Chapter 15

Fan Control

The output of a fan can be controlled by using various means including

outlet dampers, inlet-box dampers, variable inlet vanes, variable pitch, vari-
able speed, or even by varying the number of fans in operation. Each of these
techniques affects flow rate, specific output, stability, turndown ratio, start-up,
and power savings. In this chapter, the effects on the operating characteristics
of the fan will first be examined for each technique in turn. Next, the start-up
characteristics of various fans will be considered for different circumstances,
for example, single fans and multiple fans. Finally, the power savings that
can be expected at reduced ratings will be assessed.

Operating Characteristics
The operating characteristics that will be discussed in this section can all
be illustrated on a graph of specific output versus flow rate. Graphs of
pressure versus volume flow rate will be used, but specific energy versus
mass flow rate would be equally acceptable. Both fan characteristics and
system characteristics will be shown on each graph. An infinite number of
system characteristics exist. There are also an infinite number of perform-
ance-characteristic curves for a fan equipped with a control device. Only a
few representative examples will be shown on each graph. The location of the
actual operating point will depend on the setting of the control device as well
as on the system characteristic.

Outlet Dampers
The operating characteristics of a fan/outlet-damper combination can be
depicted as in either Figure 15.1 or Figure 15.2. In Figure 15.1, a constant-
speed, fan-total-pressure-versus-fan-flow-rate characteristic is shown together
with several parabolic system characteristics, all of which pass through the
origin. If we consider the resistance of the outlet damper to be a part of the
system resistance, then each of the parabolas represent the pressure-versus-
flow requirements of the combined damper and system at various damper
positions.

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15-2 FAN ENGINEERING

Figure l5.1 Fan Performance with Outlet Dampers

For a typical system, the fan-and-damper combination might operate at

point A with a wide-open damper. The fan-and-damper combination would
operate successively at points B, C, D, and E with increasing damper closure.
However, it might not be possible to achieve any lower flow rate than at E
because of leakage through the closed damper. The maximum turndown ratio
would be the flow rate at A divided by the flow rate at E. The operating
points D and E are potentially unstable because the fan characteristic has a
positive slope, as does the system characteristic. However, the fan character-
istic has a negative slope for the other operating points, which are, therefore,
expected to be quite stable.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-3

Figure l5.2 Fan Performance with Outlet Dampers

Figure 15.2 shows the same fan-and-damper combination as Figure 15.1

but from a different point of view. The damper is considered part of the fan,
so a different performance curve is given for the fan at each of the damper
positions. The top curve is identical to that in the previous figure, which can
only be achieved if the damper loss in the wide-open position is negligible.
Otherwise, the top curve would be slightly depressed. The dashed curves
correspond to several arbitrarily chosen damper positions. Although they are
marked 3/4, 1/2, and 1/4, note that the flow rate is only 3/4, 1/2, or 1/4 if the
fan operates at free delivery. The leakage rate at the fully closed position
determines the maximum turndown ratio possible.

‹#1999 Howden Buffalo, Inc.

15-4 FAN ENGINEERING

The curves shown in Figure 15.2 are only a few of the infinite number of
possible curves. Each should be considered the potential performance for the
corresponding damper setting. And the entire system of curves can be con-
sidered a map of the potential performance of the fan-and-damper combina-
tion. The performance is only potential because operation could be at any
point on the map. That point is not fixed until the system characteristic has
been established and, of course, until the damper position has been selected.
For instance, assuming a system characteristic such as the line ABCDE, the
performance would be at B for a damper setting corresponding to the 3/4
position. The system loss would be the vertical distance from the base line to
B´, and the damper loss would be the vertical distance from B to B´. The
losses C-C´, D-D´, and E-E´ increase as the damper is closed farther and
farther.
Operation is usually expected to be quite stable wherever the slope of the
fan characteristic is negative and the slope of the system characteristic is
positive. The operating points A, B, C, D, and E on Figure 15.2 are all stable
according to this criterion. There is some evidence that performance with an
outlet damper can be evaluated this way if the principal resistance of the
connected system is on the inlet side of the fan. But, if the principal resis-
tance of the system is on the discharge side of the fan, it is better to revert to
Figure 15.1. There the operating points D and E were considered potentially
unstable because the slopes of both the fan characteristic and the system
characteristic were positive.

Inlet-Box Dampers
Figure 15.3 illustrates the map of potential performance for a fan/inlet-box
damper combination. Postulating a system ABCDE, operation will be at A
for the damper in the wide-open position, at B for the 3/4 position, at C for the
1/2 position, etc. Once again, the maximum turndown ratio would be the flow
rate at A divided by the flow rate at E. This condition is limited by the
leakage through the damper as represented by the fully closed-position curve.
The degree to which the wide-open-position curve approaches that without
any IBDs depends on the loss of the IBDs in the wide-open position. The
difference between the performance with a wide-open IBD and that with a
particular closure of the IBD can be considered composed of two parts. One
part would correspond to the pressure drop caused by any resistance and, in
this respect, would resemble that caused by an outlet damper. The other part
might be due to any changes in the flow caused by the IBDs. This, then,
affects the flow through the impeller and, therefore, the output of the impeller.
The difference between B and B´´ might be due to spin or to other flow-
modifying effects. The difference between B´´ and B´ might be due to more
ordinary resistance effects. These curves are just typical, and the actual
percentage of one effect versus the other may vary greatly, depending on the
design.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-5

Figure l5.3 Fan Performance with Inlet-Box Dampers

Inlet-box dampers can be considered a part of the fan in much the same
way that outlet dampers were considered a part of the fan in the previous
section. The operating points A, B, C, D, and E on Figure 15.3 can be ex-
pected to be quite stable according to the criterion of opposite slopes for the
fan and system characteristics. Experience suggests that, if significant spin
effects exist, performance will be stable. There is some evidence that, even
without spin effects, performance with an inlet-box damper will be stable if
the principal resistance of the connected system is on the discharge side of the
fan. However, if the principal resistance of the system is on the inlet side of
the fan, it is better to consider that the operating points will be at B´, C´, D´
and E´. The nature of the intersections at D´ and E´ suggests unstable opera-
tion according to the slope criterion.

‹#1999 Howden Buffalo, Inc.

15-6 FAN ENGINEERING

Figure l5.4 Fan Performance with Variable Inlet Vanes

Variable Inlet Vanes

Figure 15.4 is a potential performance map of a fan with variable inlet
vanes. VIVs are designed to spin the air in the direction of fan rotation. Like
IBDs, VIVs can be considered to have a resistance effect as well as a flow-
modifying effect. However, since VIVs are built right into a fan, they are
almost always considered a part of the fan. the performance of the fan/VIV
combination, when connected to a system ABCDE, would be at points A, B,
C, D, or E, depending on the VIV position. Because the fan and the VIV are
so closely positioned, performance at D´ or E´ is usually considered unlikely,
and so, performance will be at D or E and stable.
As with both outlet dampers and inlet-box dampers, VIVs leak, and, so,
the turndown ratio is limited. The maximum turndown ratio for this system
would be the flow rate at A divided by the flow rate at E.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-7

Figure l5.5 Fan Performance with Variable Pitch

Variable Pitch
Figure 15.5 illustrates the potential-performance map of a fan with vari-
able-pitch capability. If we postulate a system characteristic ZABCDE,
performance will be at Z, A, B, C, D, or E, depending on the pitch setting. As
shown, the design setting is usually less than the maximum setting. The
performance at design for this system will be at A. Higher flow rates can be
achieved as at Z, and lower flow rates as at B, C, D, and E. The maximum
turndown ratio would be the flow rate at A divided by the flow rate at E for a
fan selected for basic operation at the design position. All points of operation
for this system would be stable because of the positive slope of the system
curve and the negative slopes of the fan curves at the various pitch-positions.
Such fans must be carefully selected to avoid operating at stall, as will be
discussed in connection with start up.

‹#1999 Howden Buffalo, Inc.

15-8 FAN ENGINEERING

Figure l5.6 Fan Performance with Variable Speed

Variable Speed
A map of potential performance for a fan with variable-speed capability is
shown in Figure 15.6. The individual curves are for full speed, 3/4 speed, 1/2
speed, and 1/4 speed. The full-speed curve will be identical to the fan curve
without the variable-speed device if no slip exists. However, most variable-
speed devices must slip to transmit torque. For a system such as ABCD,
performance will be at A at full speed, B at 3/4 speed, etc. Because of the
fan-law relationship of performance to speed, the performance will be stable
at all speed settings for this particular system. The turndown ratio will be
limited by the minimum speed that the variable-speed device can achieve.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-9

Figure l5.7 Performance of Two Fans in Series

Fans in Series
Figure 15.7 shows the potential performance of two identical fans in series
together with the potential performance of one of the fans alone. If the fluid
can be considered incompressible, the performance of two identical fans in
series is obtained simply by multiplying by two the pressure for one fan at the
pertinent flow rate. This is illustrated by the points A and A´. Point B is the
operating point that would result if there was only one fan in this system.
Two fans in series can be controlled by outlet dampers, inlet-box dampers,
variable inlet vanes, variable pitch, or variable speed. If each fan is equipped
with a control device, then, in general, the previous discussions pertaining to
those devices also apply to fans in series. One important distinction, espe-
cially for high-pressure fans, is that the absolute pressures in the two fans will
differ, and this should be recognized in their design.

‹#1999 Howden Buffalo, Inc.

15-10 FAN ENGINEERING

Figure l5.8 Performance of Two Fans in Parallel

It is common to use only one outlet damper or one inlet-box damper for
two fans in series. Except for the effects on pressure distribution, the location
of the outlet damper on either of the two fans is immaterial. But, this is not
true for an IBD because of the potential spin or other flow-modifying effects
on a fan so equipped.

Fans in Parallel
Figure 15.8 gives the potential performance of two identical fans in
parallel together with the potential performance of one of those fans alone.
The performance of two identical fans in parallel is obtained by multiplying
by two the flow rate of one fan at the pertinent pressure. This is illustrated by
the points A and A´ on Figure 15.8. Point B is the operating point that would
result if there were only one fan in this system.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-11

Fans in parallel can be equipped with outlet dampers, inlet-box dampers,

variable inlet vanes, variable pitch, or variable speed for control. Synchro-
nous control of the parallel fans will lead to the same kind of results that
would be obtained by a single fan. Non-synchronous control is possible, too.
Requirements might also be satisfied with only one fan or with one fan at the
wide-open position of the control device and the other fan with a partial
opening of the control device. In a system such as AB0, operation at A is
possible with both fans working in the wide-open control position. But,
operation at point B requires only one fan in the wide-open control position.
Operation between A and B requires either two fans with synchronous control
or one fan in the wide-open control position with the other fan modulated
between wide-open and fully closed. Operation between B and 0 might be
accomplished by modulating only one fan. Figure 15.8 does not show all
aspects of the problem that might have to be considered. For instance, the
turndown ratio of the control device might limit the applicability of a particu-
lar control sequence involving different fans. Even more important is the
ability to bring a second fan on line, which will be discussed separately in the
next section.

Start-up Characteristics
Start-up of a fan (or getting a fan on line) is usually a very simple process.
Usually, it involves nothing more than pushing the start button and allowing
the fan to come up to speed. Figure 15.9 illustrates what happens when a fan
is started up without complications. Since start-up involves going from
standstill to full speed, Figure 15.9 resembles Figure 15.6, which was drawn
for variable-speed operation. Before the start button is pushed, there is no
flow and, consequently, no pressure required, so operation can be considered
to be at point 0. When the fan is turned on, it will gradually accelerate and
eventually will reach the 1/4 speed. If we postulate a system such as 01234,
operation at 1/4 speed will be at point 1. Similarly, operation at 1/2 speed will
be at point 2, at 3/4 speed at point 3, and at full speed at point 4. Obviously, a
line drawn through these points illustrates the rating-point path that is fol-
lowed during the start-up process. Each of the points along this path can be
considered instantaneously established if equilibrium is also instantaneously
established. But, the path will be altered if equilibrium is not established
instantaneously. For example, if the attached system has a significant volume,
it may be necessary to pump up the duct, and the path may more nearly
approach that of 0, 1´, 2´, 3´, 4. In either case, the intersections between the
system curve and the various speed curves are all stable, and the fan easily
comes on line.

‹#1999 Howden Buffalo, Inc.

15-12 FAN ENGINEERING

Figure l5.9 Start-Up for a Fan on a Simple System

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 CHAPTER 15 – FAN CONTROL 15-13

Figure l5.10 Start-Up for a Fan with Controlled Resistance

Controlled Resistance
Another type of situation is illustrated in Figure 15.10. Here again, a
rather simple fan is accelerated from standstill to full speed during the start-up
process. The difference between this and the previous case is in the nature of
the system resistance. What is postulated here could be called a controlled-
resistance system in which a certain pressure must be achieved before
through-flow can begin. Specifically, the pressure must be raised to X before
any gas flows through the system. If equilibrium is instantly established at
each speed, the start-up process can be depicted as a straight line from 0
through 1, 2, 3, and 4 and then a parabola out to 5. If the duct volume is
significant, it may be necessary to fill up the duct, leading to a path such as 0,
1´, 2´, 3´, 4, and then on to 5. The point of rating during the filling-up process
starts at free delivery, moves gradually to the left, and in the case dia-
grammed, actually reaches shut-off.

‹#1999 Howden Buffalo, Inc.

15-14 FAN ENGINEERING

Figure l5.11 Start-Up for a Fan with Isolation Dampers

Isolation Damper
Still another simple situation is illustrated in Figure 15.11. Here again, the
fan is a simple one accelerating from zero to full speed. This one, however, is
equipped with a leak-free isolation damper. With the isolation damper closed,
the point of operation will always be at shutoff proceeding from 0 to 1, 2, 3, 4,
and 5´. As the damper is opened, the flow will begin and gradually increase
until the damper is wide-open and the point of operation is at 5. Note that the
point of operation must go over the hump of the pressure curve and that this
transition may not always proceed smoothly. The difference between the
wide-open fan curve and the parabolic-system curve is the resistance that
must be provided by the damper.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-15

Figure l5.12 Start-Up for a Fan with a Dip in the Curve

Dip in Characteristic
Yet, another start-up situation is illustrated in Figure 15.12. It is very
similar to that diagrammed in Figure 15.9. The difference is that the fan
characteristic has a dip as well as a hump. The fan roughly represented here
could be either a forward-curve fan or a variable-pitch fan at one particular
pitch setting. As before, the fan must accelerate from standstill to full speed.
For a system such as 01234, there is no problem in bringing the fan on line
because the intersections between the system curve and the various fan curves
are all stable.

‹#1999 Howden Buffalo, Inc.

15-16 FAN ENGINEERING

Figure 15.13 Start-Up for a Variable-Pitch Fan

Variable Pitch
A more complicated situation is shown in Figure 15.13. This is the same
fan that was diagrammed in Figure 15.5 except that the 5/4 pitch position has
been omitted and the starting lines (dashed) with the pitch set at the fully
closed position have been added. It is always recommended that a fan of this
type be started with the blades in the fully closed pitch position. For the
assumed system 12345678, the initial start up corresponding to the accelera-
tion to full speed will proceed from 0 through 1, 2, and 3, up to point 4. At
this point the fan has reached full speed, but the pitch mechanism has not been
changed from the fully closed position. The pitch can then be increased to
produce points 5, 6, 7 or 8 or to produce any intermediate points, as required.
All the operating points are stable because the slope of the system curve is
positive and the slopes of the fan curves are all negative. With this particular
system, the fan could be started with the pitch mechanism set at any position.
.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-17

Figure 15.14 Start-Up for a Variable-Pitch Fan

No stall would be encountered because the system line is low enough.

However, this starting procedure is recommended only for the smallest fans,
and then only when the system characteristic is well known.
Figure 15.14 is for the same fan as in the preceding figure, but with a
controlled-resistance type of system. Once again, the fan should be started at
minimum pitch, and after it is on line, then, and only then, can the pitch
mechanism be opened. Note that the points of operation 1, 2, 3, 4, and 5 are
all on the right-hand side of the humps of their respective curves even though
the dips appear to penetrate below the system line. If the fan is isolated by a
damper, the start-up procedure is to bring the fan up to speed with the damper
closed and the pitch mechanism in the fully closed position. After the fan has
come up to speed, the damper can be opened, and then, and only then, can the
pitch be increased. Start up will proceed from 0 to 0´ and then from 0´ to 1 as
the damper is opened.

‹#1999 Howden Buffalo, Inc.

15-18 FAN ENGINEERING

Figure l5.15 Start-Up for Two Fans in Series

Fans in Series
When two fans are in series, start up is just like that for a single fan, if the
two fans are started simultaneously. However, if they are not, the situation
can be examined using a diagram like that in Figure 15.15. This is the same
as Figure 15.7 but with start-up information added. First, the system 0123 is
postulated. Next, it is assumed that, while the first fan is started, the second
fan is at standstill but the flow passes through both fans. Because of the
second fan, the first sees a higher system resistance than the originally postu-
lated one. So, the path of the instantaneous start-up points for the first fan
would be along the line A from 0 to point 4. This fan would continue to
operate here as long as the system and the second fan stayed unchanged.
However, when the second fan is started, the resistance due to that fan, as
seen by the first, is gradually reduced. The first fan's point of operation
.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-19

moves from point 4 toward point 1. It reaches 1 when the point of operation
of the second fan reaches free delivery from some point beyond free delivery.
This occurs at a speed somewhere between standstill and full speed. As the
second fan accelerates further, its point of operation ascends its performance
curve while that of the first fan descends its performance curve. Ultimately,
the two identical fans will operate at identical points of rating and, of course,
at identical speeds. These points are 3´ on the one-fan curve and 3 on the
combined curve.
The various portions of the path A and the path A + B are actual paths so
the actual pressures and flow rates can be read on the appropriate scale. The
path B, however, is a relative one. It is shown on the full-speed curve to
illustrate the relative points of operation on the various part-speed curves of
the second fan as it is accelerated. Actual flow rates can be read for points
along path A + B. The pressure for the first fan will be that on the path A, and
the pressure for the second fan will be the difference between that on path A +
B and, that on path A.

Fans in Parallel
If two fans in parallel are started simultaneously, the start-up operation
will be just like that for one-fan operation. However, if they are started
separately, Figure 15.16 can be used to explain some of the situations that
might develop. This is the same as Figure 15.8, except that the start-up
conditions have been added. Start-up of the first fan proceeds along the path
A from 0 to 1 if the second fan is isolated (so there will be no backflow
through it). Ignoring the problems of isolation for the moment, start-up of the
second fan would initially have no effect because the sum of the potential
performance of the second fan and that of the first does not intersect the
system characteristic. Only after the second fan has accelerated sufficiently
does the combined characteristic intersect the system characteristic. The
second fan's relative point of operation at the initial point of intersection will
be at shut off for that fan. With further acceleration, the relative point of
operation will move from shut off to the right, as shown by the path B.
Simultaneously, the first fan's point of operation will gradually move upward
from its initial point. Eventually, when the second fan reaches full speed, the
points of operation of the two fans will be identical. These are depicted as
point 3´ on the one-fan curve and point 3 on the combined curve. Note that
the second fan's point of operation has to proceed from shutoff, over the
hump, to the normal operating point. This could cause serious instability and
even graver problems if the fan has a dip in its characteristic.
The various portions of the path A and the path A + B are actual paths so
the actual pressures and flow rates can be read directly on the appropriate
scale. The path B, however, is a relative one. It is shown on the full-speed
curve to illustrate the relative points of operation on the various part-speed
curves of the second fan as it is accelerated. Actual pressures can be read for
points along path A + B. The flow rate for the first fan will be that on the
path A, and the flow rate for the second fan will be the difference between
that on path A + B and that on path A.

‹#1999 Howden Buffalo, Inc.

15-20 FAN ENGINEERING

Figure l5.16 Start-Up for Two Fans in Parallel

Figure 15.17 can be used to examine some of the problems that occur in
starting up parallel fans that have dips in their characteristic curves. The
characteristics of each fan are approximately the same as those shown in
Figure 15.5, except that a greater turndown capability has been included and
both the 5/4 and Design curves have been omitted. The map of potential
performance for one-fan operation is shown to the left in the diagram. The
map of potential performance for the second fan has been added on the right-
hand side and represents an addition to the performance of the first fan when
the first fan is operating at the 3/4 position. If we postulate a 100% common-
.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-21

Figure l5.17 Start-Up for Two Variable-Pitch Fans

resistance system according to 01234567 and if the first fan is on line operat-
ing at point 1, then there will be no difficulty in bringing the second fan on
line. With the blade pitch for the second fan set in the minimum position, the
point of operation will hold at point 1 until the second fan develops enough
pressure, and then proceed from point 1 to point 2 as the second fan continues
to accelerate to full speed. The pitch of the second fan can then be increased
from 2 through 3, 4, 5, 6, and on up to 7, if necessary. While bringing the
second fan on line, the point of operation of the first fan must change because
the common resistance increases. For the system 01234567 in Figure 15.17,
the point of operation of the first fan begins at 1 when the second fan is first
brought on line but reaches, 7´ when the second reaches 7.

‹#1999 Howden Buffalo, Inc.

15-22 FAN ENGINEERING

Figure 15.18 Start-Up for Two Variable-Pitch Fans

The situation for the same two fans is different if a system from A through
B, C, D, E, F, and G is postulated as shown in Figure 15.18. Once again,
assuming that the first fan is on line but this time at point B, note that bringing
the second fan up to speed at the minimum blade position will not really add
to the performance. (In other words, the second fan is still not on line.)
However, it can easily be brought on line by opening the blade pitch enough
to shift the point of operation from B towards C. Continued increase in blade
pitch will produce operation at C, D, E, F, and G without any difficulties
.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-23

Figure l5.19 Start-Up for Two Variable-Pitch Fans

because operation will always be to the right of the hump on whatever per-
formance curve actualizes. If the second fan is started with an isolation
damper closed, the start-up procedure should include acceleration at minimum
blade position followed by an increase in the blade pitch sufficient to produce
a pressure behind the damper equal to that on the other side, or in other words,
a pressure equal to B. The damper can then be opened without sudden change
in operation. Following this, the pitch of the second fan can be increased to
the desired position.

‹#1999 Howden Buffalo, Inc.

15-24 FAN ENGINEERING

Systems of the type A´ B´ C´ D´ G´ in Figure 15.19 require carefully

controlled start-up. The first fan could be brought on line satisfactorily by
bringing it up to speed and then gradually increasing the pitch to the 3/4
position for operation at B´. The second fan could also be brought on line by
accelerating it to full speed with the pitch in the minimum position and then
increasing the pitch to produce operation at, say, C´´. Operation at point D´ is
even possible, but beyond that point the potential performance map is empty.
Any further increase in pitch will result in less airflow and the fan will operate
in the stall region of its performance characteristic. Since operation in stall
must be avoided, a different start-up procedure must be found. Such a proce-
dure involves reducing the pitch of the first fan enough so that the operating
pressure will be below the minimum stall pressure. A new graph is needed to
illustrate this point, and a slightly different approach will be used to construct
this new graph.
The performance map for one fan can sometimes be used to analyze the
performance of two identical fans in parallel without necessarily drawing the
combined characteristics. In Figure 15.20 the systems AB and B´G are the
same as the system ABCDEFG shown in Figure 15.18. Note that the AB
portion of this system is for one fan operation and can be used to determine
the operating points for that fan between the fully closed and the 3/4-open
pitch position. The B´G portion is for the second fan if it must be started
when the first fan is on line at B. The situation is exactly the same as that
described in connection with Figure 15.18, and there is no difficulty in
bringing the second fan on line. As the pitch of the second fan is increased,
the operating point of the first fan will move from B to G. The values of Qû
read from Figure 15.20 are the flow rates for each fan, and if there are two
fans operating, their flow rates must be added together to give the total flow
rate for two fans in parallel.
Figure 15.20 can also be used to illustrate synchronous start-up of two
fans in parallel. This is shown by the line AG. Note that the operating points
are higher on the individual pitch-position curves than for the line AB and that
they are lower than the corresponding point on the line B´G. This facilitates
start-up when the controlled resistance X is so high that operation in stall
would result from starting one fan at a time.
Figure 15.21 is for the same fans and system depicted in Figure 15.19.
The curve A´B´ shows the various operating points during the course of
starting the first fan and increasing the pitch to the 3/4 position. The curve
B´´D´G´ shows that the second fan can be brought on line but that the pitch
cannot be increased beyond the 1/6 position without putting the fan into stall.
This is only for the case when the second fan is brought on line after the first
is already operating at the 3/4 position. The two fans could be started syn-
chronously and brought on line without entering stall even with the high value
of X shown. The path of this process is from A´ directly to G´. Note that
none of the operating points is close to stall.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-25

Figure l5.20 Start-Up for Two Variable-Pitch Fans

The preceding discussions of fans in parallel are all based on postulated

systems having all their resistances common to both fans. Figure 15.22 is
drawn for a situation where part of the resistance is common to both fans and
part is separate. The common resistance consists of a controlled part at the
level of X and a variable part. The separate resistances are the same for both
fans, and the total of the separate and the common variable resistance is the
same as the total common variable resistance used for Figure 15.21. The
curve A´B´ is the same as the corresponding curve in Figure 15.21. Both
show the pressure developed across the first fan started. The pressure at B´
would be measured by a differential gauge across the points 0 and 2 on the
schematic diagram. Because of the individual resistance between 2 and 3, the
pressure at 3 would correspond to that at the point H. This is the pressure that
.

‹#1999 Howden Buffalo, Inc.

15-26 FAN ENGINEERING

Figure l5.21 Start-Up for Two Variable-Pitch Fans

would have to be developed by the second fan at the same point 3 in order for
that fan to come on line. The second fan would, therefore, come on line at the
point H´´. Because there is no flow at this point, there is also no pressure drop
across the individual resistance connected to the second fan. This pressure
drop will increase with flow, as will that of the common variable resistance.
The path H´´G´ can be used to determine the operating points for the second
fan as the pitch is increased to the 3/4 position. As the pressure drop across
the common resistance increases due to the added flow of the second fan, the
point of operation of the first will proceed from B´to G´. The path H´´G´can
be used to determine the pressure that would be read by a differential gauge
across the points 0 and 3 in the schematic diagram as the blade pitch of the
second fan is gradually increased. Note that the curve H´´G´ is much lower
.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-27

Figure l5.22 Start-Up for Two Fans in Parallel

than the curve B´´G´ of Figure 15.21. This illustrates that, as the individual
resistances increase compared with the common resistance, the chances of
avoiding operation in stall while bringing a second fan on line are much
better. If none of the resistance is common to both fans, it is necessary only
that either fan produce the pressure at A´ in order to come on line. The
operating points for either fan would, therefore, fall on the line A´G´ in Figure
15.21.

‹#1999 Howden Buffalo, Inc.

15-28 FAN ENGINEERING

Most of the preceding discussions were simplified by omitting any refer-

ence to dampers in the system. Dampers are required to keep an idle fan from
windmilling and to prevent the bypass of air around the rest of the system. In
most start-ups the damper on the second fan should not be opened until the
fan has come up to speed and enough pressure exists behind that damper to
ensure that flow will proceed in the correct direction when the damper is
opened.

Power Savings
Each of the various control devices or techniques can be used to save
power at reduced loads. Just as a map of potential performance can be drawn
with specific output and flow rate as coordinates, a map of potential perform-
ance can also be drawn with input power and flow rate as coordinates. For
each point on the specific output map, there is a corresponding point on the
input power map.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-29

Figure l5.23 Power Savings with Outlet Dampers

Outlet Damper
Figure 15.23 gives the map of potential power performance for a fan
equipped with outlet dampers. Observe that less power is required as the
damper position is changed from wide-open to 3/4, and still less at the 1/2 and
1/4 positions. This is true only if the basic power characteristic of the fan is
of the type shown, namely, one with a positive slope. Some fans' power
characteristics have a negative slope over part of the range, and it is obvious
that, in these cases, there will be a power increase rather than a power reduc-
tion if the fan is throttled with an outlet damper. Many axial-flow and pro-
peller fans have this kind of characteristic, so caution is advisable when
throttling these types of fans.

‹#1999 Howden Buffalo, Inc.

15-30 FAN ENGINEERING

Figure l5.24 Power Savings with Inlet-Box Dampers

Inlet-Box Damper
Figure 15.24 shows the power that can be saved when inlet-box dampers
are applied to a fan with a positively sloping power characteristic. The spin
produced by the IBD not only reduces the output but also decreases the input
more than a simple outlet damper would.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-31

Figure l5.25 Power Savings with Variable Inlet Vanes

Variable Inlet Vanes

The power characteristics for a fan equipped with variable inlet vanes are
shown in Figure 15.25. Using variable inlet vanes usually saves more power
than using IBDs because the VIVs can be designed to produce more effective
results. (They are usually placed closer to the impeller.)

‹#1999 Howden Buffalo, Inc.

15-32 FAN ENGINEERING

Figure l5.26 Power Savings with Variable Pitch

Variable Pitch
For a properly designed fan with variable-pitch capability, the power
savings can be dramatic, as indicated by Figure 15.26. This variation in pitch
can be achieved in various ways, including manually, pneumatically, and
hydraulically. However, the latter two can be used in automatic systems, and
they may require the continuous application of power to some auxiliary
apparatus in order to provide the necessary force when control is needed.
Theoretically, at least, this additional power should be considered when
evaluating the savings due to variable pitch.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-33

Figure l5.27 Power Savings with Variable Speed

Variable Speed
Figure 15.27 shows the power map for a fan with variable-speed capabili-
ties. The savings are, again, dramatic and predictable according to the fan
laws. The variation of speed can be achieved with several devices, including
variable-pitch belt drives, hydrokinetic fluid drives, hydroviscous fluid drives,
AC or DC adjustable-speed electric motors, and AC adjustable-frequency
electric motors. For all these techniques, the output of the drive will be less
than the input to the drive, and these drive losses, too, should be considered
when evaluating the power savings due to variable speed.

‹#1999 Howden Buffalo, Inc.

15-34 FAN ENGINEERING

Figure l5.28 Comparison of Power Savings

Comparisons
Figure 15.28 compares various methods of saving power. As noted
before, the savings resulting from an outlet damper may be substantial, but
even greater savings are usually possible with IBDs and VIVs. The very
impressive savings that can be achieved with variable pitch and variable speed
are comparable, especially when slip losses are included in the variable-speed
application. Also, multiple fans can be used to save power, as illustrated in
Figure 15.29. Obviously, only coarse control can be achieved if the choice of
operation is limited to one or two fans, both in the wide- open position.
However, fine control by any of the means discussed (including dampers,
vanes, pitch, and speed control) is possible.

‹#1999 Howden Buffalo, Inc.

 CHAPTER 15 – FAN CONTROL 15-35

Figure l5.29 Power Savings with Parallel Fans

‹#1999 Howden Buffalo, Inc.

15-36 FAN ENGINEERING

Other Control Devices

Other devices have been developed to control the output of a fan in
addition to the ones examined above. These include adjustable scrolls, sliding
inlet bells and disks, and sliding discharge cylinders. Most bear proprietary
names.
The adjustable scroll operates by reducing the size of the flow passage in
the volute thereby introducing a loss that causes a reduction in flow rate. This
device appears to act much like an outlet damper. Refer to the earlier discus-
sions of outlet dampers for comments on stability and power savings. Turn-
down ratio is quite limited.
Sliding inlet bells, sliding disks, and sliding cylinders all operate by
reducing, in varying degrees depending on position, the effective width of the
blades and blade passages. The cylinder blocks the discharge flow area while
the bells and disks block the inlet flow area. Each position produces a flow
rate/specific output characteristic that is similar to that of a narrower width
impeller. The degree of similarity will depend on how effective the device is
in eliminating the effectiveness of the blocked portions. Each position will
have a stability characteristic similar to that of a wide open fan of that width
of the same aerodynamic type. Turndown ratios may approach 100 percent if
the device is capable of producing a tightly closed position. Power savings
will be similar to those for variable-inlet vanes depending on point of opera-
tion and the degree to which the device eliminates the effectiveness of the
blocked portion of the impeller.

‹#1999 Howden Buffalo, Inc.