800

700

Fan Static P ressure (Pa)

600

500

400
P

300
PO = P x Q

200

100

Q
0
0 100 200 300 400 500 60

Fan Optimization Tool Kit

Flow Rate (m³/s

May 2014 – Version 4

Didier Dum
 160

140

120

Power (W )
100

80

P x Q PS 60

40

20

Q
0
00 300 400 500 600 700 800 900 1000

Flow Rate (m³/s)

Version 3.2 carried out by:

Didier Dumont (IPC) ; Umran Dilaver-Mehter (LCE); Lynos Kutekwatekwa (IPMEA) ; Mohammad Ali (LCE)
Written by TC experts:

Published by:
IPC, L'Isle-d'Abeau (France)
Fan Optimization Tool Kit
Revisions
Version Date Who Comments
version 1.0 09/01/14 IPC - Fan ad hoc Group Draft

version 2.0 11/02/14 IPC - Fan ad hoc Group Draft

version 3.0 11/02/14 D.Dumont - IPC Draft

version 3.1 11/03/14 D.Dumont - IPC Draft

version 3.2 19/03/14 D.Dumont - IPC Draft

version 4 06/06/14 D.Dumont - IPC Draft

Comments

OPEX / TROUBLE SHOOTING / OPERATING DIAGRAM

Correction erreur cellule "I33" fan shaft power

Correction cellule "I36" =SI(I28>0;I28*I27/I33/1000;L28*I27/I33/1000)

Insertion "5-4-flow diagram"

Insertion "5-5-Process Setting"

 Fan Optimization Tool Kit
May 2014 – Version 4

CONTENTS
HYPERLINKS FOR NAVIGATION
Spreadsheet
1 Definitions
Static pressure (SP)
Velocity pressure (VP)
Total pressure (TP)
Fan total pressure (FTP)
Fan static pressure (FSP)
Static pressure rise (SPR)
Fan output power (Po) or aeraulic power or air power
Fan Shaft power or Fan input power (Ps)
Fan motor output power (Pmo)
Absorbed Active Power or Fan motor input power (Pe)
Fan total efficiency (ηt)
Fan static efficiency (ηs)
Fan performance curve or fan pressure curve
Fan power curve
System resistance curve
Operating point
Fan peak pressure

2 Drawings
Fan Drawing
Ducting Arrangement
Plant Fow Sheet
3 Fan Laws
Change in Fan Speed
Change in Gas Density
top Change in Size
4 Site Measurement
Site measurement data
Symbol and description
Pitot inlet 1a
Pitot inlet 1b
Fan Curve
Use of fan spreadsheet
Internal Inspection
Impeller Inspection
5 Fan Performance
OPEX
Field performance measurement of fan system
Operating Diagram
top Flow diagram
Process Setting
6 Main Fan Component
Maintenance and process checks
Fan part
Additionnal fan part
Electrical

7 List of Reference Documents

list
8 Fan Trouble Shooting
SYSTEM EFFECT
top PERFORMANCE
MECHANICAL
IMPELLER
GENERAL
ELECTRICAL
BELT-DRIVES
 contents
Data imported from another
55%
50%

Period
Ref values current P-1 P-2 P-3
Fan (kWh/t) 3.80 5.20 4.78 3.99 3.59
system (kWh/t) 4.13 5.65 4.85 4.30 3.85 70
Energy cost (€/MW) 80 80 80 80 80
60
kk production (tph) x 62.5 68 74 78
50
OPEX impact (k€/year) x 57.7 29.9 7.5 -13.5
losses 57.7 29.9 7.5 0.0 40
gains 0.0 0.0 0.0 -13.5 ###
30

k€
20

10

0
current
-10

-20
ata imported from another spreadsheet: 5-1-Fan Performance
55% Fan efficiency 5.14 kWh/t fan 5.53825 Nm3/KgKK
50% System efficiency 5.65 kWh/t system N/A Nm3/Kg cement

Reference values S.E. Losses Losses per year

3.80 kWh/t fan 1.34 kWh/t 635,790 kW fan
4.13 kWh/t system 1.52 kWh/t 721,050 kW system

80.0 €/MW 50,863 € fan

57,684 € system

OPEX impact (k€/year)

70

60

50

40
gains
30 losses
20

10

0
current P-1 P-2 P-3
-10

-20
contents Field performance measu
274,141 Nm3/h 72,000 Nm3/h

T d3b 125 °C 125 °C

Rhô a 0.856 kg/m3 0.856 kg/m3

P v3a 240.6 Pa 240.6 Pa

3a 3b

P s3a -3,000 Pa -3,000 Pa

1a 1b

353 kW

rotation speed fan shaft power

1,110 rpm 321 kW

3,026 Pa Fan Total Pressure 55% Fan efficiency

3,010 Pa Fan Static Pressure 50% System efficiency

1200%

1000%

800%

600% '5-2-fan performance'!#

'5-2-fan performance'!#
400%

200%

0%
30/12/99 1/1/00 3/1/00 5/1/00 7/1/00 9/1/00 11/1/00
contents
erformance measurement of fan system

346,141 Nm3/h
126 °C
T d3b 257 Pa
10 Pa
Rhô b

P v3b

P s3b

353 kW abs power

Fan efficiency 5.14 kWh/t fan 5.53825 Nm3/KgKK

System efficiency 5.65 kWh/t system N/A Nm3/Kg cement

Reference values S.E. Losses Losses per year

3.80 kWh/t fan 1.34 kWh/t 635,790 kW fan
4.13 kWh/t system 1.52 kWh/t 721,050 kW system

80.0 €/MW 50,863 € fan

57,684 € system
an performance'!#
an performance'!#
346,141 Nm3/h
126 °C T d5
257 Pa P v5
10 Pa P s5
contents contents

Symbol Description Unit

P baro Barometric Pressure Pa
P s3a Static pressure at plane 3a Pa
P s3b Static pressure at plane 3b Pa
P s5 Static pressure at plane 5 Pa
P v3a Dyn or Velocity pressure at plane 3a Pa
P v3b Dyn or Velocity pressure at plane 3b Pa
T d3a Dry-Bulb Temperature °C
T d3b Dry-Bulb Temperature °C
T d5 Dry-Bulb Temperature °C
T w3a or b Wet-Bulb Temperature °C
N Speed of rotation rpm
Total Pressure 3a 3b A1a=A1b Area of cross section m²

absorbed kW A3a=A3b Area of cross section m²

1a 1b A2 Area of cross section m²

A5 Area of cross section m²

Wiring T°
5

P s3a P s5
Static Pressures

gas T°

rpm T° & Vib° spectrum T° & Vib° spectrum T° & Vib° spectrum T° & Vib° spectrum On line measurement of Fan Perfomance

On line analysis of the spectrum of vibrations

Charactersitics of the ball bearings
Barometric Pressure Charactersitics of the coupling
Gas composition (% vol dry) : O2=6% ; CO2=25% ; N2=69% ; H2O=7% or Rhô gas=1.4 kg/Nm3 Clinker or Cement production

fan peak
pressure
18 120
operating point
16
fan power 100
14 curve
F an p ressu re

system
12 resistance 80
curve
10

P o w er
60
8
6 fan pressure curve 40

4
20
2

0 0
0 10000 20000 30000 40000
Flow rate

Key Performance data

On line Fan Perfomance system Maintenance Implementation
Dyn or Velocity pressure at plane 3a (VP)

Fan output power (Po) or aeraulic power

System resistance curve (∆P = k ρ Q²)

Vibration analysis (Spectrum)

€uros - gains or losses
Gas Density (kg/Nm3)

Fan Operating point

Motor overheating
Sysytem efficiency
Gas velocity (m/s)
Gas flow (Am 3/s)

Fan shaft power

Recommended
Fan efficiency

Nm3/kg kk

Mandatory
kWh/t

Inputs for the performance tracking tools

Gas composition V x x x x x x x x x x x x x x x V
T d3a V x x x x x x x x x x V x x x V x
T d3b V x x x x x x x x x x V x x x V x
Barometric Pressure V x x x x x x x x x x V x x x x V
Outlet Static Pressure V x x x V V V x V V x x x x x V x
Inlet Static Pressure V V x x V V V x V V x V x x x V x
Inlet Total Pressure x V x x x x x x x x x x x x x V x
Gas Density x V x x x x x x x x x x x V V x
Inlet Velocity Pressure (VP) x V x x x x x x x x x x x x V x
Gas velocity (m/s) x x V x x x x x x x x x x x V x
Dimensions of Inlet and Oultet boxes x x x V x x x x x x x x x x x V x
Gas flow (Am3/s) x x x V V V x V V x V x x x V x
Fan output power (Po) or aeraulic power x x x x x x x V V x x x x x x V
Rotation Speed of the fan x x x x x V x x x x x x V V V x
Position of the inlet damper x x x x x V x x x x x x V V x V
Absorbed power by the motor x x x x x x V x x V V x x V V V x
Fan performance curve x x x x x x V V x x x x x x x V x
Tool for Fan Curve x x x x x x V V x x x x x x x x V
Fan Operating point x x x x x x x V V x x x x x V x
Fan shaft power x x x x x x x V x x x x x x x V
Production rate of kk, cement, etc… x x x x x x x x x x V V V x x V x
Kwh/t of reference x x x x x x x x x x x V x x V x
Nm3/kg kk of reference x x x x x x x x x x x V x x V x
€uro/MW or €uro/t kk , etc… x x x x x x x x x x x x V x x V x
Charactersitics of the ball bearings x x x x x x x x x x x x x V x x V
Charactersitics of the coupling x x x x x x x x x x x x x V x x V
Temperature of the ball bearings x x x x x x x x x x x x x V x x V
Characteristics of the fan x x x x x x x x x x x x x V x V x
Temperature of the wiring x x x x x x x x x x x x x x V x V

contents
 contents % H2O % CO2 % O2 %Ar %N2
dry 0.03 20.93 0.93 0
This spreadsheet is in addition to the the spreadsheet "5-3-operating diagram". wet 1.50 0.03 20.62 0.92 76.94
It gives the key information on data links for on-line fan performance monitoring.

Fan fan inlet box

t/h Abs power Aeraulic surface Pitot factor Total P Inlet Static P Outlet Static P fan Inlet T° Wet gas density at STP (0°C & 101.325Pa) Baro. Pressure Dust concent°
62 t/h 353 kW 2.53 m² 1.00 -2,760 Pa -3,001 Pa 0 Pa 125 °C 1.286 kg/Nm3 or 1.400 kg/Nm3 101,288 Pa 30.0 g/m3

S.E. Velo. P Fan Delta P Gas density - P°&T° RHO corr°. w/o dust (wet)

5.69 kWh/t 241 Pa 3,001 Pa 0.85559 kg/m3

Aeraulic ratio Gas density with dust

2.283 Nm3/kg 0.886 kg/m3

Gas velocity in the fan inlet box 23.31 m/s

141,539 Nm3/h or gas flow 59.08 Am3/s or 212,688 Am3/h

aeraulic power 177 kW Fan

Rot° Speed
System efficiency 50.2% 1,450 rpm

operating point
Fan efficiency 55.8%
18 120
Fan Shaft kW 317.7 kW 16
100
14
F an p ressu re

12 80
10

P o w er
60
8
6 40

4
20
2
0 0
0 10000 20000 30000 40000
Flow rate
 1) Duct Conditions
1.1) Geometry of the fan inlet 1.1.1) Cicular Duct N
Diameter

1.2) Cross Sectionnal Area 2.53 m² Sectionnal area 0.00 m²

1.3) Geometry of the fan outlet 1.3.1) Cicular Duct N
Diameter

1.4) Cross Sectionnal Area 2.40 m² Sectionnal area 0.00 m²

contents

2) Duct Gas Conditions at the Fan Inlet and Outlet

2.1) The fan Inlet T° is available : Y/N Y
125.0 °C valeur usine

2.2) The fan Inlet Static Pressure is available : Y/N Y

-3,000 Pa valeur usine

2.3) The Barometric Pressure is available : Y/N Y

101,288 Pa valeur usine

2.4) The fan Outlet T° is available : Y/N Y

125.0 °C valeur usine

2.5) The Outlet Static Pressure is available : Y/N Y

10 Pa valeur usine

contents
3) Fan Static Pressure Rise or DP
3.1) Static Pressure Rise (SPR)
3,010 Pa valeur calculée

4) Gas Density calculation

4.1) The gas composition is available : Y/N Y % H2O

4.2) % by Volume, dry of CO2 ; O2 ; Ar % by Volume, dry gas

4.3) % by Volume of water vapour % by Volume, wet gas 1.50

4.4) Wet gas density at STP (0°C & 101.325Pa) , w/o dust
1.286 kg/Nm3 valeur calculée

4.5) Wet gas density at Duct Conditions, w/o dust (INLET BOX)
contents 0.856 kg/Am3 valeur calculée

4.6) Dust concentration is available : Y/N Y

0.000 kg/Nm3
4.7) Wet gas density at STP (0°C & 101.325Pa) , with dust
1.286 kg/Nm3 valeur calculée

4.8) Wet gas density at Duct Conditions, with dust (INLET BOX)
 0.856 kg/Am3 valeur calculée

4.9) Wet gas density at Duct Conditions, with dust (OUTLET BOX)
contents 0.882 kg/Am3 valeur calculée

5) Velocity Pressure (VP) or Dynamic Pressure (INLET BOX)

5.1) The Total Pressure (TP) is available : Y/N Y
-2,759 Pa valeur usine

5.2) Velocity Pressure (VP) . (INLET BOX)

240.6 Pa valeur calculée

6) Calculation of Gas Velocity and Flow Rate (INLET BOX)

6.1) The Pitot factor is available : Y/N Y
1.000 valeur usine

6.2) Gas Velocity (INLET BOX)

contents 23.72 m/s valeur calculée

6.3) Gas Flow at Actual Duct Flow Conditions (INLET BOX)

60.107 m3/s or 216,383 Am3/h

7) Calculation of Gas Velocity and Flow Rate (OUTLET BOX)

7,1) Gas Flow at Actual Duct Flow Conditions (OUTLET BOX)
58.321 m3/s or 209,954 Am3/h

7.2) Velocity Pressure (VP) . (OUTLET BOX)

260.4 Pa valeur calculée

7.1) Gas Velocity (OUTLET BOX)

contents 0.13 m/s

8) Fan Operating Point

8.1) Rotation Speed of the impeller

8.2) = 3.1) Static Pressure Rise (SPR)

8.3) Gas Flow

59.214 m3/s

contents 8.4) Wet gas density with dust

9) Calculation of the Efficiency

9.1) Aeraulic Power
176 kW

9.2) Active Power absorbed by the Motor

9.3) System efficiency

49.7%

9.4) Fan Shaft Power

321 kW valeur donnée par courbe ventilateur

9.5) Fan efficiency

contents 54.7%
 10) Performance Tracking of the System
10.1) Production of the workshop

10.2) Specific Energy of the System : Aeraulic Power / Active Power

5.65 kWh/t

10.3) Aeraulic Ratio

2.304 Nm3/kg

10.4) OPEX per year (Positive value=gains ; Negative value=Losses)

contents -57,684 €
1.1.2) Rectangular Duct Y
Rectangular : WIDHT 1.00 m
Rectangular : LENGHT 1.27 m
Nb of inlet box(es) 2
Sectionnal area 2.53 m²

1.3.2) Rectangular Duct Y

Rectangular : WIDHT 1.20 m
Rectangular : LENGHT 2.00 m
Nb of outlet box(es) 1
Sectionnal area 2.40 m²

Main data Alternative setting

Gas temperature at Duct Conditions Average Inlet Temperature

125.00 °C 120 °C

Inlet Static Pressure at Duct Conditions Av. Inlet Static Pressure

-3,000 Pa -3,200 Pa

Barometric Pressure at Local Conditions Barometric Pressure

101,288 Pa 101,325 Pa

Gas temperature at Duct Conditions Average Inlet Temperature

125.00 °C 126 °C

Outlet Static Pressure at Duct Conditions Av. Outlet Static Pressure

10 Pa 15 Pa

3,010.0 Pa

% CO2 % O2 %Ar %N2

0.03 20.93 0.93 0

0.03 20.62 0.92 76.94

Calculat° of wet gas density at STP (0°C & 101.325Pa)

1.286 kg/Nm3 or 1.400 kg/Nm3

Calculat° of wet gas density at Duct Conditions

0.856 kg/Am3 or 0.932 kg/Am3

Dust Concentration at STP (0°C & 101.325Pa)

0.000 kg/Nm3 0.045 or 0.050 kg/Nm3

Calculat° of wet gas density at STP (0°C & 101.325Pa) 0.033 kg/Am3
1.286 kg/Nm3
Calculat° of wet gas density at Duct Conditions
 0.856 kg/Am3
Calculat° of wet gas density at Duct Conditions

0.882 kg/Am3

TP at Duct Conditions
-2,759 Pa

VP at Duct Conditions
240.6 Pa

Pitot Factor Pitot Factor

1.000 0.840

23.72 m/s

valeur calculée 144,000 Nm3/h

valeur calculée 144,000 Nm3/h

VP at Duct Conditions

260.4 Pa

valeur usine 1,450 rpm vers courbe ventilateur

valeur calculée 3,010 Pa vers courbe ventilateur

valeur calculée 59.2 Am3/s vers courbe ventilateur

valeur calculée 0.869 kg/Am3 vers courbe ventilateur

valeur calculée 176 kW

valeur usine 353 kW

valeur calculée 49.7%

née par courbe ventilateur 321 kW

valeur calculée 54.7%

 valeur usine 62.5 tph

S.E. Losses Losses per year Reference Value of the system

-1.52 kWh/t -721,050 kW 4.13 kWh/t

Reference Value of the system

1.732 Nm3/kg

Energy Cost
80.0 €/MW
Definitions
Static pressure (SP) the pressure resulting from the gas density and its degree of
contents compression and independant of the gas velocity

Velocity pressure (VP) the pressure resulting from the velocity of a gas and its air density
contents VP = ½ ρV²

Total pressure (TP) the sum of the static pressure and the velocity pressure
contents TP = SP + VP

Fan total pressure (FTP) the difference between the average total pressure at the fan outlet
contents (2) and the average total pressure at the fan inlet (1)
FTP = TP2 - TP1 = SP2 + VP2 - SP1 - VP1

Fan static pressure (FSP) the difference between the fan total pressure and the velocity
contents pressure at the outlet (2)
FSP = FTP - VP2 = SP2 - SP1 - VP1

Static pressure rise (SPR) the difference between the static pressure at the fan outlet (2) and
contents the static pressure at the inlet (1)
SPR = SP2 - SP1

Fan output power (Po) the minimum power required to move a specified rate of gas
or aeraulic power against a specified resistance
or air power then it is product of the flow (inlet and outlet conditions) and the
fan total pressure
contents Qin = flow (T1, SP1)
Qout = flow (T2, SP2)
Q = (Qin + Qout) / 2
Po = Q x FTP

Fan input power (Ps) the power delivered to the fan shaft
contents also known as fan shaft power

Fan motor output power (Pmo) the power delivered at the fan motor output (the shaft)
contents also the fan input power divided by the fan drive efficiency
Pmo = Ps / ηD

Fan motor input power (Pe) the power delivered at the fan motor input (electrical power)
or Abs. Active Power also the fan output power divider by the motor efficiency
contents Pe = Pmo / ηM
then
Ps = µM x µD x Pe

Fan total efficiency (ηt) the ratio of the fan output power to fan input power
contents also known as fan mechanical efficiency
ηt = Po / Ps
Fan static efficiency (ηs) the product of mechanical efficiency and the ratio of fan static
contents pressure to fan total pressure
ηs = ηt x FSP / FTP

Fan performance curve A curve showing the relationship between the gas flow rate
or fan pressure curve delivered by a fan and the pressure generated at the different flow
contents rates

Fan power curve A curve showing the power of a fan at different flow rates
contents
System resistance curve A curve showing how the resistance to flow through a system
contents (pressure drop) changes with the flow rate.
Typically, for turbulent flow, the curve follows the following
relationship (parabola): ∆P = k ρ Q²

Operating point The intersection of the fan pressure curve and the system
contents resistance curve.
The fan will operate at that point.

Fan peak pressure The maximum pressure the fan can deliver.
contents The fan should always operate on the right side of the peak
pressure point
 2

air out

Po Ps
ηt
Pmo Pe
ηD ηM

Power
air in source

Fan Drive Motor

or Pe = U x I x 1,732 x Cos(phi)
U : Volts ; I : Amps ; Cos(Phi) : power factor
 fan peak
pressure
18 120
operating
point
16
fan 100
14 power
system curve
12 80
Fan pressure

resistance
curve
10

Power
fan 60
8 pressure
curve
6 40
4
20
2
0 0
0 10000 20000 30000 40000
Flow rate
1) Fan Drawing
contents

e
pl
am
Ex
2) Ducting Arrangement
contents

3) Plant Fow Sheet

contents
am
pl
e
contents Change in Fan Speed

contents Change in Gas Density

contents Change in Size
 contents

Static Pressure Taps

Inlet Box Damper

3a 3b

1a 1b

S
Process Inlet and Oultet
101,325 Pa P baro 125 °C T d3a 2.53 m² A1a+A1b 1.27 m² A1a=A1b
-3,300 Pa P s3a 125 °C T d3b 0.96 correction factor for rec
-3,300 Pa P s3b 126 °C T d5 2.53 m² A3a+A3b 1.27 m² A3a=A3b
10 Pa P s5 25 °C T w3a or b
242.9 Pa P v3a 1,110 rpm N 2.43 m² A2
242.9 Pa P v3b gas composition
256.6 Pa P v5 0.03 % CO2 dry 2.43 m² A5
20.93 % O2 dry
0.93 %Ar dry
1.5 % H20
90 deg Fan Inlet damper position
0 deg = 100% open ; 90 deg = 100% closed
intenance - Fan & Motor Temperature Maintenance - Fan & Motor Vibration
50 °C Fan B. 1a 125 °C Wir. 1 1 mm/s Fan B. 1a 0 mm/s x
80 °C Fan B. 1b 125 °C Wir. 2 2 mm/s Fan B. 1b 0 mm/s x
75 °C Mot. Coupl. 126 °C Wir. 3 3 mm/s Mot. Coupl. 0 mm/s x
60 °C Mot. Opp. Coupl 4 mm/s Mot. Opp. Coupl
0 mm/s x
0 mm/s x
0 mm/s x
 Static Pressure Taps

Inlet Box Damper

5 Static Pressure Taps

Site Measurements
Inlet and Oultet boxes Measured motor data
1.32 m L1a=L1b 1.00 m W1a=W1b 2 nb of inlet box 400 V Volts 1
correction factor for rectangular duct 390 V Volts 2
1.32 m L3a=L3b 1.00 m W3a=W3b 2 nb of inlet box 410 V Volts 3
400 V av. Volts
2.53 m L2 1.00 m W2 595 A Amps 1
598 A Amps 2
2.53 m L5 1.00 m W5 601 A Amps 3
598 A av. Amps
0.85 Power Factor

352 kW Cal. Abs Power

353 kW Meas. Abs Power
 Operation data
1,500 tpdkk Clinker production
62.5 tph Clinker production
for ID fan ; Raw Mill Fan ; Kiln filtre fan ; etc…
or

150 tph Cement production

for Mill Fan ; Filtre fan ; Separator fan ; etc…
 contents
Symbol Description
P baro Barometric Pressure
P s3a Static pressure at plane 3a
P s3b Static pressure at plane 3b
P s5 Static pressure at plane 5
P v3a Dyn or Velocity pressure at plane 3a
P v3b Dyn or Velocity pressure at plane 3b
T d3a Dry-Bulb Temperature
T d3b Dry-Bulb Temperature
T d5 Dry-Bulb Temperature
T w3a or b Wet-Bulb Temperature
N Speed of rotation
A1a=A1b Area of cross section
A3a=A3b Area of cross section
A2 Area of cross section
A5 Area of cross section

Static Pressure Taps

or data Motor Nameplate data

500 kW Installed power
400 V Volts 2
3 phase
50 Hertz
811 A Full Load Amps
1,450 rpm Speed of rotation

0.89 Power Factor

Unit
Pa
Pa
Pa
Pa
Pa
Pa
°C
°C
°C
°C
rpm
m²
m²
m²
m²
 TCEA PITOT CALCULATION SHEET - V07 Use of the calculation sheet

plant : Fan ad hoc group Date : 07-Fev-14 Time : 11h18-11h30

workshop : IPC Origin of the source : air
Condition of the test : fan IPC Measurement point : Fan Inlet boxes contents

Warning : erreur de saisie dim° Conduite minimum of measurement points 25 6 Aeraulic surface 4.91 m2
Circular : DIAMETER 2.50 m Dynamic Pressure Pa pos° pitot Avg. Dyn. Pressure 240.62 Pa
Tapping 1 240.62 0.110 m RHO w/o dust (wet) 0.856 kg/m3
2 0.368 m RHO with dust (wet) 0.886 kg/m3
Rectangular : WIDHT 1.32 m 3 0.738 m
Rectangular : HEIGHT 1.00 m 4 1.763 m Velocity 23.31 m/s
5 2.133 m Flow (wet) 114.43 m3/s
Temperature 125 °C 6 2.390 m Flow (wet) 76.15 Nm3/s
Static Pressure -3000 Pa 7 Flow (wet) 411,941 m3/h
8 Flow (wet) 274,141 Nm3/h
Pitot Tube Ratio 1.000 9

10 P°&T° correction 0.6655

Dust concentration 30.0 g/m3 11

Dust concentration 0.05 kg/Nm3 12

13
Calculation of gas flow at reference conditions
Dust flow (t/h) 12.358 14

15 % H2O ref 0.00

16 Flow (H2O ref) 270,029 Nm3/h
Barometric Pressure 101,288.0 Pa 17

Atmospheric Pressure Ratio or 18 % O2 ref 10.00

1.000 19 Flow (H2Oref @ %O2ref) 1,718 Nm3/h
Elevation "h" 0m 20 Flow (H2Oref @ %O2ref) 0.48 Nm3/s
Atm. Pressure @ "h" 10,336.0 mmWG NB VAL : 1
Atm. Pressure @ "h" 101325.00 Pa VAL maxi : 240.62

75% Rule : correct dynamic pressure data distribution

GAS COMPOSITION dry humid

M : Gas Molecular Weight (Wet) M : Gas Molecular Weight (dry) % H2O 1.50 Gas Density (wet) 1.286 kg/Nm3
P°&T° RHO corr°. w/o dust
28.799 g/mole 28.963 g/mole % CO dry 0.00 0.00 (wet)
0.856 kg/m3

Standard Atmospheric Composition 0.03% % CO2 dry 0.03 0.03

20.93% % O2 dry 20.93 20.62 Gas Density (H2O ref) 1.293 kg/Nm3
P°&T° RHO corr°. w/o dust
%Ar dry (H2O ref)
0.860 kg/m3
0.93% 0.93 0.92
78.10% %N2 dry 76.94

610084673.xlsx Printed 09/04/2022

 TCEA PITOT CALCULATION SHEET - V07 Use of the calculation sheet

plant : Fan ad hoc group Date : 07-Fev-14 Time : 11h18-11h30

workshop : IPC Origin of the source : air
Condition of the test : fan IPC Measurement point : Fan Inlet boxes contents

DUCT minimum of measurement points 9 6 Aeraulic surface 1.27 m2

Circular : DIAMETER Dynamic Pressure Pa pos° pitot Avg. Dyn. Pressure 240.62 Pa
Tapping 1 240.62 RHO w/o dust (wet) 0.856 kg/m3
2 RHO with dust (wet) 0.856 kg/m3
Rectangular : WIDHT 1.32 m 3

Rectangular : HEIGHT 1.00 m 4 Velocity 23.72 m/s

5 Flow (wet) 30.05 m3/s
Temperature 125 °C 6 Flow (wet) 20.00 Nm3/s
Static Pressure -3000 Pa 7 Flow (wet) 108,192 m3/h
8 Flow (wet) 72,000 Nm3/h
Pitot Tube Ratio 1.000 9

10 P°&T° correction 0.6655

Dust concentration 0.0 g/m3 11

Dust concentration 0.00 kg/Nm3 12

13
Calculation of gas flow at reference conditions
Dust flow (t/h) 0.000 14

15 % H2O ref 0.00

16 Flow (H2O ref) 70,920 Nm3/h
Barometric Pressure 101,288.0 Pa 17

Atmospheric Pressure Ratio or 18 % O2 ref 10.00

1.000 19 Flow (H2Oref @ %O2ref) 0,451 Nm3/h
Elevation "h" 0m 20 Flow (H2Oref @ %O2ref) 0.13 Nm3/s
Atm. Pressure @ "h" 10,336.0 mmWG NB VAL : 1
Atm. Pressure @ "h" 101325.00 Pa VAL maxi : 240.62

75% Rule : correct dynamic pressure data distribution

GAS COMPOSITION dry humid

M : Gas Molecular Weight (Wet) M : Gas Molecular Weight (dry) % H2O 1.50 Gas Density (wet) 1.286 kg/Nm3
P°&T° RHO corr°. w/o dust
28.799 g/mole 28.963 g/mole % CO dry 0.00 0.00 (wet)
0.856 kg/m3

Standard Atmospheric Composition 0.03% % CO2 dry 0.03 0.03

20.93% % O2 dry 20.93 20.62 Gas Density (H2O ref) 1.293 kg/Nm3
P°&T° RHO corr°. w/o dust
%Ar dry (H2O ref)
0.860 kg/m3
0.93% 0.93 0.92
78.10% %N2 dry 76.94

610084673.xlsx Printed 09/04/2022

TCEA PTK Fan curve v 8.4.02 fan IPC IPC- speed @ 1450rpm - damper @ 53° - Fan ad hoc group - 7 / 2 / 2014
Plant : Fan ad hoc group Date : 2/7/2014 Time :
Workshop : IPC Name :
Fan : fan IPC Measurement condition :
Comments : courbe tracé selon un Delta H de pression TOTALE

DESIGN BASIS INDUSTRIAL BASIS

Pressure fan curve type : Static DP 1

Gas conditions at: Fan inlet FAN INLET FAN OUTLET

Gas composition % volume dry %volume wet Gas composition % volume dry % volume wet % volume dry
% H2O 1.50 1.50 % H2O 1.50 1.50 1.50
% CO dry 0.00 % CO dry 0.00
% CO2 dry 0.03 0.03 % CO2 dry 0.03 0.03 0.03
% O2 dry 20.93 20.62 % O2 dry 20.93 20.62 20.93
%Ar dry 0.93 0.92 %Ar dry 0.93 0.92 0.93
%N2 dry 76.94 %N2 dry 76.94
Process Design Data Process Measurements Process Measurements
Barometric Pressure 101,325.0 Pa Barometric Pressure 101,288.0 Pa 101,288.0
Static Pressure -3,615.9 Pa Static Pressure -3,000.0 Pa 10.0
Temperature 125 °C °C Temperature 125 °C °C 125 °C
Gas Density w/o dustv(wet) 1.286 kg/Nm3 Gas Density w/o dustv(wet) 1.286 kg/Nm3 1.286
Dust concentration g/m3 Dust concentration g/m3
Gas Density with dust (wet) 0.8506 kg/m3 Gas Density with dust (wet) 0.8556 kg/m3 0.8818
Duct internal cross section 2.53 m2 2.40
Parameters of the fan Parameters of the fan Gas Flow and Density
N1 = 1450 rpm N2 = 1450 rpm 144,000
Delta H = 3608.8 Pa Delta H = 3010 Pa FAN INLET
Qv = 86.806 Am3/s Qv = Am3/s Average flow
Rho gaz = 0.855 kg/m3 Rho gaz = kg/m3 Average density
D1 Impeler = 2.050 m D2 Impeler = 2.050 m FAN OUTLET

fan shaft power = 444.00 kW Motor absorbed power = 353.0 kW Dynamic Pressures
Gas flow Tolerance = +/- 2.50% Fan shaft kW / Abs. kW) efficiency = 91% FAN INLET
Pressure tolerance = +/- 5.00% fan shaft power = 321.2 kW FAN OUTLET
Power tolerance = +/- 8.00% Fan inlet damper position = 53 ° = 41.1% opened too much closed
Efficiency of the fan Efficiency of the fan
h= 70.6% h= 55.5% based on curves hypothesis

h= 55.9% based on Total DP and average flow and density

fan IPC IPC- speed @ 1450rpm - damper @ 53° - Fan ad hoc group - 7 / 2 / 2014

7000

6000

5000 75 °
60 °
75 ° 45 °
60 ° 30 °
4000 45 °
Delta H (Pa)

75 ° 30 °
60 °

45 °
3000 30 °

75 ° 60 °
45 ° 30 ° 15 °
2000
30 °
45 ° 0°

1000 75 ° 60 °

0
0 20 40 60 80 100 120
Gas flow (Am3/s)

Equivalent orifice curve - Design Design point Equivalent orifice curve - Trial
0
0 20 40 60 80 100 120
Gas flow (Am3/s)

Equivalent orifice curve - Design Design point Equivalent orifice curve - Trial

trial point @ 1450 rpm & Damper @53° uncertainty Fan curve @ 1450rpm & Damper @ 53°
TCEA PTK Fan curve v 8.4.02 fan IPC IPC- speed @ rpm - damper @ ° - Fan ad hoc group - 7 / 2 / 2014
Plant : Fan ad hoc group Date : 2/7/2014 Time :
Workshop : IPC Name :
Fan : fan IPC Measurement condition :
Comments : courbe tracé selon un Delta H de pression TOTALE

fan IPC IPC- speed @ 1450rpm - damper @ 53° - Fan ad hoc group - 7 / 2 / 2014
500

450
0° 0° 0°
0° 0°
0° 0°
400 0° 0°
0°
350 0°
0°
Fan Shaft Power (kW)

300
0°
250
0°
200 0°

150 0°
0°
100

50

0
0 20 40 60 80 100 120
Gas flow (Am3/s)

fan IPC IPC- speed @ 1450rpm - damper @ 53° - Fan ad hoc group - 7 / 2 / 2014

90%

80%

70%

60%
Fan efficiency (%)

50%

40%

30%

20%

10%

0%
0 20 40 60 80 100 120

Gas flow (Am3/s)

 Page 1

contents

FAN OUTLET
% volume wet
1.50
0.00
0.03
20.62
0.92
76.94
Measurements
Pa
Pa
°C
kg/Nm3
g/m3
kg/m3
m2
w and Density
measured Nm3/h
60.107 Am3/s
59.214 Am3/s
0.869 kg/m3
58.321 Am3/s
Pressures
240.6 Pa
260.4 Pa
too much closed

age flow and density

0°

120
 120

@ 53°
 Page 2

0°
0°

120

120
0) Généralités
0-1) To fill only the yellow cell with blue letters / and press the key "F

0-2) press "F9" to calculate - The spreadsheet is commanded by "F9"

1) Design Process Data

DESIGN BASIS
Gas composition
% H2O 80.00 %volume wet
% CO dry 0.00 0.00
% CO2 dry 0.03 0.03
% O2 dry 20.93 20.93
%Ar dry 0.93 0.93
%N2 dry -1.89
Barometric Pressure 101,325.0 Pa
Static Pressure -300.0 Pa
Temperature 350 °C °C
Gas Density w/o dustv(wet) 0.936 kg/Nm3
Dust concentration 0.00 g/m3
Gas Density calculated with dust (wet) 0.4090 kg/m3

Parameter of the fan

N1 = 740 tr/min
Delta H = 1570 Pa
Qv = 24.5 m3/s
Rho gaz = 0.407 kg/m3
D1. Roue 2.07 m
fan shaft power 49.50 kW
h= 0.00 %

2) Industrial Process Data

INDUSTRIAL BASIS - FAN INLET

Gas composition %volume wet
% H2O 10.00 10.00
% CO dry 0.00 0.00
% CO2 dry 0.03 0.03
% O2 dry 20.93 20.93
%Ar dry 0.93 0.93 checkout
%N2 dry 68.11 100.00
Barometric Pressure 95,000.0 Pa
Static Pressure -5,000.0 Pa
Temperature 300 °C °C
Gas Density w/o dustv(wet) 1.248 kg/Nm3
Dust concentration 0.00 g/m3
 Gas Density calculated with dust (wet) 0.5284 kg/m3

Parameter of the fan

N1 = 300 tr/min
Delta H = 213.9 Pa
Qv = 16 m3/s
Rho gaz = 0.510 kg/m3
D1. Roue 2.07 m
fan shaft power #REF! kW
h= x %

3) Design Fan Curves : Flow / Pressure / Efficiency and Shaft Power

FAN CURVES - DESIGN DATA ENTRY

number of points: 9
Qv Delta H h Shaft Power
Am3/s Pa % kW
0 6240 350
25 6380 450
50 6500 575
75 6570 680
100 6420 775
125 6060 880
150 5520 1000
175 4870 1100
200 4149 1200
with blue letters / and press the key "F9" to calculate

he spreadsheet is commanded by "F9"

1-1) to fill the cell "E4" ; % H2O volume at the sampling point
1-2) to fill the cell "E5" ; % CO dry in volume at the sampling point
1-3) to fill the cell "E6" ; % CO2 dry in volume at the sampling point
1-4) to fill the cell "E7" ; % O2 dry in volume at the sampling point
1-5) to fill the cell "E8" ; % Ar dry in volume at the sampling point : 0,93% for air

1-6) to fill the cell "E10" ; Barometric pressure

1-7) to fill the cell "E11" ; Static Pressure at the sampling point
1-8) to fill the cell "E12" ; gas temperature at the sampling point
calcul automatique
1-9) to fill the cell "E14" ; dust concentration at the sampling point
calcul automatique

1-10) to fill the cell "E18" ; design speed of the impeller

1-11) to fill the cell "E19" ; static DeltaP , design of the fan --> Design operating point
1-12) to fill the cell "E20" ; Flow rate, design of the fan --> Design operating point
1-13) to fill the cell "E21" ; Gas density. Notice, if this cell remains empty, the value of Rhô in "E15" will be taken into account for the
1-14) to fill the cell "E22" ; Diameter design of the impeller of the fan. If the diameter is not known, to put 1
1-15) to fill the cell "E23" ; Fan shaft power --> Design operating point
calcul automatique
1-16) press "F9" to calculate

INDUSTRIAL BASIS - FAN OUTLET

%volume wet
10.00 10.00 2-1) to fill the cell "M4" et "Q4" ; % H2
0.00 0.00 2-2) to fill the cell "M5" et " Q5" ; % C
0.03 0.03 2-3) to fill the cell "M6" & "Q6" ; % CO
20.93 20.93 2-4) to fill the cell "M7" et "Q7" ; % O2
0.93 0.93 checkout 2-5) to fill the cell "M8" et "Q8"; % Ar
68.11 100.00
95,000.0 Pa 2-6) to fill the cell "M10" ; Barometric
0.0 Pa 2-7) to fill the cell "M11" et "Q12" ; Sta
305 °C °C 2-8) to fill the cell "M12" et "Q12" ; ga
1.248 kg/Nm3 calcul automatique
0.00 g/m3 2-9) to fill the cell "M14" et "Q14" ; du
 0.5530 kg/m3 calcul automatique

22,000 Nm3/h Gas Flow Measured 2-10) to fill the cell "q17" ; Gas Flow ra
51,971 Am3/h FAN INLET 14.4 Am3/s 2-11) to fill the cell "M18" ; Industrial s
49,666 Am3/h FAN OUTLET 13.8 Am3/s 2-12) to fill the cell "M19" ; Static Delt
14.116 Am3/s average Gas Flow 2-13) to fill the cell "M20" ; Gas Flow R
0.5407 kg/m3 average Gas Density 2-14) to fill the cell "M21" ; Gas Densit
2-15) to fill the cell "M23" ; Diameter o
calcul automatique
calcul automatique
2-16) press "F9" to calculate

3.-1) Choose the flow unit for the curve design data entry (m3/h, m3/min or m3/s)

3-2) Choose the pressure unit for the curve design data entry (mbar, mmWG or Pa)

3-3) Fill the yellow cells with data from the original fan curves
Always start by the upper cells
In each line, the data for pressure, efficiency and shaft power must correspond to the same flow
E15" will be taken into account for the formulas of transformation.

-1) to fill the cell "M4" et "Q4" ; % H2O volume at the sampling point
-2) to fill the cell "M5" et " Q5" ; % CO dry in volume at the sampling point
-3) to fill the cell "M6" & "Q6" ; % CO2 dry in volume at the sampling point
-4) to fill the cell "M7" et "Q7" ; % O2 dry in volume at the sampling point
-5) to fill the cell "M8" et "Q8"; % Ar dry in volume at the sampling point : par défaut 0,93%

-6) to fill the cell "M10" ; Barometric pressure

-7) to fill the cell "M11" et "Q12" ; Static pressure at the sampling point
-8) to fill the cell "M12" et "Q12" ; gas Temperature at the sampling point

-9) to fill the cell "M14" et "Q14" ; dust concentration at the sampling point
-10) to fill the cell "q17" ; Gas Flow rate Nm3/h
-11) to fill the cell "M18" ; Industrial speed of the impeller
-12) to fill the cell "M19" ; Static DeltaP --> industrial operating point
-13) to fill the cell "M20" ; Gas Flow Rate. Notice, if this cell remains empty, the value of Gas Flow Rate in "Q20" will be taken into account for the
-14) to fill the cell "M21" ; Gas Density. Notice, if this cell remains empty, the value of Gas Flow Rate in "Q21" will be taken into account for the for
-15) to fill the cell "M23" ; Diameter of the impeller of the fan, generally the same one as the Design if any change of wheel. If the diameter is not kn

-16) press "F9" to calculate

the same flow

Q20" will be taken into account for the formulas of transformation.
1" will be taken into account for the formulas of transformation.
nge of wheel. If the diameter is not known, to put 1
1) Internal inspection - Running Clearance

contents Side xx (opp. coupling side) Supplier recod°

A 40 10
B 50
C 35 13 (+2,0)
Radial
D 20
E 25 10
F 30 7 (0,-2)
G (top) 30 11 (0,-2)
Axial
G (bottom) 30 11 (0,-2)
Inspection carried on Feb. 24th, 2014
by Gas-Handling/Plant School/xxxxxx

Shaft

Inlet cone

11 (0,-2) Impeller
G
cold

2) Internal inspection - Anti Rotating blades

contents
 C

D B

E A

3) Internal inspection - Inlet Spacing

Inlet Spacing should be the same both sides for double inlet fan
 contents Side xx (coupling side) Supplier recod°
A 28 10
B
C 19 13 (+2,0)
Radial
D
13 (0,+2) E 29 10
cold F 26 7 (0,-2)
G (top) 35 25 (+2,0)
Axial
G (bottom) 40 25 (+2,0)
Inspection carried on Feb. 24th, 2014
by Gas-Handling/Plant School/xxxxxx

Shaft

7 (0,-2)
cold
25 (+2,0)
G
cold

contents

or double inlet fan

or
 C

B D

Shaft

Inlet cone

Impeller F
 13 (0,+2)
cold

7 (0,-2)
cold
1) Before Cleaning

2) After Cleaning

OK

contents
Deficient Fan Perfoma
There was a system eff
t Fan Perfomance
as a system effect
contents
Performance Test
Replacement
Inspection Visit
Inspection and adjustement
Cleaning
Lubricating
Item Chap. 1 Chap. 2 Chap. 3 Chap. 4

1-0 Fan parts

1-1 Impeller and shaft Kiln stop Kiln stop
1-2 Inlet Cone Kiln stop Kiln stop
1-3 Bearing yes
1-4 Fan housing Kiln stop
1-5 Sealings yes M Kiln stop
1-6 Protection guards
1-7 Fan support
1-8 Foundation
1-9 Expansion joint Kiln stop Kiln stop
1-10 x Kiln stop
1-11 x

2-0 Additional Fan parts

2-1 Transmission / Coupling M
2-2 Motor
2-3 Regulation Damper yes Kiln stop Kiln stop
2-4 Vibration sensor
2-5 Access Platform Kiln stop
2-6 Inlet & Outlet ducting Kiln stop

3-0 Electrical
3-1 Temperature sensors Kiln stop
3-2 Vibration monitoring M
3-3 Power Monitoring
3-4 Pressure Monitoring Kiln stop
3-5 Speed Monitoring Kiln stop
3-6 Damper position if no VSD Kiln stop Kiln stop
3-7 VSD parameter Kiln stop
3-8 Gas Flow monitoring Kiln stop

4-0 Measurement
4-1 Bearing Temperature
4-2 Vibration level
4-3 Gas Temperature Kiln stop
4-4 Gas Flow Kiln stop
4-5 Static Pressure (inlet & outlet) Kiln stop
4-6 Impeller rotation speed
4-7 Absorbed power
4-8 Gas Analysis Kiln stop
4-9 Clinker Production
Chap. 5 Chap. 6

x M= Monthly
Q: Quarter
x

yes
yes
Q
Q
Q
Q
Q
Q
Q
contents

e
pl
am
Ex
 contents

Ex
am
pl
e-
C ou
pl
in
g

Ex
Ex
am
p
bo le-
xe I &
s O
contents

Example- motor data

Example- Freq. Conv. data

Ex
am
na pl
m e-
ep m
lat oto
e r
 REFERENCE DOCUMEN

Ref
PUBLICATION 200
PUBLICATION 201-90
PUBLICATION 202-88
PUBLICATION 203-90

Chap 6. Fluid Flow

x
x
x
x
x
x
x
PR PYR P06-16 V1.1
PR PYR P06-17 V1

ISO 3966
ISO 5167-1.2003
ISO 5801

contents
 REFERENCE DOCUMENTS

Title
AIR SYSTEMS
FAN AND SYSTEMS
TROUBLESHOOTING
FIELD PERFORMANCE MEASUREMENT OF FAN SYSTEMS

Cement Process Engineering VADE-MECUM

How to measure airflow by Pitot tube

How to measure static pressure by Pitot tube
How to measure gas temperature by thermocouple
How to measure moisture of gas by wet bulb temperature
How to measure moisture content of gases using silica gel
How to measure gas composition by gas analyser
How to measure false air
How to measure fan efficiency of the main fans
How to improve fan efficiency by internal inspection

Fan Curve

Measurement of fluid flow in closed circuits - Velocity area method using Pitot static tubes
Measurement of fluid flow by means of pressure differential devices
Industrial Fans - Performance testing using standardized airways
 Type Year Author
External Publication 1987 AMCA
External Publication 1990 AMCA
External Publication 1988 AMCA
External Publication 1990 AMCA

Internal Document 2010 LAFARGE

Procedure x LAFARGE
Procedure x LAFARGE
Procedure x LAFARGE
Procedure x LAFARGE
Procedure x LAFARGE
Procedure x LAFARGE
Procedure x LAFARGE
Procedure 2008 LAFARGE
Procedure 2008 LAFARGE

Internal Document 2012 LAFARGE

International Standard 2008 ISO

International Standard 2003 ISO
International Standard 2007 ISO
 contents

PERFORMANCE
Problem

Low air Flow

High air Flow

System Resistance is greater than estimated

System Resistance is lower than estimated

contents

MECHANICAL
Problem
 General Fan Noise,
at very low frequency, high magnitude

Bearing noise varying from a

'dry' rumble to a squeal

Rough lumpy sound.

Shaft seal squeal

Air noise

Vibration
 Vibration

contents

IMPELLER - Centrifugal Fan

Problem

Impeller excessively noisy

Damaged Impeller

contents

GENERAL
Problem

Motor Noise

contents
ELECTRICAL
Problem

Fan running the wrong way.

Fan won't run

Fan runs in alternate direction.

Electrical hum

Motor overheating or high

current draw.
 Motor overheating or high
current draw.

contents

BELT-DRIVES
Problem

Various problems

contents

SYSTEM EFFECT
Problem

The design performance is not reached.

The rotation speed is higher than expected.
The operating point does not match with the fan curve.
 Description of the SYSTEM EFFECT
The figure 1 illustrates fan performance. The fan has a VSD. The point "1n" is the design operating point.

System Resistance is greater than estimated + system effect

ratio
Figure n°1 Design Actual
Actual / Design
gas flow 183,8 Am3/s 82% 150 Am3/s
rotation speed 989 rpm 94% 930 rpm
845 rpm
rotation speed 989 rpm 85%
expected spee

The figure 2 illustrates fan performance. The fan has a VSD. The point "1n" is the design operating point.
Bad installation : Description of the possible cause of SYSTEM EFFECT
Possible Cause (Source from AMCA publication 201-90)

back to contents

Centrifugal Fan Outlet Duct Elbows

Bad installation : Description of the possible cause of SYSTEM EFFECT

Possible Cause (Source from AMCA publication 201-90)

back to contents

Duct Branches
Bad installation : Description of the possible cause of SYSTEM EFFECT
Possible Cause (Source from AMCA publication 201-90)

back to contents

Inlet Vortex

Bad installation : Description of the possible cause of SYSTEM EFFECT

Possible Cause (Source from AMCA publication 201-90)

back to contents

Inlet Turning Vanes

Bad installation : Description of the possible cause of SYSTEM EFFECT

Possible Cause (Source from AMCA publication 201-90)

back to contents
 Inlet Ducts

Bad installation : Description of the possible cause of SYSTEM EFFECT

Possible Cause (Source from AMCA publication 201-90)

back to contents

Volume control dampers

Bad installation : Description of the possible cause of SYSTEM EFFECT

Possible Cause (Source from AMCA publication 201-90)

back to contents

Inlet Duct Elbows

Internal recirculation of gas : Description of the possible cause of SYSTEM EFFECT
Possible Cause

back to contents

Internal recirculation of gas

Source of data : FANTECH / AMCA / IPC D.Dumont

Possible Cause
Faulty instruments
The wrong size fan has been installed
The fan is running backwards

Fan speed is too slow

Fan speed is too slow

Internal recirculation of gas

The ductwork is undersized

Check the cut-off position

Bad installation

Faulty instruments
The wrong size fan has been installed

Fan speed is too high

The ductwork is oversized

The ducting and/or the grilles may be smaller than design, which will
increase the system resistance

The ducting and/or the grilles may be larger than design, which will
decrease the system resistance

Possible Cause
The fan could be running in stall.
The fan is operating in unstable zone.
System Resistance is greater than estimated

Improper greasing.

The bearings may be loose on the shaft

or bearing support.

The bearings have not been properly

tensioned

The bearings may have brinelled (a localized surface corrosion)

Brinelling occurs when the fan is vibrated during transit or through
ground vibration when stored.

This causes the bearing to vibrate at a single point and therefore

indenting the bearing race.

Problems with brinelling usually occur shortly after a fan is installed.

Excessive belt tension.

The seals may have dried out.

Air noise can be generated from a number of sources such as grilles,

bends, badly designed duct fittings, excessive duct velocities etc.

The impeller may be out of balance.

The shaft may be bent.

Impeller may be worn as a result of handling abrasive or corrosive

materials.

Material such as dust or grease could be sticking to the fan blades.

The impeller may have been damaged by loose material in the duct
system.
Vibration being transmitted through the
building structure.

Possible Cause
The impeller may be striking the fan casing or inlet cone, check for
the following causes:
1) Impeller may be loose on the motor or drive shaft.

2) Impeller incorrectly mounted onto the shaft

3) Impeller not centred in the casing

4) Casing inlet cone may be damaged

5) Bent motor or drive shaft

6) Impeller not centred on the inlet cone.

7) The inlet cone has been damaged

8) Shaft loose in bearings.

9) Bearing loose on its support.

10) The cut-off in the fan discharge has been damaged.

11) Cut-off is insecure.

Impeller bulging. This could be caused by the impeller being built
from lighter than specified materials or the fan is running above its
recommended speed.

Possible Cause

Firstly determine if the noise is electrical

or mechanical.
Possible Cause

Incorrect wiring.

Wrong electrical supply.

Electrical connections in the motor terminal box or starter are not

tight.

For single-phase motors the capacitor is not wired in or is faulty.

Fuses are blown

Belts on belt-driven units have broken.

Overloads have tripped out.

If a variable speed drive (VSD) has been fitted incorrect installation

can cause an electrical 'spike' causing the motor windings to fail.

The capacitor is not in circuit or it could

be faulty.

Alternatively, the connections could be poor or incorrect.

Electronic speed-controllers can generate an electrical hum.

If a variable speed drive (VSD) is fitted incorrectly it can cause a high

level of harmonics in the supply.
Phase imbalance on three-phase motor.
Motor is not designed for the electric supply ie. wrong voltage or
frequency.

Motor is overloaded and drawing greater than the nameplate amps.

Motor has excessive clearance between stator and rotor. In this

situation the motor will run slower than the normal speed. ie. have
excessive slip.
Faulty instruments.
Incorrect power supply

Three-phase motor running with one phase disconnected.

In that case, the motor will draw uneven current on each phase

Impeller has too much inertia for the motor power and does not
achieve full speed.

Excessive dirt on the motor cooling fins so the heat is not able to
dissipate.

If the motor is out of the airstream either the cooling fan is not fitted
or the air inlet to the motor cooling fan is obstructed.
Excessive stopping or starting

A conventional three-phase motor is connected in Delta when it

should be in Star, or vice-versa.

A 2-speed motor, when switching from high to low speed, can

generate heat if the supply is not switched off.

Backward-curved centrifugal impellers may be running in the wrong

direction.
When running in the wrong direction they will tend to overload the
motor.
Airflow capacity will be down to approximately 30-40% of full flow.

If the fan is a forward-curved centrifugal there may be insufficient

system resistance.

Error in the motor selection for the required duty.

With belt-drive units incorrect pulley selection or pulleys on the wrong
shafts
Gas density greater than design.

Possible Cause
The belts are loose and striking the beltguard.

Belts are wearing out too quickly and/or the belts are too tight.

The pulleys are worn.

The belt may be the wrong cross-section for the pulley.
The pulleys may be incorrectly aligned.
The drive selection may be incorrect.
The fan, motor or its base may not be securely fastened.

Possible Cause

Bad Installation :
 Centrifugal Fan Outlet Duct Elbows

Duct Branches

Inlet Vortex

Inlet Turning Vanes

Inlet Duct design

Volume control dampers

Inlet duct Elbows

Internal recirculation of gas

he fan has a VSD. The point "1n" is the design operating point.
1) System Resistance is greater than estimated. The point n°4 has a higher pressure compared to the point n°3
2) Point 4 is the operating point : [ 150 Am3/s ; 9290 Pa]
3) Point 3 is the design operating point : [ 150 Am3/s ; 8000 Pa] with no System Effect
4) The rotation speed of the impeller is higher (point n°2) compared to the actual flow volume (point n°4). There is System E
There is higher rotation speed of the impeller to achieve the actual flow volume (point n°4)
Key Information : It can have System Effect when System Resistance is lower than estimated.
5) The loss of volume flow is the difference between point n°1 and point n°4. Internal recirculation of gas can give such loss
6) In operation, the loss of pressure is the difference between point n°4 and point n°2.
7) The tables below show the key infomation of the loss of performance
7-1) Higher System resistance increases around 5,5% the rotation speed, and by 17% the absorbed power
7-2) System Effect increases around 10% the rotation speed, and by 33% the absorbed power
System Resistance is greater than estimated + system effect System Resistance matches w ith design
ratio ratio
Figure n°1 Design Actual Figure n°2 Design
Actual / Design Actual / Design
gas flow 183,8 Am3/s 82% 150 Am3/s gas flow 183,8 Am3/s 82%
rotation speed 989 rpm 94% 930 rpm rotation speed 989 rpm 81%
845 rpm
rotation speed 989 rpm 85% rotation speed 989 rpm 81%
expected speed

he fan has a VSD. The point "1n" is the design operating point.
System Resistance matches with design. There is no system effect
Gas Flow variation is proportional to rotation speed of the impeller.
ause of SYSTEM EFFECT
Description

Source AMCA: … If an elbow must be located near the outlet fan it

should have a minimum radius to duct diameter ratio of 1.5 and
should be arranged to give the most uniform airflow possible…

100% Effective duct length gives no SEF.

AMCA gives ratio and rules to determine SEF (System Effect Factor)
by using tables.
ause of SYSTEM EFFECT
Description

Source AMCA: Standard procedures for the design of duct systems

are all based on the assumption of uniform flow profiles in the
system.
In figure (right side) branche takeoffs or slipts are located too close
to fan outlet.
Non uniform flow conditions will exist and pressure loss and air flow
will vary widely from the design value.

Practical experiences have shown System Effect in that case.

ause of SYSTEM EFFECT
Description
Source AMCA: … Another major cause of reduced performance is
an inlet duct condition that produces a vortex or spin in the airstream
entering a fan inlet. (see counter-rotating swirl figure)

The ideal inlet condition is one which allws the air to enter axially and
uniformly without spin in either direction. A spin in the same direction
as the impeller rotation (pre-rotation) reduces the pressure volume
curve by an amount dependent upon the intensity of the vortex

The effect is similar to the change in the pressure-volume curve

achieved by inlet vanes installed in a fan inlet ; the vanes induce a
controlled spin in the direction of impeller rotation reducing the
volume flow rate.

A counter-rotating vortex at the inlet may result in a sligth increase in

the pressure-volume curve but the power will increase substantially

ause of SYSTEM EFFECT

Description

Source AMCA: Turning vanes will usually reduce the pressure loss
through an elbow…

…Where space limitations prevent the use of optimum fan inlet

connections, more uniform flow can be achieved by the use of
tutning vanes in the inlet elbow…

… A non uniform airflow entering a duct elbow with turning vanes will
leave the duct elbow with non uniform airflow...

ause of SYSTEM EFFECT

Description
Source AMCA:
Figures (a) and (b) show the best condition by using a curved bell
inlet to avoid System Effect.
 Figure ( c ) : … Fans that do not have smooth entries and are
installed without ducts exhibit flow characteristics similar to a sharp
edged orifice in that a vena contracta is formed. The reduction in flow
area caused by the vena contracta and the following rapid expansion
causes a loss which should be considered as a System Effect.

Practical experience has shown an increase of the gas flow by 35%

after installation of a curved bell inlet on a fresh air intake. Initial
design was similar to the figure ( c). Final design is similar to the
figure (b).

…If it not practical to include such a smooth entry, a converging

taper (figure d) will substantially diminish the loss of energy , or a
even simple flat flange (figure e) on the end of the duct or fan will
reduce the loss to about one half of the loss through an unflanged
entry.

ause of SYSTEM EFFECT

Description
Source AMCA:
Volume control dampers are manufactured with either "opposed"
blades or "parallel" blades.
When partially closed, the parallel bladed damper diverts the air
stream to the side of the duct.This results in non-uniform velocity
profile beyond the damper and flow to branch ducts close to the
downstream side may be seriously affected.

The use of an opposed blade damper is recommended when volume

control is required at the fan outlet.

ause of SYSTEM EFFECT

Description
Source AMCA:

…Non-uniform flow into a fan inlet is the most common cause of

deficient fan performance. (see figure on the right side)
An elbow located at, or in close proximity to the fan inlet will not allow
the air to enter the impeller uniformly.
SEF can be calculated via specific table and the tabulated System
Effect Curve by AMCA

The second figure shows a very poor design of inlet duct. The
reduction in capacity and pressure for this type of inlet condition is
impossible to tabulate…
This inlet design must be avoided.
Capacity losses as high as 45% have been observed in poorly
designed inlets such on the second figure.

Existing installation can be improved with guide vanes.

The better alternative would be a special designed inlet box similar to
that shown on the third figure.
e possible cause of SYSTEM EFFECT
Description

Internal recirculation in one of the main cause of poor performance.

The figure on the right side shows a fan which has deficient
performance due to internal reciculation of the gas.

Existing installatrion can be improved by:

1) a good inlet spacing and running clearance. (See example below)

2) by installing stainless steel sectors causing a new system

resistance to internal re-circulation of the gas.The dimensional
proportions of cones are not respected. Only the running clearance
area is drawn.
Recommended Action
Ensure Intsrument are accurate and calibrated where necessary
Check the fan specifications are correct for the particular system
Check rotation of the impeller.
Check the motor speed,
if belt driven, check the pulley ratio
Check the build-up on the blades

Check the inlet spacing and the running clearance - See spreadsheet
spreadsheet internal inspection
internal inspection

Check the duct work and grilles are the correct size. If smaller than design,
this will increase the system resistance
Check the drawing and/or contact the supplier

Check the entry and discharge conditions to the fan are of a good design.

Check the position of the inlet dampers

Check the condition of the expansion joint which can have the same effect
than an inlet damper when it is deformed.

The three most common causes of deficient performance (system effect) of

the fan are:
1) improper outlet connections. Avoid location of split or duct branch close
to to fan discharge. Provide a straight section of duct to allow for air
Section System Effect
diffusion.
2) non-uniform inlet gas flow
3) swirl at the fan inlet
In that cases, the rotation speed of the impeller may be from 5% to 10%
higher than the expected operating point.

Ensure Intsrument are accurate and calibrated where necessary

Check the fan specifications are correct for the particular system
Check the motor speed,
if belt driven, check the pulley ratio
Check the duct work and grilles are the correct size. If larger than design,
this will decrease the system resistance

Check the ductwork and system components are the correct size

Check that all the dampers are open

Check that all the registers are open
Check the ducting is clear of rubbish
Check connectors are installed correctly
Check is filters are dirty, is the cleaning system is in operation
Check ducts are correctly installed and of good design.
Check the ductwork and system components are the correct size. Check
the leaks around flexible connections, inspection doors.

Recommended Action
Check the actual fan performance against the fan curve to determine
where on the curve it is operating.
If it is to the left of the peak pressure point the fan is generally in stall. If in
stall see if the ductwork can be modified to eliminate high pressure loss
sections.
Low amps could indicate the fan is in stall.
Check the "System Resistance is greater than estimated" in chapter
PERFORMANCE

Check the bearings are packed with the correct grade and amount of
grease.

If the bearings are of the sealed-for-life type replace them.

Tighten the adaptor sleeve or collar.

Re-tension as required

Replace the bearings.

To avoid brinelling the fan impeller should be rotated frequently, at least

daily.

Check and adjsut the belt tension

The seals may require lubrication or may be misaligned.

Check the duct design is such it does not generate turbulence and
therefore noise.

An attenuator may be needed to resolve the problem.

Site balancing may be practical but, if not, remove the impeller and
balance.

The shaft will have to be replaced.

The impeller will have to be replaced.

Clean the impeller blades. This should be done on a regular basis if dust
and/or grease is constantly present in the air being handled.

Depending on the level of damage the impeller may have to be replaced

Check vibration isolators have been fitted and, if fitted, check they are
correctly positioned.

Vibration isolators are fitted but not strong enough.

If bottoming, adjust if possible or replace with more suitable mounts.

Fit flexible connectors between the fan and ductwork.

Recommended Action

Tighten the fixings.

Re-install the impeller onto the shaft with the key installed correctly

Adjust to the correct position.

Repair the damage.

Replace the shaft

Check and re-align as required.

Repair or replace.

Tighten the bearing rings.

Tighten the fixing bolts.

Repair or replace.

Refit securely.

Replace the impeller but also check the fan speed. Advise supplier of the
problem.

Recommended Action

If the noise doesn't stop instantly, but runs down with the motor, the
problem is more likely to be mechanical, generally the bearings.

If the motor is switched off and the noise stops instantly the problem is
more likely to be "electrical". Sometimes, the sheet steels of the rotor move
on the shaft. Replace the motor.
Recommended Action

To reverse the rotation of a three-phase motor interchange any two supply

leads.

Check the electrical supply matches the motor nameplate.

Check and tighten as necessary.

If a capacitor is fitted check with a multimeter or replace.

Before replacing fuses check the motor circuit for any faults.

Replace the belts and re-align the drive.

Check the motor before resetting the overloads.

Check the motor windings and if failed replace the motor. Check the
installation is in accordance with the VSD supplier's recommendations.

Check with multimeter or replace.

Check all connections and ensure there are no loose terminals.

If the electronic controller is not faulty explore using a SSC single-phase 2-

speed switch in its place.
Alternatively, use an auto-tranformer speed controller.

Check the installation conforms to the VSD supplier's recommendations.

Check and correct the supply.

Check the electrical supply matches the motor nameplate.

Check the correct motor is fitted. If correct check the pitch-angle if an axial
fan or the belt-drive details if a belt-driven fan.

If these are correct contact the supplier.

Check motor speed, if slow contact the supplier.

Ensure all instruments are accurate and calibrated where necessary.

Check the electrical supply matches the motor nameplate.
Check if it is the power supply or the motor windings.
If a winding has failed the motor may need to be replaced.
Fitting correct overloads or phase protection will prevent this problem.
Check the inertia of the load and reduce as necessary.
Alternatively, fit a larger motor.

Remove the dirt and dust on the motor body and between the cooling fins.
Increase the maintenance frequency.

Fit the motor cooling fan if not fitted and remove any obstructions from the
air inlet to the motor.
Check the control system and reduce the number of starts/hour as
recommended.

Check the motor nameplate and re-wire correctly.

Switch off the power first and allow the motor to run down before engaging
low speed.
Alternatively, use a time delay interlock.

Check and correct the direction of rotation of the impeller if necessary.

Ensure the duct system is installed correctly and, if necessary, lower the
fan speed.
Alternatively, increase the system resistance by fitting perforated metal on
the fan inlet but note that this is inefficient.
Check the motor nameplate and change as necessary.

Check the pulley ratio and that the pulleys are on the correct shafts.

Increase the motor size to suit.

Recommended Action
Adjust the belts to the correct tension.
Adjust the belts to the correct tension.
Also check the belts are a matched set, if they are not replace the complete
set.
Replace both the pulleys and belts.
Check and replace the belts as necessary.
Check the pulleys and realign as necessary.
Check and change as necessary.
Check and secure as necessary.

Recommended Action

Click and check "Low Air Flow" in PERFORMANCE chapter

 access to description and figures

access to description and figures

access to description and figures

access to description and figures

access to description and figures

access to description and figures

access to description and figures

access to description and figures

spreadsheet internal inspection

n°4 has a higher pressure compared to the point n°3

00 Pa] with no System Effect

compared to the actual flow volume (point n°4). There is System Effect
he actual flow volume (point n°4)
Resistance is lower than estimated.
n°1 and point n°4. Internal recirculation of gas can give such loss
een point n°4 and point n°2.
performance
rotation speed, and by 17% the absorbed power
ed, and by 33% the absorbed power
System Resistance matches w ith design
ratio
Actual Figure n°2 Design Actual
Actual / Design
0 Am3/s gas flow 183,8 Am3/s 82% 150 Am3/s
30 rpm rotation speed 989 rpm 81% 800 rpm
45 rpm 800 rpm
rotation speed 989 rpm 81%
cted speed expected speed
Figures

Figures

System Effect
in operation
Figures

Figures

Figures
Figures

Figures

Very good design

Fan eff. = 81%
 Figures

impeller
stainless steel sectors

inlet cone