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Introduction
This procedure explains how to measure the efficiency of a fan.
Improving fan efficiency and / or reducing damper pressure loss will lower the power consumption of the
plant.
Improving the ID fan efficiency (when in limit) will maintain the kiln feed at the highest level.
Indeed, poor fan efficiency wastes kW, lowers the gas flow available for the kiln and consequently
reduces the kiln feed to maintain the level of O2 kiln inlet.
Where to begin
Give priority to 20% of the fans making up 80% of the global power consumption.
Special attention should be given to the fans where dampers or louvers operate in a closed position
(>50% closed). Their efficiency may be good but they could be wasting power unnecessarily.
In the long term, the profitability of the optimization of each fan >36 kW should be evaluated.
1 How to improve fan efficiency by internal inspection (false air, internal build up, bad
gaps)
When an optimised fan(*) is operating with an efficiency level less than 72%, an opportunity study
should be made to see if replacement of the impellor or complete fan could be justified economically, by
power savings (and / or by production increase if appropriate).
In the case of a fixed speed fan normally operating with a high damper pressure loss, an opportunity
study should be made to determine if either
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Safety aspects
In the course of working in and around a fan, persons can be exposed to several hazards, depending on
the fan in question. It is necessary to conduct a full risk assessment for each case.
Prerequisites
Measurement conditions: process has to be as stable as possible. For example, for measuring ID fan,
disconnect Lucie and freeze the fan speed.
Measurements are generally conducted at normal operating conditions to avoid the need to extrapolate.
Measuring points installed for fan gasflow, and for pressure and temperature at fan damper inlet, fan
inlet and fan outlet
Known duct areas at measuring points and fan inlet and outlet flanges, confirm with site measurements,
if possible.
Measurement accuracy of fan power from control system and or motor control centre verified by
electrical department portable test equipment.
Obtain the fan performance curves and design data from the fan supplier
The performance curves normally consist of two curves:
- a graph of volume against pressure. The type of pressure used to draw the curve can vary from
supplier to supplier and even country to country, so make sure that the type of pressure used for
the curve is known (fan static pressure, fan total pressure or static pressure rise across the fan).
- a graph of volume against fan shaft power
- the volume used for these curves usually relates to the fan inlet conditions.
Sometimes fans have inlet louvers or variable inlet vanes, which suppress the pressure and power
curve. In this case it is normal for the supplier to provide a series of volume vs pressure and volume
verses power for a range of damper positions up to 100%.
Design data can vary from supplier to supplier, but would normally include the impellor diameter,
fan speed, gas density, dust content in gas stream, mechanical design temperature, inlet and outlet
pressure, shaft power, installed motor power, inlet and outlet duct areas, plant altitude and
operating point (volume, pressure, shaft power and efficiency). In any case, the fan speed and gas
density relating to the curves will be required as a minimum.
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be adjusted by the density effect of the dust, e.g. with a gas density of 1,4 Kg/Nm3 and a dust
concentration of 50 g/Nm3 would increase the effective density to 1,45 Kg/Nm3.
Tools
Pitot tube standard or S type for dusty gases, with known factor.
Manometer, digital or Hg column
Thermocouple and digital thermometer
Any instrument required to determine gas density:
1 Lafarge standard spreadsheet for re-drawing the fan curves at different speeds and
gas densities.
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Action Steps
1.
2.
damper position for comparison with the control system indication. When a damper is located
close to the fan inlet, the space for a good measuring point may be limited.
Fan inlet
Measure the static pressure, the temperature and duct section at the inlet of the fan according to
the available fan curve.
It should be clarified if this static pressure measurement is before or after the damper. This depends
whether the damper is included in the fan curve or not.
Fan Outlet
Measure the static pressure, the temperature and duct section at the outlet of the fan.
The measurements at the inlet, outlet and airflow should be done at the same time. If it is not
possible, try to correct them with the help of on-line sensors. Use a Pitot tube for measuring static
pressures.
3.
Calculate shaft power by taking into account the efficiency of the drive components
If the losses from the drive components are not available from the supplier, assume the following
standard values:
assume 3%
assume 3.5%
assume 6%
losses will be higher with poor tensioning of belts. Losses will differ for wound rotor motors, or DC
motors. VFD losses not included depends on meter location before or after VFD box.
4.
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Action Steps
In the case of a variable speed fan, compare the measured speed against that shown in the control room
For a fixed speed fan compare with the design speed.
5.
however, for combustion products additional measurements are necessary, at least oxygen and humidity
plus combustion calculations to be able to calculate the gas density.
6.
7.
Plot the corrected gas flow and pressure difference on the same graph as the corrected curve
Using the relation PV2 (P pressure difference, V gas volume) calculate the pressure difference for a
range of gas volumes and plot the system resistance curve on the same graph.
Determine the shaft power of the fan and together with the fan inlet gas flow plot this point on the
graph
For detailed analysis also use the fan inlet and outlet areas at the appropriate flanges for correction of
pressures. Fan curves are given for the fan from inlet to outlet flanges, although we seldom measure
right at the flange. For approximate estimates this level of precision is not needed. For very precise
measurements e.g. Performance guarantee testing, it is recommended.
8.
= 100 x P x Q
W
9.
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Treatment of results
efficiency
with
If after modification (elimination of false air and build-up, adjusting gaps at nominal), the efficiency is
still low, investigate the options to increase efficiency, by fan or by impellor replacement.
If high damper pressure loss check normal operating range and investigate potential options to reduce.
For an ID fan prone to build up, it is recommended to evaluate the efficiency systematically before
and after a long kiln stop to evaluate the impact of the precise internal cleaning of the fan.
A thorough clean-up of the build-up inside the impeller or between the impeller and the inlet cone,
can improve the efficiency of 5 percent.
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Preheater
Kiln
Preparation work :
Damper
Outlet
Ps,
T,
Section
Inlet
Ps, T,
Section
ID
fan
kW
Appendix
1.
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