Facilities Management University of Moratuwa Industrial Systems Fans and Blowers

Fans and Blowers

Saranga N B
Lesson overview

1. History of the Fan

2. Introduction to the Fans
3. Types
Learning of Fans and Blowers
objectives Keywords
4. Assessment of Fan and Blowers
5. Energy Efficiency Opportunities

Standards
1. History of the Fans

• Pictorial records showing some of the earliest fans date

from around 3000 BC and there is evidence that the
Greeks, Etruscans and Romans all used fans as cooling and
ceremonial devices, while Chinese literary sources
associate the fan with ancient mythical and historical
characters.
• The first electric fan was created by Dr. Schuyler Skaats
Wheeler in 1886
2. Introduction to the Fans

• Most manufacturing plants use fans and blowers

for ventilation and for industrial processes that
need an air flow. Fan systems are essential to keep
manufacturing processes working.
• Fans and blowers are differentiated by the
method used to move the air, and by the system
pressure they must operate against.
• A typical fan system consists consist of a fan, an
electric motor, a drive system, ducts or piping,
flow control devices, and air conditioning
equipment (filters, cooling coils, heat exchangers,
etc.)
2. Introduction to the Fans Contd.
System Resistance
• The term “system resistance” is used when referring to the
static pressure. The system resistance is the sum of static
pressure losses in the system. The system resistance is a
function of the configuration of ducts, pickups, elbows and the
pressure drops across equipment, for example bag filter or
cyclone.
• The system resistance varies with the square of the volume of
air flowing through the system. For a given volume of air, the
fan in a system with narrow ducts and multiple short radius
elbows is going to have to work harder to overcome a greater
system resistance than it would in a system with larger ducts
and a minimum number of long radius turns.
3. Types of Fans and Blowers

1. Centrifugal Fans
• Centrifugal fans increase the speed of an air stream with a
rotating impeller.
• The speed increases as the reaches the ends of the blades and
is then converted to pressure.
• These fans are able to produce high pressures, which makes
them suitable for harsh operating conditions, such as systems
with high temperatures, moist or dirty air streams, and
material handling.
• Centrifugal fans are categorized by their blade shapes.
3. Types of Fans and Blowers Contd.

1.1 Centrifugal Fans-Radial Fans

Radial fans, with flat blades
Advantages:
• Suitable for high static pressures (up to 1400 mmWC) and high temperatures
• Simple design allows custom build units for special applications
• Can operate at low air flows without vibration problems
• High durability
• Efficiencies up to 75%
• Have large running clearances, which is useful for airborne-solids (dust, wood
chips and metal scraps) handling services
Disadvantages:
• Only suitable for low-medium airflow rates
3. Types of Fans and Blowers Cont.

1.2 Centrifugal Fans- Forward curved

Forward curved fans, with forward curved blades
Advantages:
• Can move large air volumes against relatively low pressure
• Relative small size
• Low noise level (due to low speed) and well suited for residential heating, ventilation, and air
conditioning (HVAC) applications.
Disadvantages:
• Only suitable for clean service applications but not for high pressure and harsh services
• Fan output is difficult to adjust accurately
• Driver must be selected carefully to avoid motor overload because power curve increases steadily with
airflow
• Relatively low energy efficiency (55-65%)
3. Types of Fans and Blowers Cont.

1.3 Centrifugal Fans- Backward inclined

Backward inclined fan, with blades that tilt away from the direction of rotation.
Advantages:
• Can operate with changing static pressure (as this does not overload the motor)
• Suitable when system behavior at high air flow is uncertain
• Suitable for forced-draft services
• Flat bladed fans are more robust
• Curved blades fans are more efficient (exceeding 85%)
• Thin air-foil blades fans are most efficient
Disadvantages:
• Not suitable for dirty air streams (as fan shape promotes accumulation of dust)
• Thin airfoil blades fans subject to erosion
3. Types of Fans and Blowers Cont.

2. Axial Fans
• Axial fans move an air stream along the axis of the fan.
• Popular with industry due to inexpensive, compact and light.
• Fans work can be compared to a propeller on an airplane.
• The fan blades generate an aerodynamic lift that pressurizes the air.
• Although the fans are typically designed to generate flow in one direction, they can operate in the
reverse direction too.
• This characteristic is useful when a space may require contaminated air to be exhausted or fresh air to be
supplied. Axial fans are frequently used in exhaust applications where airborne particulate size is small,
such as dust streams, smoke, and steam.
• Axial fans are also useful in ventilation applications that require the ability to generate reverse airflow.
3. Types of Fans and Blowers Cont.

2.1 Axial Fans- Propeller fans

Advantages:
• Achieve maximum efficiency, near-free delivery, and are often used in rooftop ventilation applications
• Can generate flow in reverse direction, which is helpful in ventilation applications
• Not combined with extensive ductwork (because the generate little pressure)
• Generate high airflow rates at low pressures
• Inexpensive because of their simple construction
Disadvantages:
• Relative low energy efficiency
• Comparatively noisy
3. Types of Fans and Blowers Cont.

2.2 Axial Fans- Tube axial fans

Tube-axial fan, essentially a propeller fan placed inside a cylinder
Advantages:
• Higher pressures and better operating efficiencies than propeller fans
• Suited for medium-pressure, high airflow rate applications, e.g. ducted HVAC installations
• Can quickly accelerate to rated speed (because of their low rotating mass) and generate flow in reverse
direction, which is useful in many ventilation applications
• Create sufficient pressure to overcome duct losses and are relatively space efficient, which is useful for
exhaust applications
Disadvantages:
• Relatively expensive
• Moderate airflow noise
• Relatively low energy efficiency (65%)
3. Types of Fans and Blowers Cont.

2.3 Axial Fans- Vane axial fans

Advantages:
• Suited for medium- to high-pressure applications (up to 500 mmWC), such as induced draft service for a
boiler exhaust
• Can quickly accelerate to rated speed (because of their low rotating mass) and generate flow in reverse
directions, which is useful in many ventilation applications
• Most energy efficient (up to 85% if equipped with airfoil fans and small clearances)
• Suited for direct connection to motor shafts
Disadvantages:
• Relatively expensive compared to propeller fans
3. Types of Fans and Blowers Cont.

3. Blowers
• Blowers can achieve much higher
pressures than fans, as high as 1.20
kg/cm2.
• They are also used to produce
negative pressures for industrial
vacuum systems.
• The centrifugal blower and the
positive displacement blower are
two main types of blowers.
3. Types of Fans and Blowers Cont.

3.1 Centrifugal Blowers

• Centrifugal blowers look more like centrifugal pumps than fans.
• The impeller is typically gear-driven and rotates as fast as 15,000
rpm. In multi-stage blowers, air is accelerated as it passes through
each impeller. In single-stage blower, air does not take many turns,
and hence it is more efficient.
• Centrifugal blowers typically operate against pressures of 0.35 to
0.70 kg/cm2, but can achieve higher pressures.
• One characteristic is that airflow tends to drop drastically as
system pressure increases, which can be a disadvantage in
material conveying systems that depend on a steady air volume.
Because of this, they are most often used in applications that are
not prone to clogging.
3. Types of Fans and Blowers Cont.

3.2 Positive Displacement Blowers

• Positive displacement blowers have rotors, which
"trap" air and push it through housing.
• These blowers provide a constant volume of air even
if the system pressure varies. They are especially
suitable for applications prone to clogging, since they
can produce enough pressure (typically up to 1.25
kg/cm2) to blow clogged materials free.
• They turn much slower than centrifugal blowers (e.g.
3,600 rpm) and are often belt driven to facilitate
speed changes.
4. Assessment of Fans and Blowers

Peak Efficiency or Best Efficiency Point

• As the flow rate increases, the efficiency
increases to certain height (“peak
efficiency”) and then decreases with
further increasing flow rate. (Point at the
peak of one of the curves)
• The peak efficiency is also called the Best
Efficiency Point (BEP)
• The peak efficiency ranges for different
types of centrifugal and axial fans are
given in the Table
5. Energy Efficiency Opportunities

1. Choose the Right Fan

• Important considerations when selecting a fan are:
• Noise
• Rotational speed
• Air stream characteristics
• Temperature range
• Variations in operating conditions
• Space constraints and system layout
• Purchase costs, operating costs (determined by efficiency and maintenance), and operating life
• The “systems approach” requires knowing the interaction between fans, the equipment that supports
fan operation, and the components that are served by fans. The use of a “systems approach” in the fan
selection process will result in a quieter, more efficient, and more reliable system.
5. Energy Efficiency Opportunities Contd.

2. Reduce the System Resistance

• The fan operates at a point where the system
resistance curve and the fan curve intersects.
• The system resistance has a major role in determining
the performance and efficiency of a fan. In the figure,
if the system resistance is increased then the operating
point moves from A to B. The result is that the air flow
of the fan reduces, and thus the fan efficiency.
• The system resistance changes
• Marginally by the formation of the coatings /
erosion of the lining in the ducts
• Drastically, in some cases, due to the change of
equipment, duct modifications
5. Energy Efficiency Opportunities Contd.

3. Operate Close to BEP

• It is earlier described that the fan efficiency increases
as the flow increases to certain point and thereafter it
decreases. The point at which maximum efficiency is
obtained is called the peak efficiency or “Best
Efficiency Point” (BEP).
• Normally it is closer to the rated capacity of the fan at
a particular designed speed and system resistance.
• Deviation from the BEP will result in increased loss and
inefficiency.
5. Energy Efficiency Opportunities Contd.

3. Maintain Fan Regularly

Regular maintenance of fans is important to maintain
their performance levels. Maintenance activities include:
• Periodic inspection of all system components
• Bearing lubrication and replacement
• Belt tightening and replacement
• Motor repair or replacement
• Fan cleaning
5. Energy Efficiency Opportunities Contd.

4. Control the Air Flow

1. Pulley change

Advantages
• Permanent speed decrease
• Real energy reduction
Disadvantages
• Fan must handle capacity change
• Only applicable if V-belt system or motor

2. Dampers: Reduce the flow and increase the upstream pressure

Advantages
• Inexpensive
• Easy to install
5. Energy Efficiency Opportunities Contd.

Disadvantages
• Limited adjustment
• Reduce flow but not energy consumption
• Higher operating and maintenance costs

3. Inlet guide vanes: Create swirls in the fan direction thereby lessening the angle between incoming air and
fan blades, and thus lowering fan load, pressure and airflow.

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
5. Energy Efficiency Opportunities Contd.

4. Variable pitch fans: Changes angle 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
• Reduced efficiency at low loads
5. Energy Efficiency Opportunities Contd.

5. Variable speed drives (VSDs): Reduce 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
5. Energy Efficiency Opportunities Contd.

6. Operate more fans in parallel (instead of one large fan)

Advantages
• Less expensive and better performance than one large fan
• Can be equipped with other flow controls
• High efficiencies at varying demand
• Risk of downtime avoided

Disadvantages
• Only suited for low resistance system

7. Operate fans in series

Disadvantages
• Not suited for low resistance systems
5. Energy Efficiency Opportunities Contd.

Advantages
• Lower average duct pressure
• Less noise
• Lower structural / electrical support required
• The fan curve of two fans in series starts high but drops rapidly. At the point where the fan curve meets
the High Resistance System curve, i.e. the operating point, the flow is much higher than that of a single
fan. In other words, the efficiency gain is significant. But at the operating point in a Low Resistance
System, the flow is low and practically the same as that of a single fan. This is why fans in series are not
suited for low resistance systems
• Fan curve of two fans in parallel does not start high but drops much slower. In a High Resistance System
the operating point is only slightly higher than that of a single fan. In other words, the efficiency gain in a
High Resistance System is minimal. But in a Low Resistance System the operating point of two fans in
parallel is relatively high. This is why fans in parallel are suited for low resistance systems.
Facilities Management University of Moratuwa Industrial Systems Fans and Blowers

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