MODULE II PART B

Maintenance Engineering
Certificate Course

By Career Guidance Cell (CGC)

Department of Mechanical Engineering,
College of Engineering and Computer Science
 MODULE II
Plant Facilities Maintenance
 VENTILATION AND EXHAUST
SYSTEMS
AIR FLOW FUNDAMENTALS

A fan or air-moving device is simply the machine

which supplies the air with the energy required to
move it. It overcomes inertia, or reluctance to move
from rest and friction, or resistance to continuous
flow, both of which are always present.

Mechanical energy supplied to the rotating wheel of

the fan is transferred to the air to increase its
velocity and raise its pressure enough to overcome
the resistance and produce the required flow.
 FUNDEMENTAL RELATIONSHIPS
Fan capacity (cfm). Volume of air moved by the fan per unit of time. Stated
customarily in cubic feet per minute. Air at a density of 0.075 lb/ft3 is always
implied unless specifically stated otherwise.

Static pressure (SP). Pressure produced by the fan which can exist whether
the air is confined in a closed duct. Expressed in inches of water gage (in
WG). It can be regarded as simply the potential energy produced by the fan
and required to overcome resistance to flow offered by the system. Other
terms often used synonymously are fan static, system resistance, and system
static.
 FUNDEMENTAL RELATIONSHIPS
Velocity pressure (VP). Pressure produced by the fan which can exist only
when the air is in motion and is always exerted in the direction of airflow.
Air moving at a velocity of 4000 fpm will exert a pressure of 1 in WG on a
stationary object in its path.

VP for any other velocity can be easily calculated, since it varies as the
square of the velocity. At 8000 fpm the VP is 4 in WG; at 2000 fpm the VP is
0.25 in WG.

Total pressure (TP). The sum of the static pressure and velocity pressure, in
WG.
 FUNDEMENTAL RELATIONSHIPS
Outlet velocity (OV). cfm divided by the inside area of the fan outlet (or
discharge area) in square feet (ft2) equals the outlet velocity in feet per
minute (fpm).

Brake horsepower (bhp). Power input—the power that must be supplied at

the fan shaft to produce the required cfm and pressure.

Static efficiency (SE).Not the true mechanical efficiency but convenient to

use for comparing fans, since most published performance data show SP, not
TP.
𝑆𝑡𝑎𝑡𝑖𝑐 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 ∗ 𝑐𝑓𝑚 ∗ 𝑆𝑃
 FUNDEMENTAL RELATIONSHIPS
Total efficiency (ME). True mechanical efficiency—power output
divided by power input.
𝑇𝑜𝑡𝑎𝑙 𝐸𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑐𝑦 = 𝐶𝑜𝑛𝑠𝑡𝑎𝑛𝑡 ∗ 𝑐𝑓𝑚 ∗ 𝑇𝑃
Fan rating. A statement of fan performance for one condition of
operation. Includes fan size, speed, capacity, pressure, and horsepower.
Also used merely to specify only the cfm and SP desired.

Free-delivery capacity. Fan capacity with no resistance or static

pressure (a condition rarely, if ever, encountered in practical
applications!). It is common practice, however, to publish propeller-fan
and occasionally axial-fan capacities at free delivery.
 FUNDEMENTAL RELATIONSHIPS

Static no-delivery pressure (SND). Also called shutoff pressure, it means

the static pressure produced by the fan at zero cfm.

Tip speed. Peripheral speed of the fan wheel in fpm.

 Standards.

• Air Moving and Conditioning Association (AMCA) has developed

Standard Test Codes which are generally used and accepted
throughout the industry.

• The fan manufacturer publishes performance data based on actual

tests of a representative number of fan sizes.

• Catalogs usually contain other useful and necessary information such

as fan weights, dimension prints, optional equipment, and other
technical data
Drive arrangements for centrifugal fans
 Designations for rotation
and discharge of centrifugal
fans
Part of a typical rating table. The fan is a backward-curved airfoil-blade type.
Air density at various altitudes
 Calculation
A fan is inherently a constant-volume machine. It will handle the same cfm
when operating in a fixed system at a constant speed regardless of changes in
air density; however, the pressure developed and the horsepower required will
vary directly as the air density.
Assume that a fan is required to deliver 16,776 cfm at 1 in SP under the above
conditions of 200F and 5000-ft altitude. Using the rating table, proceed as
follows:
1. Density factor is 0.668.
2. Equivalent SP is 1 in/0.668 = 1.5 in
3. Enter table at 16,776 cfm under 1.5 in SP and read 613 rpm and 5.74 bhp.
4. rpm is correct as read.
5. bhp required is 5.74 x 0.668 = 3.83.
FAN PERFORMANCES

Typical fan-performance curves.

 Calculations

Governing Expressions

1. Cfm varies directly as the rpm.

2. Pressure varies as the rpm squared.
3. Hp varies as the rpm cubed.
Types of Fans and
recommendations
Fans can be divided into four
general categories: propeller,
axial, centrifugal, and special-
purpose.

High static pressure fans are best

of heatsinks and radiators. High
airflow fans are best for open
spaces.
Various types of air-moving devices. All the units shown are designated as
arrangement No. 4, with the wheel mounted on the motor shaft, but they are
usually available with V-belt drive as well. A tube-axial fan is similar to a
vane-axial fan except that the air-straightening vanes downstream from the
wheel are omitted. The performance characteristics shown are typical for
propeller and axial fans. The in-line fan is a mixed-flow type utilizing a
backward-curved-blade centrifugal wheel in an axial-fan cylindrical housing,
with curved air-straightening vanes downstream from the wheel.
 Types
Propeller. Consists of a propeller or disk-type wheel within a mounting ring, panel, or
cage Wheel and/or housing may be sheet metal, cast metal (usually aluminum),
fabricated steel(or other metal) plate or various plastics, protective coatings, and
combinations of materials. It may be direct-drive with the wheel mounted on the motor
shaft or belt-driven with the wheel mounted on its own shaft and bearings.

Axial. A tube-axial fan is essentially a propeller fan enclosed in a short cylindrical

housing. A vane-axial fan incorporates specially designed vanes, which may be either
upstream or downstream from the fan wheel. The vanes straighten the inherent
spiraling flow pattern of the wheel, thereby converting some of the velocity component
of the airstream to useful static pressure. Vane-axial fans can develop much higher
static pressures than tube-axials. Construction may include fabricated steel, cast metal,
plastic, various combinations of materials, and special protective coatings. May be
either direct-drive or belt-driven.
Types of centrifugal
fans
The drawings illustrate the three basic
types of centrifugal-fan wheels with their
typical scroll-shaped housing shown in
outline. Direction of wheel rotation is
indicated by an arrow. The radial-blade
wheel shown is a simple paddle type. The
large number of blades is typical for the
forward-curved type. Backward-curved
wheels have fewer blades. Radial types
generally have the smallest number of
blades. Typical performance characteristics
are also shown for each type. The jet
pump is an air-moving device sometimes
used to avoid passing extremely hot or
contaminated air through a fan.
 Types of Fans
Backward-Curved-Blade Centrifugal. This type of fan is capable of the highest
efficiency and lowest sound level of all centrifugal fans, particularly those with
airfoil-shaped double-thickness blades. Standard units are fabricated from steel
plate or sheet. Also obtainable in a wide variety of special metals and protection
coatings. Wheel blades may be flat, single-thickness, and curved, or double-
thickness and curved with an airfoil-shaped cross section.

Forward-Curved-Blade Centrifugal. Characterized by a large number of wide

shallow blades, very large inlet area relative to wheel diameter, and low speed
compared with other centrifugal fans for equal volume and measure. Sometimes
called squirrel-cage fan or multivane fan. Usual construction is fabricated steel
but may be other metals when required. Also obtainable with protective
coatings or all plastic in the smaller sizes as well as various combinations of
materials.
 Types of Fans
In-Line-Flow Centrifugal. Also referred to as a tubular centrifugal, it is actually a mixed-flow
fan. It consists of a centrifugal wheel in an axial housing. Straightening vanes downstream
from the wheel convert some of the velocity component of the airstream into useful static
pressure.

Power Roof Exhausters. These units usually consist of a package complete with base for roof
mounting, backdraft damper, and either propeller, axial, or centrifugal wheels. Available in a
variety of styles, direct or belt drive, special metal and plastic construction, or special
coatings. Centrifugal types discharge air around periphery of wheel, deflecting air
downward. Others usually discharge air vertically.

Jet Pumps. These devices can be useful where the air or gas is too hot or corrosive to pass
through a fan. They are also called injectors or ejectors. They are available from many
manufacturers or may be designed and specially made for a specific application.
 Types of Fans

Belt-driven propeller fan for medium Inlet end of direct-connected tube- Inlet end of direct-connected vane-axial
duty. Most units can be obtained for air axial fan. Note electrical connections fan. Motor shaft supports and drives
flow in either direction. This fan is for and grease fittings brought outside wheel. Vanes behind wheel straighten
wall mounting and will exhaust air from housing. Arrows are provided near inherent spiraling motion of air as it
a space, drawing it over the motor and nameplate to indicate direction of leaves the wheel and increase static
the drive. wheel rotation and airflow. pressure
 SELECTING FANS FOR SEVERE DUTY
Industrial-fan applications often involve troublesome maintenance problems caused
by high temperature, corrosion, and abrasion.

High Temperature. The fan-maintenance problems associated with high

temperatures can some times be minimized or eliminated by cooling the airstream
before it passes through the fan. The methods worth considering are:

1. Spray cooling. Cooling the air with water sprays is very effective. It has the
added advantage of sometimes resulting in a considerable reduction in volume
and fan size.
2. Dilution cooling. Cold air can be bled in on the suction side of the fan to produce
a cooler mixture. The cold air must be introduced in a manner that provides
enough time and turbulence to produce a mixture with fairly uniform
temperature at the fan. It is not as effective as spray cooling but can often be
used where only a moderate amount of cooling is needed.
 SELECTING FANS FOR SEVERE DUTY
3. Air-to-air heat exchangers. The possibilities with this method vary in complexity.
They require careful analysis to determine their feasibility. Occasionally, the waste
heat can be recovered and used for space heating or in some other process. All
these methods increase the system resistance and consequently the power
consumed by the fan.

4. Water-cooled ductwork. This method is sometimes used where exhaust-air

temperatures are extremely high, electric-arc steel-melting furnaces, for example.
A short section of ductwork, the collecting hood, or both may be water-jacketed
and cooled with a recirculating system or with waste water. On very large
installations it is feasible to utilize the heated water in a waste-heat boiler or other
process.
 CORROSION
Corrosion. All types of fans are available with a variety of special protective paints
and coatings, rubber covering, all-plastic construction, special metal construction,
and various combinations of materials, all intended to make them more resistant to
attack. The problem is so complex and the variety so great that a list of specific
recommendations cannot be made. Following are some general recommendations:

1. Avoid, if possible, using a fan with the motor or bearings in a corrosive

airstream. Although such fans are satisfactory for some applications, a
single-inlet centrifugal fan such as arrangement 1 is the best choice if the
problem is severe.
2. Use a shaft seal on centrifugal fans to prevent corrosive material from
leaking or being blown out of the housing toward the inboard fan bearing.
 CORROSION
3. Keep inlet and outlet connections tight. Flanged and gasketed connections
are obviously superior to slip-type in this respect.
4. Use a drain connection at the lowest point in the fan housing if the
airstream contains mist or condensable vapor.
5. When it is feasible, install the fan on the clean-air side of the air-cleaning
device if the system includes one. There are exceptions, of course; some
gases that may be handled easily when dry become corrosive after passing
through a wet scrubber or gas absorber.
6. AMCA Publication 99, a standard handbook, includes some very useful
information concerning the preparation of centrifugal fans for protective
coatings..
 ABERATION
Abrasion. The radial-blade centrifugal is by far the best type to consider
when the fan must handle air containing abrasive material. Their only
disadvantage is their relatively low efficiency compared with the other types
of centrifugal fans. When the volume and pressure requirements are such
that a very large reduction in power consumption can be realized by using
another type of fan, economics may dictate the choice.

1. Steel wear plates attached to the wheel blades—may be welded on or

bolted and replaceable
2. Replaceable wear liners for the fan scroll and sides—may be steel or cast
iron
3. Hard-facing the wheel blades with materials such as tungsten carbide
 HANDLING FLAMMABLE GASES OR VAPORS
Wherever a flammable or explosive mixture is handled by the fan, either
continuously or only infrequently, it is imperative to eliminate all possible
sources of ignition. The table below lists the sources and suggested
preventive measures. AMCA Standard 401-66 classifies fans or air-moving
devices (AMD) with spark-resistant construction into three types.
 Eliminating Noise problems
1. Inspect the fan for possible mechanical sources of noise. Investigate at least these possibilities:

a. Worn or dry bearings or coupling

b. Loose set screws on fan wheel or V-belt-drive sheaves
c. Broken or loose bolts or fasteners
d. Bent fan shaft
e. Fan wheel or motor out of balance
f. Weak or unstable foundation or fan mounting
g. Loose dampers or inlet vanes
h. Speed too high
i. Fan rotating in wrong direction
j. Foreign material in fan
k. Fan wheel rubbing on housing
l. Vibration transmitted to fan from some other source
 Eliminating Noise problems
2. Locate the fan either in an unoccupied space or as remote as possible from an occupied
space. The OSHA requirements apply only to the noise people may be subjected to—not to
the noise generated by the fan.

3. Install a good vibration-isolation base under the fan and motor unit and provide a heavy,
rigid foundation for the entire assembly. This will prevent transmitting vibration to the
building structure.

4. Install flexible connections between the fan inlet and/or outlet and the connecting
ductwork. Do not use the fan housing to support the ductwork.

5. Install sound attenuators on the fan inlet or outlet as necessary. Many commercial units
are avail able for this purpose.
 Safety Devices
Protective Screens. Screens should always be installed on a centrifugal or axial fan whenever the
inlet or outlet is open while it is in operation. Propeller fans should usually have the entire motor
and drive enclosed. Screens are an obstruction in the airstream, and the mesh should not be too
fine,
generally not finer than 1-in mesh for centrifugal fans and 1/2-in mesh for propeller fans.

Coupling Guards. The guard must be strong enough to provide complete protection. It must also be
easily removable for servicing.

Belt Guards. A V-belt drive is a friction drive and will generate heat. Air must be allowed to
circulate freely around all parts of the drive to dissipate the heat; do not enclose it completely.
Use an open-mesh expanded metal guard if possible.

Disconnect Switches. Unless there is an established lockout procedure where the fan is remote
from its starter, always install a disconnect switch at the fan to prevent accidental starting and
injury
to maintenance personnel.
 Safety Devices
Protective Devices. Many devices are available which will automatically detect a fan malfunction.
They can be arranged to shut down the fan or send an audible or visible signal to call attention to the
problem. Among the many possibilities are sensing excessive vibration, high bearing temperature, loss
of coolant or lubricant flow, and loss or reduction in airflow. They are worth considering if the fan is
vital to a process or if access to it is difficult
Periodic Inspections
Periodic Inspections
Periodic Inspections
Periodic Inspections
Periodic Inspections
Periodic Inspections
 References
Maintenance Engineering Handbook 7th Edition by Keith Mobley (Author),
Lindley Higgins (Author), Darrin Wikoff (Author), Publisher : McGraw-Hill
Professional; 7th edition (March 21, 2008), ISBN-10 : 0071546464, ISBN-13 :
978-0071546461
Thank You
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