The Basics Of: Axial Flow Fans
The Basics Of: Axial Flow Fans
Page 1 of 35
CONTENTS
Page
FOREWORD ........................................................................................................................ 3
FIGURES ............................................................................................................................. 3
NOMENCLATURE ............................................................................................................. 4
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
REFERENCES ..................................................................................................................... 34
DEDICATION ...................................................................................................................... 34
Hudson Products Corp.
Page 2 of 35
FOREWORD
This manual is designed to familiarize users
with applications for axial flow fans,
velocity recovery stacks, seal discs, and
variable flow fans. Calculations are provided
for estimating fan power consumption and
noise.
FIGURES
Page
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
Page 3 of 35
NOMENCLATURE
English Letter Symbols
ACHE
ACFM
ACT
ASP
ATP
AVP
BHP
BPF
CS
CFM
DR
Eff
D
FPM
HP
LP
LW
MSL
N
NFA
PWL
r
PWM
R
RH
RPM
SCFM
SF
SP
SPL
SR
STD
EffTotal
EffStatic
TP
V
VFD
VP
VR
VVI
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
=
Page 4 of 35
density
ACT (act)
STD (std)
exit (ex)
c
=
=
=
=
actual condition
standard condition
velocity recovery stack exit
fan curve condition at standard density
1
2
in
out
SL
des
eff
=
=
=
=
=
=
=
inlet, condition 1
outlet, condition 2
inlet
outlet
sea level
design
effective
Subscripts
Page 5 of 35
Page 6 of 35
Fan Laws - Set of laws that predict performance changes if one or more parameters are
changed from one fan or operating condition
to another. These laws govern airflow, pressure capability and power required among
many other parameters.
The Basics of Axial Flow Fans
Page 7 of 35
DENSITY
I-P:
lbs per cubic ft (lb/ft3)
metric: kilograms per cubic meter (kg/m3)
SI:
(kg/m3)
Note standard density
I-P
=
metric =
SI
=
0.075 lb/ft3
1.201 kg/m3
1.201 kg/m3
ROTATIONAL SPEED
I-P:
revolutions per minute (RPM)
metric: turns/min
SI:
turns/min
TEMPERATURE
VOLUME
I-P:
cubic feet per minute (CFM)
metric: cubic meters per second (m3/s)
cubic meters per hour (m3/h)
SI:
cubic liters per second (l3/s)
I-P:
degrees Farenheit (oF)
metric: degrees Celsius (oC)
SI:
degrees Celsius (oC)
AREA
I-P:
ft2
metric: m2
SI:
m2
PRESSURE
I-P:
inches of water (in. - H2O)
metric: mm of water (mm - H2O)
SI:
Pascals (N/m2)
POWER
I-P:
HP (horsepower)
metric: kW (kilowatt)
SI:
kW (kilowatt)
Page 8 of 35
TIP SPEED
PRESSURE
I-P:
ft/min
metric: m/s
SI:
m/s
VIBRATION AMPLITUDE
I-P:
mils (1/1000 inches)
metric: microns (1/1000 mm)
SI:
microns (1/1000 mm)
VOLUME
35.314 * m3 = ft3
0.02832 * ft3 = m3
VIBRATION FREQUENCY
I-P
DENSITY
Standard density = 0.075 lb/ft3
16.018 463 * lb/ft3 = kg/m3
Standard density = 1.201 kg/m3
LENGTH
25.4 * inch = mm
3.281 * m = ft
1000 * mm = micron
0.3048 * foot = m
TEMPERATURE
(oC * 1.8) + 32 = oF
(oF - 32) / 1.8 = oC
AIRFLOW
2118.64 * m3/s = ft3/min
0.000 471 947 * ft3/min = m3/s
POWER
0.746 * HP = kW
Page 9 of 35
Page 10 of 35
BHP =
If you have any questions, or require a
copy of the Hudson Tuf-Lite Fan
Rating Program or specification
curves please contact the Hudson
Fan Sales department for assistance at
1-800-634-9160.
6356 * EffTOTAL
TP = SP + VP
TP = Total Pressure
SP = Static Pressure
VP = Velocity Pressure
EffSTATIC =
Normally, pressures are given at actual
conditions (density) so the equation becomes:
TPACT * ACFM
6356 * BHP
SPACT * ACFM
6356 * BHP
Velocity (ft/min) =
()
Density Ratio =
ACFM(ft3/min)
NFA (ft2)
ACT
()
STD
SP = ASP * 1 / DR
Note: Hudson fan curves are based on
standard conditions and 12,000 FPM tip
speed. If operating conditions are given in
actual conditions, they must be converted
to standard conditions before referring to the
fan curve to determine performance.
V
AVP =
4005
2
1
Page 11 of 35
CFM = fn(RPM)1
Airflow varies in direct proportion to
RPM
SP or TP = fn(RPM)2
Pressure capability varies with the
square of a change in RPM
Horsepower
5.0
Total Pressure
in.-H2O
10
6
2
10
6
2
Pitch
Angle
Velocity
Pressure
Airflow (CFM)
HP = fn(RPM)3
Power required varies with the cube
of a change in RPM.
Air Density
Page 12 of 35
TPc * ACFMc
6356 * BHPstd
TPact * ACFM
6356 * BHPact
Curve RPM
=Actual RPM
Calculate SF 2 and SF 3
Note: If fan is operating at 12,000 FPM
tip speed, SF = 1 when using Hudson
curves.
6. Prepare to enter curve: c = curve cond.
ACFMc = ACFMdesign * SF
TPc = TPstd * SF 2
ASP
ATP
7. Enter curve:
2. Calculate exit velocity pressure:
Read up from ACFMc to TPc. Find pitch
angle, and interpolate if necessary. Read
up to design pitch angle on HP lines.
Read left to design BHP (std).
ACFM
Pexit
2
VPex =
6356 * EffTOTAL
BHPstd
(1/DR) * SF 3
Page 13 of 35
HP Saved (percentage)
20
16
12
Hz = cycles/second
in Hz
0
0.1
0.2
0.3
0.4
Stall Points
4 blades
6 blades
8 blades
8 blades
3. Horsepower ranges:
Allow a 2 pitch angle margin of safety
before stall for a conservative fan
operating point.
Page 14 of 35
6-10 ft dia
12 ft
14 ft
16 - 20 ft
24 - 30 ft
36 - 40 ft
7.5 - 15 HP
20 - 30 HP
30 - 60 HP
50 - 100 HP
100 - 250 HP
150 - 300 HP
The Basics of Axial Flow Fans
5. Fan stacks:
Assume 7 angle per side and 70% (0.7)
recovery efficiency.
Tip Vortex (Leakage)
Fig. 5
6. Noise levels:
@ 12,000 FPM
7.
75% minimum
6.1
Page 15 of 35
Minimum
1/4 in.
1/4 in.
1/4 in.
1/2 in.
Maximum
1/2 in.
5/8 in.
3/4 in.
1 in.
Tip Clearance
Fig. 6
6.2
Vena Contracta
\\
6.3
Since most of the work is done by the
outer portion of the fan blade, the
result can be a loss of efficiency as high
as 15-20%. An additional adverse
effect can be increased vibration.
To prevent this loss, consider the use
of an inlet bell attached to the bottom
of the fan ring. A properly designed
inlet bell provides a smooth transition
as the air is gathered from all directions
into the plane of the fan as shown in
Fig. 8.
Page 16 of 35
$
kW-HR
93 125
75 100
56
75
37
50
19
25
0
0
137.7 BHP
0.835 Total efficiency
0.512 Static efficiency
0.619 Total pressure actual
With the VR stack:
BHP = 123.6
0.840 Total efficiency
0.571 Static efficiency
0.559 Total pressure (actual)
Page 17 of 35
60
50
% Increase in ASP
1.8
CFM 2
For ACHEs: SP2= SP1
CFM1
40
30
20
10
Page 18 of 35
0
0
10
15 20
25
% Increase ACFM
30
6.6
2. Environmental losses are more
difficult to determine but are a function of actual fan tip clearance, fan
inlet conditions, number and size of
beams under the fan and structural
geometry. These losses must be
accounted for when determining
driver power requirement.
Example:
For a given fan selection:
Actual Fan Brake Horsepower = 62
BHP (at the fan shaft)
Example:
Electric Motor Efficiency 95%
Example:
Drive System Efficiencies:
Gear Boxes 98%
V-Belts 95%
Cog Belts 98%
Example:
Conservative Estimate of
Environmental Losses 97%
Therefore if:
HPin = Total Horsepower Required
= Fan Horsepower Required
(Eff Motor) (Eff Drive) (Eff Environment)
= 69.6 HP
ACT
Density Ratio =
=
STD
Effect of Density
Page 19 of 35
460 + 70F
460 + Tair
Page 20 of 35
BPF =
No.Blades * RPM
60
We think of this as how the fan interacts with the structure. The critical
frequency is the frequency at which
the blade pass frequency coincides with
the blades 1st mode natural frequency.
We believe that a more important
frequency is the beam pass frequency.
This is the number of obstructions or
beams one blade passes over per
revolution. For example, if there are
four beams in a fan turning 300 RPM,
the beam pass frequency is:
BPF =
Think of beam pass as how the structure interacts with the fan blade.
It is also very important to consider
harmonics of the fan RPM.
Harmonics are integer multiples of the
fan speed. The 1st harmonic = 1 x RPM.
In Hudsons Tuf-Lite fan rating
program, both blade pass and beam
pass frequencies are calculated and
compared to 1st mode fan resonance, as
well as the 1st harmonic assuming the
number of beams are input. A
Frequency Safety Margin is
calculated as the closest margin
between any two of these frequencies.
We recommend 5% as a minimum
safety margin for trouble-free
operation.
Page 21 of 35
6.8
SR =
4 13
= 0.10
12 14
Velocity Profiles
Seal Disc
Straight Chord Fan
Poor Efficiency
Straight
Chord Fan
Tapered
Chord Fan
Positive
Flow
Negative
Flow
6.9
Airfoil twist
Page 22 of 35
Page 23 of 35
Force
Diaphragm
Airflow
Aero Moment
Rotation
Force
Spring
140
Horsepower
120
100
Rated hp
Airflow
80
60
40
20
AV Force Diagram
Fig. 16
-40
Negative
Signal-(psi)
-20
-60
Typical Components:
A typical variable-pitch fan hub mechanism
is shown in Fig. 18. The basic components
are:
Hub spring
Diaphragm
Piston
Blade shafts with eccentric actuator
Rotary air joint
Valve positioner
Page 24 of 35
Valve Positioner
Hub Spring
Low Pitch Limit
Stop Nuts
High Pitch
Limit Stops
Diaphragm
Upper Piston
Blade Attachment
Lower Piston
Blade Shaft
Process Control:
There are several methods used to control
process temperature in an air-cooled heat
exchanger:
Control Methods:
The valve positioner is a closed-loop
feedback device that receives the control signal, (usually 3 - 15 psi) and supply
pressure up to 100 psi (689 kPa). Valve
positioners are used when airflow is critical,
such as in ACHE condensing application.
Page 25 of 35
Fluid bypass
On-off fan operation
Two-speed fans
Louvers
Variable speed fans
Variable pitch fans
Page 26 of 35
Horsepower
21
31
41
2
40
cfm1 2.8 1
Where: HP1 =
HPdes
cfmdes
des
20
4
Variable-Pitch HP
Fixed-Pitch HP
60
Energy Comparison:
1.2
1
1.0
31
21
1
.8
.6
3
.4
.2
150
14
2
4
175
200
10
2
225
250
275
300
System
Resistance
325 Line
Page 27 of 35
Flow
Power
Elevation
350 ft (107 m)
500
2 Fixed-Pitch On
Des. Point
2 Fixed-Pitch On
(1-1/2 Speed)
400
300
200
100
Variable-Pitch
at Zero Flow
Design Airflow
Required
Variable-Pitch
Airflow
0
100 90
80
70
60
50
40
30
20
Ambient Temperature F
Estimated Total
kW-hr/yr
Temperature
Step 4. Using HP-hours for each temperature range, tabulate the total for the
year. The power required is kW =
HP (0.746). Arrive at an energy
cost per year for each scheme.
Energy
Cost/yr
$.035/kW-hr
First
Costs
Case 1
162,670
2 Fixed-Pitch
$5,693
Base
Case 2
142,080
2 Fixed-Pitch
1-1/2 SP (Manual)
$4,973
+$1,000
Case 3
70,887
1 Fixed-Pitch
1 Variable-Pitch
$2,481
+$3,715(a)
Page 28 of 35
100% of base
59% of base
50% of base
Page 29 of 35
Page 30 of 35
+5
0
-5
A
C
-10
-15
-20
-25
-30
B and C
B
Frequency Responses for
Weighting Characteristics
-35
-40
-45
-50
20
50
0
200
0
500
0
10,
000
20,
000
100
500
200
Noise-Related Nomenclature
100
9.1
The dB(A) is the most common weighting system. It expresses sound levels with
a single number instead of having to
specify the noise of each octave band.
9.2.2
9.2.1
9.3
ACHE Noise
Page 31 of 35
TipSpeed
+ log HP
1000
Fan diameter
Fan tip speed
Blade Type
Blade pitch angle
Inlet conditions
Horsepower
For example:
14 ft fan
237 RPM (10, 424 FPM tip speed)
25.1 HP
Motor noise
Belt or gear noise
Bearing noise
Reflected noise from supports
Background noise
Page 32 of 35
9.4
Noise Testing
Frequently, the ACHE must be tested for
confirmation that its noise does not
exceed specifications imposed by the
purchaser. There are two basic types
of tests normally performed before
shipment:
Page 33 of 35
REFERENCES:
Monroe, Robert, CTI Paper TP74-03, Cooling Tower Fans - Today and Tomorrow,
Jan. 1974
Monroe, Robert, CTI Paper TP97-12, Maximizing Fan Performance,
Feb. 1997
API Standard 661, Fourth Edition, Air-Cooled Heat Exchangers for General Refinery
Services, Nov. 1997
API Standard 631M, First Edition, Measurement of Noise from Air-Cooled Heat
Exchangers, June 1981
DEDICATION
The Basics of Axial Flow Fans is a compilation of work performed by many Hudson
Products engineers and employees. However, one individual deserves special recognition.
Mr. Robert C. Monroe, who worked tirelessly for Hudson from January 28, 1967 to his
retirement on August 1, 1997, was not only a major contributor to the contents of this book but
also to the success of Hudson Products Corporation in manufacturing quality fiberglassreinforced, plastic fan blades. Bobs expertise, vision and hard work were
Page 34 of 35
a McDermott company
Hudson, Auto-Variable, Combin-Aire, Exact-A-Pitch, Fin-Fan, Heatflo, Hy-Fin, Solo Aire, Split-Flo, Stac-Flo, Steamflo, Thermflo, Tuf-Edge, Tuf-Lite
and Tuf-Lite II are registered trademarks of Hudson Products Corporation.
2000 McDermott Incorporated. All Rights Reserved.
Hudson Products Corp.
M0100-186 5M W1/00
Page 35 of 35