Fans and Blowers

Training Session on Energy
Equipment
Fans & Blowers

Electrical Equipment
Fans & Blowers
Presentation from the

“Energy Efficiency Guide for Industry in Asia”
www.energyefficiencyasia.org
1
© UNEP 2006
Training Agenda: Fans & Blowers
Introduction
Fans & Blowers
Types of fans and blowers

Assessment of fans and blowers
Energy efficiency opportunities
2
© UNEP 2006
Electrical Equipment Introduction
1. Fan components
Fans & Blowers
2. System resistance
3. Fan curve
4. Operating point
5. Fan laws
3
© UNEP 2006
Introduction
Fan Components
Provide air for ventilation and

Fans & Blowers
industrial processes that need air flow

Turning Vanes
(typically used on
short radius
Outlet elbows)
Diffusers
Heat
Exchanger
Baffles
Filter Inlet
Vanes
Motor
Controller
Centrifugal Variable Frequency
(US DOE, 1989) Fan Belt Drive 4
Motor
Drive
© UNEP 2006
Introduction
System Resistance
• Sum of static pressure losses in

Fans & Blowers
system
• Configuration of ducts, pickups, elbows
• Pressure drop across equipment
• Increases with square of air volume

• Long narrow ducts, many bends: more
resistance
• Large ducts, few bends: less resistance
5
© UNEP 2006
Introduction
System Resistance
System resistance curve for various
Fans & Blowers
flows
Actual with
system
resistance
calculated
(US DOE, 1989) 6

© UNEP 2006
Introduction
Fan Curve
Performance curve of fan under

Fans & Blowers
specific conditions
• Fan volume
• System static
pressure
• Fan speed
• Brake
horsepower
(US DOE, 1989) 7

© UNEP 2006
Introduction
Operating Point
Fan curve and system curve intersect

Fans & Blowers
Flow Q1 at
pressure P1 and
fan speed N1
Move to flow Q2
by closing damper
(increase system Move to flow Q2
resistance) by reducing fan
speed
8
(BEE India, 2004)
© UNEP 2006
Introduction
Fan Laws
Fans & Blowers
9
(BEE India, 2004) © UNEP 2006
Introduction
Fans & Blowers

10
© UNEP 2006
Types of Fans & Blowers
Types of fans
Fans & Blowers
• Centrifugal
• Axial
Types of blowers
• Centrifugal
• Positive displacement
11
© UNEP 2006
Centrifugal Fans
• Rotating impeller increases air velocity

Fans & Blowers
• Air speed is converted to pressure

• High pressures for harsh conditions
• High temperatures
• Moist/dirty air streams
• Material handling
• Categorized by blade shapes

• Radial
• Forward curved 12
• Backward inclined © UNEP 2006
Centrifugal Fans – Radial fans

• Advantages
Fans & Blowers
• High pressure and temp

• Simple design
• High durability
• Efficiency up to 75%
• Large running clearances
• Disadvantages (Canadian Blower)
• Suited for low/medium

airflow rates only 13
© UNEP 2006
Centrifugal Fans – Forward curved

• Advantages
Fans & Blowers
• Large air volumes against

low pressure
• Relative small size
• Low noise level
• Disadvantages
• Not high pressure / harsh
( Canadian Blower)
service
• Difficult to adjust fan output
• Careful driver selection
14
• Low energy efficiency 55-65%
© UNEP 2006
Centrifugal Fans - Backward-inclined

• Advantages
Fans & Blowers
• Operates with changing

static pressure
• Suited for high flow and
forced draft services
• Efficiency >85%
• Disadvantages ( Canadian Blower)

• Not suited for dirty airstreams
• Instability and erosion risk
15
© UNEP 2006
Axial Fans
• Work like airplane propeller:
Fans & Blowers
• Blades create aerodynamic lift

• Air is pressurized
• Air moves along fan axis
• Popular with industry: compact, low

cost and light weight
• Applications
• Ventilation (requires reverse airflow)
• Exhausts (dust, smoke, steam)
16
© UNEP 2006
Axial Fans – Propeller fans

• Advantages
Fans & Blowers
• High airflow at low pressure

• Little ductwork
• Inexpensive
• Suited for rooftop
ventilation
• Reverse flow
• Disadvantages
• Low energy efficiency (Fan air Company)
17
• Noisy
© UNEP 2006
Axial Fans – Tube axial fans

• Advantages
Fans & Blowers
• High pressures to overcome

duct losses
• Suited for medium-pressure,
high airflow rates
• Quick acceleration
• Space efficient
• Disadvantages
• Expensive
(Canadian Blower)
• Moderate noise
18
• Low energy efficiency 65% © UNEP 2006
Axial Fans – Vane axial fans

Fans & Blowers
• Advantages
• Suited for medium/high
pressures
• Quick acceleration
• Suited for direct motor shaft
connection
• Most energy efficient 85%
• Disadvantages
(Canadian Blower)
• Expensive
19
© UNEP 2006
Blowers
Fans & Blowers
• Difference with fans

• Much higher pressures <1.20 kg/cm2
• Used to produce negative pressures for
industrial vacuum systems
• Types
• Centrifugal blower
• Positive displacement
20
© UNEP 2006
Centrifugal Blowers
• Gear-driven impeller
Fans & Blowers
that accelerates air

• Single and multi-stage
blowers
• Operate at 0.35-0.70 kg/
cm2 pressure
(Fan air Company)
• Airflow drops if system
pressure rises 21
© UNEP 2006
Positive Displacement Blowers

• Rotors trap air and push it through

Fans & Blowers
housing
• Constant air volume regardless of
system pressure
• Suited for applications prone to
clogging
• Turn slower than centrifugal blowers
• Belt-driven for speed changes 22
© UNEP 2006
Introduction
Fans & Blowers

23
© UNEP 2006
Fan Efficiency and Performance

• Fan efficiency:
Fans & Blowers
• Ratio of the power conveyed to air stream

and power delivered by the motor to the fan
• Depends on type of fan and impeller
• Fan performance curve

• Graph of different pressures and
corresponding required power
• Supplier by manufacturers
24
© UNEP 2006
Peak efficiency or Best Efficiency

Point (BEP)
Fans & Blowers
Airfoil Peak
Type of Fan Efficiency
Backward Range
Centrifugal fans:
Efficiency
Radial
Airfoil, Backward 79-83
curved/inclined
Modified radial 72-79

Radial 69-75
Tubular
Pressure blower 58-68
Forward curved 60-65
Axial fans:
Forward
Vane axial 78-85
Tube axial 67-72
Flow rate
Propeller 45-50
25
(BEE India, 2004) © UNEP 2006
2005
Methodology – fan efficiency

Before calculating fan efficiency

Fans & Blowers
• Measure operating parameters

• Air velocity, pressure head, air stream temp,
electrical motor input
• Ensure that
• Fan is operating at rated speed
• Operations are at stable condition
26
© UNEP 2006

Step 1: Calculate air/gas density

Fans & Blowers
t = Temperature of air/gas
at site condition
Cp = Pitot tube constant,

0.85 (or) as given by the
Step 2: Measure air velocity and manufacturer
calculate average ∆p = Average differential
pressure
γ = Density of air or gas at

test condition
Step 3: Calculate the volumetric

flow in the duct
27
© UNEP 2006

Fans & Blowers
Step 4: Measure the power drive of the motor
Step 5: Calculate fan efficiency

• Fan mechanical efficiency
• Fan static efficiency
28
© UNEP 2006
Difficulties in Performance
Assessment
Fans & Blowers
• Non-availability of fan specification

data
• Difficulty in velocity measurement
• Improper calibration of instruments
• Variation of process parameters
during tests
29
© UNEP 2006
Introduction
Fans & Blowers

30
© UNEP 2006
Electrical Equipment Energy Efficiency Opportunities
1. Choose the right fan

Fans & Blowers
2. Reduce the system resistance

3. Operate close to BEP
4. Maintain fans regularly
5. Control the fan air flow
31
© UNEP 2006
Energy Efficiency Opportunities
1. Choose the Right Fan

• Considerations for fan selection

Fans & Blowers
• Noise
• Rotational speed
• Air stream characteristics
• Temperature range
• Variations in operating conditions
• Space constraints and system layout
• Purchase/operating costs and operating life
• “Systems approach” most important!

32
© UNEP 2006
1. Choose the Right Fan

• Avoid buying oversized fans

Fans & Blowers
• Do not operate at Best Efficiency Point

• Risk of unstable operation
• Excess flow energy
• High airflow noise
• Stress on fan and system
33
© UNEP 2006
2. Reduce the System Resistance

• Increased system resistance

Fans & Blowers
reduces fan efficiency
• Check periodically
• Check after system
modifications
• Reduce where
possible
34
(BEE India, 2004)
© UNEP 2006
3. Operate Close to BEP

Fans & Blowers
• Best Efficiency Point = maximum

efficiency
• Normally close to rated fan capacity
• Deviation from BEP results in
inefficiency and energy loss
35
© UNEP 2006
4. Maintain Fans Regularly

• Periodic inspection of all system

Fans & Blowers
components
• Bearing lubrication and replacement
• Belt tightening and replacement
• Motor repair or replacement
• Fan cleaning
36
© UNEP 2006
5. Control the Fan Air flow

a) Pulley change
Fans & Blowers
b) Dampers
c) Inlet guide vanes
d) Variable pitch fans
e) Variable speed drives (VSD)
f) Multiple speed drive
g) Disc throttle
h) Operating fans in parallel
37
i) Operating fans in series © UNEP 2006

a) Pulley change: reduce motor/drive

Fans & Blowers
pulley size
• Advantages
• Permanent speed
decrease
• Real energy reduction
(BEE India, 2004)
• Disadvantages
• Fan must handle capacity change
• Only applicable if V-belt system or motor
38
© UNEP 2006

b) Dampers: reduce flow and increase

Fans & Blowers
upstream pressure
• Advantages
• Inexpensive
• Easy to install
• Disadvantages
• Limited adjustment
• Reduce flow but not energy consumption
• Higher operating and maintenance costs
39
© UNEP 2006

c) Inlet guide vanes

Fans & Blowers
• Create swirls in fan direction

• Reduce angle air and fan blades
• Lowering fan load, pressure, air flow
• Advantages
• Improve efficiency: reduced load and airflow
• Cost effective at 80-100% of full air flow
• Disadvantage
• Less efficient at <80% of full air flow
40
© UNEP 2006

d) Variable pitch fans: changes angle

Fans & Blowers
incoming airflow and blades

• Advantages
• High efficiency at range of operating conditions
• No resonance problems
• No stall problems at different flows
• Disadvantages
• Applicable to axial fans only
• Risk of fouling problems
41
• Reduced efficiency at low loads © UNEP 2006

e) Variable speed drives (VSDs): reduce

Fans & Blowers
fan speed and air flow

• Two types
• Mechanical VSDs
• Electrical VSDs (including VFDs)
• Advantages
• Most improved and efficient speed control
• Speed adjustments over continuous range
• Disadvantage: high costs 42

© UNEP 2006

e) Variable frequency drives

Fans & Blowers
• Change motor’s rotational speed by

adjusting electrical frequency of power
• Advantages
• Effective and easy flow control
• Improved efficiency over wide operating range
• Can be retrofitted to existing motors
• Compactness
• No fouling problems
43
• Reduced energy losses and costs © UNEP 2006

f) Multiple speed drive

Fans & Blowers
• Changes fan speed from one speed to

other speed
• Advantages
• Efficient control of flow
• Suitable if only 2 speeds required
• Disadvantages
• Need to jump from speed to speed
• High investment costs 44
© UNEP 2006

g) Disc throttle:
Fans & Blowers
Sliding throttle that changes width of

impeller exposed to air stream
• Advantages
• Simple design
• Disadvantages
• Feasible in some applications only
45
© UNEP 2006

h) Operate more fans in parallel (instead

Fans & Blowers
of one large fan)

• Advantages
• High efficiencies at varying demand
• Risk of downtime avoided
• Less expensive and better performance than
one large fan
• Can be equipped with other flow controls
• Disadvantages
46
• Only suited for low resistance system
© UNEP 2006

i) Operate fans in series

Fans & Blowers
• Advantages
• Lower average duct pressure
• Less noise
• Lower structural / electrical support required
• Disadvantages
• Not suited for low resistance systems
47
© UNEP 2006
5. Controlling the Fan Air Flow

Comparing
Fans in
Fans & Blowers
Parallel
and Series
(BEE India, 2004) 48

© UNEP 2006
5. Controlling the Fan Air Flow

Comparing
the impact of
Fans & Blowers
different types
of flow control
on power use
(BEE India, 2004) 49

© UNEP 2006
Training Session on Energy
Equipment

Fans & Blowers

Fans & Blowers
THANK YOU
FOR YOUR ATTENTION
50
© UNEP 2006
Disclaimer and References
• This PowerPoint training session was prepared as part of

the project “Greenhouse Gas Emission Reduction from
Electrical Equipment/
Industry in Asia and the Pacific” (GERIAP). While

Fans and Blowers
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.
• The GERIAP project was funded by the Swedish
International Development Cooperation Agency (Sida)
• Full references are included in the textbook chapter that is
51
available on www.energyefficiencyasia.org
© UNEP 2006

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Training Session on Energy

Fans & Blowers

Presentation from the

Types of fans and blowers

Provide air for ventilation and

industrial processes that need air flow

• Sum of static pressure losses in

• Increases with square of air volume

(US DOE, 1989) 6

Performance curve of fan under

(US DOE, 1989) 7

Fan curve and system curve intersect

Types of fans and blowers

• Rotating impeller increases air velocity

• Air speed is converted to pressure

• Categorized by blade shapes

Centrifugal Fans – Radial fans

• High pressure and temp

• Disadvantages (Canadian Blower)

• Suited for low/medium

Centrifugal Fans – Forward curved

• Large air volumes against

Centrifugal Fans - Backward-inclined

• Operates with changing

• Disadvantages ( Canadian Blower)

• Blades create aerodynamic lift

• Popular with industry: compact, low

Axial Fans – Propeller fans

• High airflow at low pressure

Axial Fans – Tube axial fans

• High pressures to overcome

Axial Fans – Vane axial fans

• Difference with fans

that accelerates air

Positive Displacement Blowers

• Rotors trap air and push it through

Types of fans and blowers

Fan Efficiency and Performance

• Ratio of the power conveyed to air stream

• Fan performance curve

Peak efficiency or Best Efficiency

Modified radial 72-79

Methodology – fan efficiency

Before calculating fan efficiency

• Measure operating parameters

Methodology – fan efficiency

Step 1: Calculate air/gas density

Cp = Pitot tube constant,

γ = Density of air or gas at

Step 3: Calculate the volumetric

Methodology – fan efficiency

Step 4: Measure the power drive of the motor

Step 5: Calculate fan efficiency

• Fan static efficiency

• Non-availability of fan specification

Types of fans and blowers

1. Choose the right fan

2. Reduce the system resistance

1. Choose the Right Fan

• Considerations for fan selection

• “Systems approach” most important!

1. Choose the Right Fan

• Avoid buying oversized fans

• Do not operate at Best Efficiency Point