operation due to small opening(25%) of suction vane
* Fan power Consumption
Operation
* Fan flow rate : 48% of rated flow
Rate
Q-P Performance
Current suction vane opening is 25%.
curve(Rate)
Rate(A)
With suction vane throttling, Q-P
performance curve is changed.
Efficiency curve is also changed, which
resulted in efficiency degradation from
Suction vane opening(25%)
A1 to B1. (82.2% ⇒ 12.3%)
Although the efficiency is decreased

Rated eff.(A1)
compared to rate value, power
consumption is reduced because of
Efficiency decreasing Operating point(B) decreasing pressure and flow rate.
It is needed to reduce power

consumption maintaining current fan
system pressure and flow rate.
Oper. Eff(B1)
▪ Improvement
- Low efficiency operation improvement by installing inverter to F.D. fan.
Q-P Performance Cross point of Q-P performance curve

curve(Rate) and improvement point(B) is
Origin point(C)
improvement origin point.
Improvement origin point(C) and

improvement point(B) is on the same
resistance curve, so new Q-P curve can
be obtained by fan speed control(green
New eff.(C1) color).
Eff. increasing New OP(B) ☞ Estimated power consumption(inverter)

= [825.5㎥/min x 190mmAq]/[6120 x
0.822(Fan) x 0.95(Motor) x 0.715(Inverter)]
Q-P Performance
curve(Inverter) = 45.9kW
Current eff(B1)
☞ Power saving = 220kW – 45.9kW = 174kW
▪ Concept
- Installing high voltage inverters in electric furnaces
<High voltage inverter>
Furnace Collector Flow

필요량 Note
No Inverter
Inverter
Inverter
Not
Not
Pressure
Capa(kW) Flow(CMM) Volt(V) Running(h/y) Ampere(A)
(mmAq)
▪ Comparison between before and after

- Before Installing high voltage inverters
Design Measured Damper Avg.

No Flow(CMM)
Temp(℃) Flow (CMM) opening(%) Power(kW)
No 1 100 5,000 3,310~3,819 50~100 477.3
No 2 200 5,000 3,778~5,165 12~20 575.3
- After Installing high voltage inverters
Damper Avg. Reduced Applied

Frequency Aircon Power saving
호기 Tap opening power Power hour
(Hz) (kW) (kWh)
(%) (kW) (kW) (h/year)
7 100 54 5.8 368.8 108.5 8,106 879,501
No 1
1 100 40 5.8 200.8 276.5 338 93,457
13 25 45 5.8 328.8 246.5 7,050 1,737,884
No 2
1 20 40 5.8 210.8 364.5 294 107,076
※ Total power saving : 2,817,918kWh/year, Payback period : 1.8 year

▪ Concept
- Cooling fan of rolling mill(hot rolling process) driving motor is operating with constant speed regardless of cooling load
- Proposal of fan speed control referring to exhaust air temperature
Main motor cooling exhaust (35%) is

returned and mixed with out air, which
increase supply air temperature.
Exhaust
24.9℃ Room Exhaust
Fan Room Sub 22.5℃
Return
24.9℃ 18.5℃
Out air Main
14.5℃ 110kW
Main
18.5℃
Filter
110kW Sub
Cooling air Δt between main motor inlet and outlet is 6.4℃ (rated Δt
is 15℃). Motor heat load is smaller than rate value
▪ Improvement idea
- Fan speed control according to motor cooling load(minimum flow is maintained)
Fan speed control by exhaust air Return air mixing only winter season
temperature (VSD by motor cooling load) (100% exhaust during the rest of seasons)
Exhaust TIC
30.5℃ Room
Fan Room Sub exhaust
24.5℃
14.5℃
Out air Main
14.5℃ VVVF
VVVF
Main
14.5℃
Filter
Sub
CONTENTS
Basics of Pump System & Energy Saving
01 Overview of Pump System

02 Case Study of Pump Power Saving
01 II. Basics of Pump System 20
Overview of Pump System
▪ Centrifugal Pump
- a mechanical device designed to move a fluid by means of the transfer of rotational energy from one or more
driven rotors, called impellers
- Energy is transferred to fluid by rotating impellers.
- Rotating impellers(centrifugal force) → Mechanical Energy → Velocity Energy → Pressure Energy(in Spiral casing)
- Volute Pump
☞ Velocity energy from impeller is changed to pressure energy by volute
- Turbine Pump
☞ Velocity energy from impeller is changed to pressure energy by guide vane
<Volute Pump(low pressure)> <Turbine Pump(high pressure)> <Pump and Drive>

▪ Single Suction & Double Suction Pumps

- Single Suction : for low ~ medium flow rate
- Double Suction : for large flow rate
▪ Piping and accessories

Mainly energy loss point
when throttling <Single suction single stage> <Double suction single stage>
Manual shut off valve
Manual shut off Balancing valve

valve
Check valve
Strainer
<Valves(butterfly, gate, globe) >
Flexible joint
Flexible joint
<Centrifugal Pump & Impeller>

▪ Lift Head(m)
𝑃𝑠
✓ Suction Head (vacuum gage) : 𝛾
𝑃𝑠 𝑉𝑠2
= 𝐻𝑠 + ℎ𝑠 +
𝛾 2𝑔
Water level
(Discharge) 𝑃𝑑
✓ Discharge Head :
𝛾
𝑃d
= 𝐻d + ℎd
𝛾
✓ Total Head (system head) 𝐻

Vacuum gage
𝑑 𝑉2
𝐻 = 𝐻𝑠 + ℎs + 𝐻d + ℎd + 2𝑔
Press gage
✓ Total Head(valve pressure loss included) 𝐻 ′

𝑉2
𝐻 ′ = 𝐻𝑠 + ℎs + 𝐻d + ℎd + 2𝑔
𝑑
+ ℎ𝑣𝑎𝑙𝑣𝑒
It is needed to minimize total head(H) and valve pressure

Water level
(Suction)
loss(H’).
<Pump lift head>

▪ Pump Performance Curve

- Power increases as flow rate increase
- Usually, best efficiency point is designed at rated point
Efficiency
Resistance Curve
Rated point
Best Efficiency Point Head(m) Q-H curve

Q-H Curve
Flow rate(㎥/h)
Efficiency Curve(%)
(Rated HP) Motor(kW)
(Shaft Power HP)

Shaft Power(kW)
Flow rate
<Pump Performance Curve>

▪ Pump Parallel Operation : Example of 3 pumps in parallel operation

① Composite curve of parallel 3 pumps can be obtained by arithmetically adding each flow rate
② Operating point change : 1 pump operation(A1) → 2 pumps operation(A2) → 3 pumps operation(A3)
③ Each pump operating point change : 1 pump operation(A1) → 2 pumps operation(A5) →3 pumps operation(A4)
A4
Total
Head A5
Discharge
Flow rate
※ Flow rate is not proportional to the number of pumps and gradually slows down
※ It is required to operate optimal number of pumps by flow rate optimization
※ If the number of parallel operation pumps is increased, the efficiency of each pump decrease because of
low flow rate operation
▪ Synthesizing Resistance Curve

- Series combination of pipelines (RA, RB) with different resistances
☞ The resistance of the synthetic pipeline is the sum of each the resistances along the vertical axis at a certain
flow rate (Resistance increasing, Flow rate decreasing)
- Parallel combination of pipelines (RA, RB) with different resistances
☞ The resistance of the synthetic pipeline is the sum of each flow of RA and RB along the horizontal axis at a
certain head (Resistance decreasing, Flow rate increasing)
<Serial combination of resistance> <Parallel combination of resistance>

▪ Pump Power
theoretical power Shaft power motor input Power consumption

(pump output) (motor output) power (inverter input)
pump motor inverter

efficiency efficiency efficiency
Electric power(kW) Power usage per 1 second(unit time)
Electric energy(kWh) Amount of power consumed for a certain period of time
[Head(m)] × [Flow rate(㎥/min)]

Shaft Power(BHP) =
(kW) 6.12 × [Pump Efficiency(%)/100]
▪ Impeller Trimming
- If excessively trimmed, the efficiency of pump deteriorates
- Trim within 80% of impeller diameter considering pump casing
Operating Point A B C 𝐷′2 2

✓ 𝑄𝑎 = 𝑄𝑏 ×
𝐷2
Flow rate(㎥/min) 12 13.6 12
𝐷′2 2
Total head(m) 36.5 34 30 ✓ 𝐻𝑐 = 𝐻𝑏 ×
𝐷2
Impeller Dia(mm) 359 359 ? 𝐷′2 4
✓ 𝐿𝑐 = 𝐿𝑏 ×
𝐷2
Shaft power(kW) 84 88.7 ?
Resistance curve
Head (valve throttling)
𝑄𝑎 12
✓ 𝐷′2 = 𝐷2 × = 359 × = 337𝑚𝑚
Pipe line 𝑄𝑏 13.6
resistance curve
337 4
✓ 𝐿𝑐 = 88.7 × = 69𝑘𝑊(15kW saving)
359
Shaft power
01 I. Basics of Pump System 28
▪ Variable Speed Drive

- Speed control is appropriate for frequent changes or short-term changes in flow rate.
- Speed Control results in significant savings because reduction of pump efficiency can be minimized.
𝑄1 𝑛1
Total ✓ =
head 𝑄0 𝑛0
𝐻1 𝑛1 2
✓ =
𝐻0 𝑛0
𝐿1 𝑛1 3
✓ =
𝐿0 𝑛0
- Before speed reduction(valve throttling)

☞ Operation point [A2, La] → [A1, L1]
Shaft
Power - After speed reduction(Performance curve)
☞ Operation point [A2, La] → [C2, Lc]
(Discharge) Flow rate - Power saving(shaft power) = L1 - Lc
<Performance analysis of variable speed drive>
▪ Pressure Indication Control(Automatic Control)

- Pump discharge pressure remains constant even though the valve opening rate decreases and the operating
point changes to A→B→C.
- The operating point of the pump changes to A→D→E, the rpm of pump changes to n0→n1→n2, and shaft
power changes to 1→2→3 Total
head
Shaft
Power
(Discharge) Flow rate

<Discharge pressure indication control by inverter>
▪ Pump Selection Program

- Using pump selection program provided by pump manufacturer free of charge, pump capacity selection,
rotation speed change, parallel operation can be estimated.
<Sample of pump selection program>
✓ (input) float rate, head, type, motor frequency,

number of poles, liquid temperature
✓ (output) pump performance curve recommended
✓ Performance can be estimated in case of
changing pump speed and impeller size, and
parallel operation
▪▪ Inverter
Inverter
-- Supplying variable
Supplying variable voltage
voltage and
and frequency
frequency power
power to
to the
the motor
motor using
using the
the commercial
commercial voltage
voltage and
and frequency
frequency
electricity as
electricity as input
input
-- For
For Variable
Variable motor
motor speed
speed
-- VVVF(Acronym
VVVF(Acronym of of Variable
Variable Voltage
Voltage Variable
Variable Frequency),
Frequency), VSD(Variable
VSD(Variable Speed
Speed Drive),
Drive), VFD(Variable
VFD(Variable Frequency
Frequency Drive)
Drive)
Input
power
source Voltage and
frequency variation
(0~400Hz) Motor Speed Control
Prevailing voltage DC voltage Output voltage
Storing transformed
DC energy in DC link
Inverter output voltage(PWM)
<Principe of Inverter and Internal circuit>
▪ High Voltage Inverter <High voltage inverter>

- Applied voltage is over 440V (Ex : 3300V, 6600V)
- Cost of investment is too high than low voltage inverter, so economically infeasible if the savings are small)
▪▪ Magnet Drive Coupling

Inverter
-- A device that
Supplying controls
variable the magnetic
voltage flux density
and frequency power by adjusting
to the motor the distance
using between the
the commercial permanent
voltage magnet and
and frequency
the conductor
electricity as input
- Transferred torque is variable, which reduces energy(power) especially to high-voltage power (3.3 kV or more)
large-capacity motor
Primary side Secondary side
Connected
to motor
directly Variable Speed
(rotating at Operation
the rated linked to
speed ) driven pump
shaft
<Principe of magnet drive coupling>

Example of Magnet Drive Coupling installation

▪▪ Inverter
< Example of magnet coupling installation(fixed speed)> <Automatic control using MGC>
Case Study of Pump Power Saving
▪ Concept
- Reducing pressure loss by separating pipe line considering proper supply pressure
- [1,350㎥/h x 50m x 260kW] 6 of 7 (8,100㎥/h, 1,560kW) Operating(#4 off)
- (Operating) flow rate 5,915㎥/h(average 986 ㎥/h Ea), Total Power Consumption 1,195kW(Average 199kW/Ea)
(inverter)
• Problem
- Supply valve opening is low(25~100%), Cause of pressure loss
- Discharge pressure is too high, not separated by user point
pressure
Heat exchanger (Pump discharge 5.4~5.6kg/㎠g, but required pressure for Steam
turbine condenser inlet is 2.8kg/㎠g (44% of total discharge flow
Pressure loss by
valve throttling rate)
Cooling
Tower
▪ Improvement
- Separating STG supply pipe line / Replacement of #1, #2 pumps with low head pump
- Estimated power consumption of new pump : 149kWx2Ea
- Power saving = Converted Power of STG condenser flow – Estimated Power Consumption of new pumps
= 1,195kWx [2600㎥/h / 5,915 ㎥/h] –149kW x 2Ea
= 226kW
(inverter)
• (Saving Effect)
- Electric power saving 1,793MWh/year
Heat exchanger
Cooling
Tower
(New)
▪ Concept
- The number of pumps operated is optimized in cooling tower pumps
- (As is) 300kW x 2Ea /
2, 884㎥/h, Pump ΔP 3.5kg/㎠(Suction : 0.1kg/㎠G, Discharge 3.6kg/㎠G), Total Power Consumption 531kW(266kW, 265kW)
• Problem
- Pump Efficiency reduction by low flow rate (efficiency rate :
82% → operating 55%)
Turbo Comp Group Turbo Chiller Group
- Total flow rate is 2, 884 ㎥/h, which is near one pump
rate(2700 ㎥/h)
- Δt of compressors & chillers is small(Refrigerator Δt : 2.9℃ ,
Compressors Δt : 1.8℃), which means excessive flow rate.
(Rate) Head(m)
(Oper) Power
(Rate)
▪ Improvement
(Comp)
(Refri)
- Reducing number of operating pumps (2Ea → 1Ea)
- Estimated power consumption 300kW (3000㎥/h), 231kW Saving
Flow rate(㎥/h)
▪ Concept
- Reducing discharge valve loss using speed control device(inverter)
- (As is) [750㎥/hx40mx132kW] x 2 Ea (1 running, 1 standby), (Operating) flow rate 721㎥/h, Power consumption #B 114kW
Pressure loss in discharge valve = 1.3kg/㎠ = 3.9kg/㎠g -2.6kg/㎠g (33.3% of discharge pressure)
Absorption Chiller(1213USRT)
Demi Valve pressure loss
Water Rated flow : 734㎥/h Rated Point
3.9K(Local PG) 2.6K(estimation) Improved Point

(Local PG)
(P.loss ▲13m)
▪ Improvement
- Reducing discharge valve loss by lowering pump speed(by inverter)
- Discharge vale is fully opened.
- Inverter inlet power = = [114kW x (100%-33%)/100%] / 0.95(inverter efficiency) = 80kW
- Power saving = 114k – 80kW = 34kW (269 MWh/year)
▪ What is Cv(Flow Coefficient)

- Definition : Under valve pressure difference 1psi(0.07㎏/㎠), Flow rate(US gal/min) of 60℉ Water
- When Cv is 40, if Δp of valve is 1 psi, the flow rate is 40USgal/min.
- Cv is given in valve data sheet.
▪ How to estimate valve pressure loss

- Using
- ΔP(kg/㎠) can be found.
G1 : Liquid density(kg/㎠), Q1 : volume rate of liquid, Flow Coefficient vs. Valve Opening
ΔP : pressure diffence of valve(kg/㎠) (Sample)
<(Sample) Valve Data >

CONTENTS
Energy Audit Process
01 What is energy audit?
02 Energy audit process of fan equipment
03 Energy audit process of pump equipment

01 III. Energy Audit Process 40
What is Energy Audit?
Definition
A technical consulting service provided by energy audit companies

in order to reduce energy costs and GHG (greenhouse gas emissions)
Procedure
Figure out the pattern of energy use and the cause of energy loss
Suggest recommendations of energy conservation opportunities
Conduct pre-feasibility study and report
▪ Financial benefits that contribute to a reduction in operating costs and/or

an increase in profits for an organization
▪ Organizational benefits that assist in the management of a facility and improve

its productivity and/or safety
▪ Environmental benefits that achieve an additional value beyond the organization

by reducing CO2 emissions.
• Collecting basic data

- collect basic specification data(motor, pump, fan etc)
- voltage, current, power, power factor
- analysis for transformer of operation(load factor, loss factor, etc)
• Measurement data in field
- measurement data in field by measuring tool

- main data : voltage, current, power, power factor, power consumption
• Data analysis
- analysis of operation status and estimation energy consumption by
measured data
- analyze the cause for the efficiency decrease
• Reviewing the saving possibilities and methods

- reviewing saving possibilities and method to increase energy efficiency
• Deciding the most reasonable improvement method

- conclude the final improvement method after several feasibility studies
• Reporting to the client

Energy Audit Process of Fan Equipment
Determine
Check System Check Check Damper loss factor
Nameplate
Measure Measure Measure

Electric Power Air Pressure Air Flow
Industry Boiler FD-Fan A Identify Fan Equipment on-site
•Visit a site with data obtained in advance.(P&ID

and PFD drawings and DCS screen output)
•Determine whether the same system to the actual
design drawings.
•After checking the status of equipment such as
leakage, installation, etc, then note if there is wrong.
Process Cooling Motor Cooling Boiler ID-Fan

B Check nameplate of fan utility
• Check that the nameplate information on-site

Nameplate facilities is consistent with materials provided in
advance.
• Also, check and note for the needs of other
materials provided by nameplate.
- The Motor voltage, power, speed, efficiency.
- The pump manufacturer and model, air flow, air
pressure, temperature
Precautions
• Pay extremely attention to check nameplate Near
attached to the rotating equipment.
• Take a flashlight for safety about checking the

nameplate and moving around in the dark.
• Take a safety helmet for moving confined space.
• Take hearing protection Against noise. (Risk

deafness occurs when a long time neglected)
Checking the ratio of damper

C opening position(%)
• Check and note about fan up/downstream

Suction Damper damper opening directly
Discharge Damper • How checking as follows:

① Fan Suction damper: It is Fan integrated
damper that is divided into the automatic
motorized damper and manual damper,
indicated by the rate of 0% to 100%.
② Air conditioner duct damper: Damper which
is associated with the fan installed in the
duct are for volume control or shutting, etc.
① ② Precaution
• Do not manipulate damper to check

opening position.
• Care must be taken for falling accidents

to check Damper installed in a high
Opening Position 30% position.
Opening Position 50%
D
① ② Check Loss Factor
Mainly, energy loss of equipment is due to damper

throttling losses, bag filter, heat exchanger
equipment, etc.
• Excessive loss will occur in the below.
① Bag Filter and Cyclone Dust collectors :
② Heat Exchangers
③ Damper throttling
③ Precaution
• Be careful about hazardous

① substances, when move around to
check the fan installed in the system.
• Be aware of the risk of falling accidents

accessing to the high place in order to
identify system losses.
Fan discharge-side flow measurement E Air flow measurement
• Airflow measured by an anemometer.

• Airflow through the calculations obtained
after measuring the area of the sphere is
calculated.
• Review the difference between measured
airflow data and the expected airflow data.
• If the measurement data come out with
different values and expectations, following
case.
- Damper throttling that occurs.
- Pollution due to the suction side of the filter.
- Deterioration due to fan’s impellers wearing
Precaution
• You should pay attention to safety for

falling down, when measuring airflow in
stack of fan’s upper side.
• Do not damage facility, if excessive force is
Fan suction filter side airflow measurement applied to open the access door by the
equipment. (Pipe, Wrench, Monkey etc)
Air Conditioner Fan F Wind pressure measurement

wind pressure measurement
• If you have a pressure gauge installed on the site,
then read the value or DCS screen.
• Direct measurement using diagnostic equipment is
needed, when display’s value in field is incorrect.
• The pressure measurement points are as follows.
- Fan’s suction side and discharge side.
- Up/down stream on the resistance elements of
equipment in the system.
Duct wind pressure Precaution

measurement
• Do not damage facility, if excessive force
is applied to open the access door by the
equipment. (Pipe, Wrench, Monkey etc)
• Do not directly measure the pressure on
the equipment that contains the
hazardous substance. Check the substance
of the fluid and temperature in advance.
• Be careful not to let contaminants in eyes,
when measuring positive pressure duct.
ENERGY LOSS FACTOR IMPROVEMENT
Air pressure loss Installing

the Inverter
Air flow loss
Low efficiency Problem Replacing

Analysis the Pulley
Load fluctuations
Converting
Excessive capacity poles of motor
A How to improve fan by using inverter

Inverter inside the panel
Installing the inverter
MCCB to inverter panel

➢ How to interpret the performance curve

• When damper closing, rating point-A move to point-B
• At that time, efficiency curve also changed and power
loss is occurred because fan efficiency is downing
• If fan is operated point B by using inverter, fan
efficiency is increased due to changing the efficiency
curve
➢ The expected frequency for inverter operation

• Current operating point to draw a curve passing
through the resistance that meet each other to find the
point is C
• By controlling the fan RPM, QP curve passing through
the new operating point can be drawn.
• At this time, RPM control rate is Q∝N,
H∝N2, P∝N3 789:1 = 683:Х1 , 351:12 = 263:Х22
• Х1 = 0.866 Х2 = 0.866 Match airflow and pressure,
so if the current rotational speed becomes reduced to
86.6%. In other words, operating 60 (Hz) to 51.9 (Hz)
B Improvement methods replacing pulley
➢ The basic principles of replacing the belt Pulley

Fan Pulley • Fan efficiency would be down when control
damper for controlling airflow. So, Change fan
RPM according to changing airflow
➢ Relation of airflow, pressure, Pulley diameter

• Fan’s airflow is proportional to the rotational
speed, pressure is proportional to the square
of rotational speed, power is proportional to
three square
인버터 전용 배전반
• Relation of rotational speed(N), airflow(Q),

pressure(H), Pulley diameter(D)
(N0, Q0, N0, D0 is before replacement)
N/N0 = Q / Q0 = H1/2/ H0 1/2 = D0 / D
Before replacement After replacement
Energy Audit Process of Pump Equipment
Check Check
Check System Nameplate Check Valve Loss factor
Measure Electric Measure Measure Measure

Power Height Pressure Flow
A Identify Pump equipment on-site
• Visit a site with data obtained in advance.(P&ID

and PFD drawings and DCS screen output)
• Determine whether the same system to the
actual design drawings.
• After checking the status of equipment such as
leakage, installation, etc, then note if there is any
thing wrong.
B Check nameplate of pump utility
• Check that the nameplate information on-site

facilities is consistent with materials provided in
advance.
• Also, check and note for the needs of other
materials provided by nameplate.
- The Motor voltage, power, speed, efficiency.
- The pump manufacturer and model, flow, head
Precautions
• Pay extremely attention to check nameplate
Near attached to the rotating equipment.
• Take a flashlight for safety about checking

the nameplate and moving around in the
dark.
• Take a safety helmet for moving in confined

space.
• Take hearing protection against noise. (Risk

deafness occurs in the long time neglected)
Checking the ratio of valve opening

C position(%)
• Check and note about pump up/downstream

of the ratio of valve opening position
directly with the naked eye.
• How checking as follows:
① Gate valve : Observe the length of the
screw from a range of left / right (or up /
down).
② Geared Valves: scale "O" and "S" is
represented by, and the "O" stands for the
Open represents a 100% open, “S “ stands
for the Shut represents 100% protection.
③ Lever valve: Observe from the central axis
of each grid (Open / Close).
Precaution
• Do not manipulate arbitrarily valves to

check opening position.
• Care must be taken in falling accidents to

check valve installed in a high position.

①
D Check the system loss factor
• Loss factors of pump (flow / head) are throttling valve,

strainer contamination, check valves malfunction, pressure
reducing valves, automatic valves include the amount of
essential oils, Make sure checking the installation and
operation.
① Check Valve: preventing the backflow of fluids.
② pressure reducing valves: a constant pressure supply.
③ Automatic Flow Valves: Flow Supply Schedule.
④ strainer: the removal of contaminants, pump protection
Precaution
• Be careful with dangerous environment

to move around to check accessories
installed in the system.
• Most are installed in a dark room, so

flashlights, hard hat, safety equipment, etc
will be needed.

①
E Measuring flow
• Ultrasonic flow meter is used a lot.

• Measure flow after checking the estimated flow
(nominal flow, etc).
• If you get the other value comparing with the
expected value , then looks out for this cause.
• If you get different measurements comparing with
the rated value ,it typically have the following causes.
- Throttle valves (low flow).
- High capacity (high flow).
- wearing Impeller (low flow).
Precaution
• It should be well chosen the measurement point

to get the true value.
- Select horizontal pipe that fluid flow up.
- Exclude measuring point near valve installing
point or bend.

①
F Measuring Pressure
• Read the pressure of fluid that DCS screen or

reading value of field installed on gauge.
• It should be measured directly by energy audit
equipment if field values are not reliable.
• Pressure measurement points are as follows.
- Pump suction and discharge
- Expected pressure loss point of valves and
equipment of the up / downstream side
Precaution
• When pressure is measured using

equipment(digital manometer) directly, it should
be taken in the following.
- Excessive force can result in crack and
leakage loosening the attached pressure gage.
- Identify the contents of the fluid in advance, so
that it should not be the cause of hazard to the
body when leaked.

①
G Measuring Height
• It should be measured the maximum height of the

fluid supply equipment (heat exchangers, etc.) for
calculating the total head of the pump.
※ If the flow of the highest user point is low, the

head of pump should be optimized, and a separate
booster pump can be considered for power saving.
Precaution
• You must grasp the stair handrail to move

around for preventing falling accident
occurred due to negligence.
• You must pay attention to walking on top of the

installed equipment, collisions with objects, etc.
ENERGY LOSS FACTOR IMPROVEMENT
Pressure(Head) loss Installing

the Inverter
Flow loss
Problem Replacing
Loss of pump efficiency
Analysis the Impeller
Load fluctuations
Replacing
The high efficiency
Excessive capacity pump
A Improvement methods using the inverter

• Moving from point-A to point-B when valve has

closed
• Actually pump is operating at point-C. Because valve
pressure loss caused by resistance of valves. It cause
to pump power loss due to valve pressure loss
• thus, it is possible to control flow by using inverter
without valve pressure loss
➢ The expected frequency for inverter

operation
• Meet each other point is point-D by drawing new
resistance curve pass over point-C
• It could draw new Q-H curve that pass over point-
Cby controlling R.P.M of pump
• Q∝N, H∝N2, P∝N3 200:1 = 164:Х1 , 135:12 = 91:Х22
• Х1 = 0.82 Х2 = 0.82
R.P.M → 82%, Frequency 60(Hz) → 49.2(Hz)
B Replacing(cutting) the impeller


• Rating point-A move to point-B due to throttling
valves
• Proper system operation point is the C, it is being
caused by power loss
• Point C is to be driving by replacing the impeller
➢ Method of Reducing the impeller

➢ Should find point-D(90m3/h, 1,400m) that meet
point-O to point-C(74.4m3/h, 1,150m) line with
performance curve
➢Operating point should be moved to the point-C in
accordance with the law of affinity, The diameter of
the new impeller is
74 .4
D' = D × = 0.91D( flowbase )
90
1150
D' = D × = 0.91D( flowbase )
1400
➢In other words, Replace the impeller is shrunk to

91.0 percent (9% Trimming)
C Improvement methods replacing pump capacity


Thank you

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Energy Efficiency Training of Trainers in 2022

Introduction to Fan, Pump and Energy Saving Opportunity

27th October, 2022

Ⅰ Basics of Fan System & Energy Saving

Ⅱ Basics of Pump System & Energy Saving

Ⅲ Energy Audit Process

Basics of Fan System & Energy Saving

01 Overview of Fan System

Overview of Fan System

Air blower Compressor

Forward curved backward curved

Sirocco Fan(multi-blade) Turbo Fan

Overview of Fan System

▪ Characteristics of Sirocco fan

▪ Characteristics of Turbo fan

Air foil fan

Overview of Fan System

Surging Operation Overload

Overview of Fan System

▪ Fan Power Equation

Q(㎥ / min) × H(mmAq )

N(revolutions per minute(RPM))  Flow(Q), N2 (RPM)  Pressure(H) ,

[Boiler system] [Dusting]

Overview of Fan System

▪ Fan Volume Control

• Air Volume Changing from QA to QB

Overview of Fan System

• Current Air Volume Can be reduce from QA to QB and system

Overview of Fan System

▪ Inlet Guide Vane Control

• Operating Point moves from A to B by guide vane

< Inlet Guide Vane Control>

Overview of Fan System

Fan power(%), Shaft Power(%)

Fan flow rate of change(%)

Case Study of Fan Power Saving

※ Low efficiency operation due to small opening(25%) of suction vane

* Fan power Consumption

* Fan flow rate : 48% of rated flow

Case Study of Fan Power Saving

Although the efficiency is decreased

It is needed to reduce power

Case Study of Fan Power Saving

Q-P Performance Cross point of Q-P performance curve

Improvement origin point(C) and

Eff. increasing New OP(B) ☞ Estimated power consumption(inverter)

Case Study of Fan Power Saving

<High voltage inverter>

Furnace Collector Flow

Case Study of Fan Power Saving

▪ Comparison between before and after

Design Measured Damper Avg.

No 1 100 5,000 3,310~3,819 50~100 477.3

No 2 200 5,000 3,778~5,165 12~20 575.3

- After Installing high voltage inverters

Damper Avg. Reduced Applied

※ Total power saving : 2,817,918kWh/year, Payback period : 1.8 year

Case Study of Fan Power Saving

Main motor cooling exhaust (35%) is

Case Study of Fan Power Saving

Basics of Pump System & Energy Saving

01 Overview of Pump System

Overview of Pump System

<Volute Pump(low pressure)> <Turbine Pump(high pressure)> <Pump and Drive>