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PEMP

RMD 2501

Fans and Blowers

Session delivered by:


Prof Q.H.
Prof. Q H Nagpurwala

06a M.S. Ramaiah School of Advanced Studies 1


PEMP

Session Objectives RMD 2501

This session is intended to discuss the following:


Types and working principle of fans and blowers
Applications of various fans and blowers
Pressure rise
rise, flow coefficient and efficiency
Velocity triangles
Performance characteristics
Fan laws

06a M.S. Ramaiah School of Advanced Studies 2


PEMP

What is a Fan? RMD 2501

Any device that produces a current of air by the movement of


broad surfaces can be called a fan.
Fans fall under the general classification of turbomachinery
turbomachinery
and have a rotating impeller at least partially encased in a
stationary housing.
Fans are similar in many respects to pumps. Both are
turbomachines that transfer energy to a flowing fluid. It is easy to
distinguish between fans and pumps: pumps handle liquids; fans
handle gasses.
Broadly speaking, the function of a fan is to propel, displace, or
move air or gas.

06a
M.M.S.
S. Ramaiah School
Ramaiah of Advanced
School Studies, Studies
of Advanced Bangalore 3
PEMP

Fans, Blowers and Compressors RMD 2501

Fans, blowers
F bl andd compressors are differentiated
diff i d byb the
h methodh d usedd to
move the air, and by the system pressure they must operate against.
Difference Between Fans Blower and Compressors
DifferenceBetweenFans,BlowerandCompressors
Equipment SpecificRatio PressureRise(mmWC)
Fans Up to 1 11
Upto1.11 1136
Blowers 1.11to1.20 1136to2066
Compressors Morethan
More than
1.20

As per American Society of Mechanical Engineers


(ASME) the specific ratio the ratio of the
discharge pressure to the suction pressure is used
for defining the fans and blowers

06a
M.M.S.
S. Ramaiah School
Ramaiah of Advanced
School Studies, Studies
of Advanced Bangalore 4
PEMP

Components of Fan/Blower System RMD 2501

Turning Vanes
(typically used on
short radius elbows)

Outlet
O tl t Diffusers
Diff

Provide air for


ventilation and
Heat
industrial Exchanger
processes that
need air flow Baffles

Filter Inlet
Vanes

Motor
Controller

Centrifugal Fan/Blower
Variable Frequency Drive
Belt Drive
Motor

06a
M.M.S.
S. Ramaiah School
Ramaiah of Advanced
School Studies, Studies
of Advanced Bangalore 5
PEMP

Parts of a Fan / Blower RMD 2501

1
1. I ll
Impeller
2. Blade
3. Shroud
4
4. H b
Hub
5. Housing
6. Inlet
7
7. Outlet
8. Guide Vanes

Centrifugal housing
include side plate and
scroll
ll sheets.
h t
Axial housing includes
the outer and inner
cylinder, belt tube

06a
M.M.S.
S. Ramaiah School
Ramaiah of Advanced
School Studies, Studies
of Advanced Bangalore 6
PEMP

Fan Types RMD 2501

Fans are classified


F l ifi d according
di to the
h direction
di i off flow
fl through
h h the
h
impeller:

Axial Flow: Air flows through the impeller parallel to,to and at a
constant distance from the axis. The pressure rise is provided by the
direct action of the blades
Centrifugal or radial flow: Air enters parallel to the axis of the fan
and turns through 900 and is discharged radially through the blades. The
blade force is tangential causing the air to spin with the blades and the
main pressure is attributed to this centrifugal force
Mixed flow: Air enters parallel to the axis of the fan and turns through
an angle
g which may g from 300 to 900. The ppressure rise is ppartially
y range y
by direct blade action and partially by centrifugal action
Cross Flow: air enters the impeller at one part of the outer periphery
flows inward and exits at another part of the outer periphery.
periphery

06a M.S. Ramaiah School of Advanced Studies 7


PEMP

Centrifugal Fans RMD 2501

R t ti impeller
Rotating i ll increases
i i velocity
air l it
Air speed is converted to pressure
High pressures for harsh conditions
High temperatures
Moist/dirty air streams
Material
M t i l handling
h dli
Categorized by blade shapes
Radial
Forward curved
Backward inclined

06a M.S. Ramaiah School of Advanced Studies 8


PEMP

Centrifugal Fan Impeller Types RMD 2501

Backward inclined Open Type


Radial tip Blades Backward inclined
Radial Tip Blades

Airfoil
Blades
with
Higher
Efficiency

Open Type Forward


Backward Backward Curved
inclined inclined Radial Blades Type
radial
di l Tip Blades
blade

06a M.S. Ramaiah School of Advanced Studies 9


PEMP

Centrifugal Fans RMD 2501

Forward-curved fans are used


in clean environments and
operate at lower
temperatures Well suited for
temperatures.
low tip speed and high-
airflow at lower pressures

Paddle blade or
radial fan
Backward curved
Radial
R di l fans
f h
have hi
high
h static
t ti
pressures (up to 1400 mm Backward-inclined fans are
WC) and can handle heavily more efficient than forward-
contaminated airstreams. curved fans. Also known as
Well suited for high "non-overloading" because
Forward curved or
temperatures and medium changes in static pressure do
blade tip speeds multi-vane radial fan
not overload the motor

06a
M.M.S.
S. Ramaiah School
Ramaiah of Advanced
School Studies, Studies
of Advanced Bangalore 10
PEMP

Applications of Centrifugal Fans RMD 2501

Augmenting
g g Air Fan
Scanner Air Fan
Booster Air Fan
Burner Air Fan
Degasser Blower
Combustion Air Fan
Oil Vapour Exhaust
Fan
Purge Gas Blowers
Inline Fans
Supply Air Fan
Exhaust Air Fan
Ventilation Fan
Radial Blowers
Turbo Blowers
(Centrifugal)
FD Fan
ID Fan
In-series
In series Blowers
Igniter Air Fan
Seal Air Fan
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PEMP

Centrifugal Fans RMD 2501

T
Type Ch
Characteristics
t i ti T i l A li ti
TypicalApplications
High pressure, medium flow, Various industrial applications,
Radial efficiency
y close to tube axial fans, suitable for dust laden, moist
power increases continuously air/gases

Medium pressure, high flow, dip


Low p
pressure HVAC,, packaged
p g
F
Forward
d curved
d i pressure curve, efficiency
in ffi i
units, suitable for clean and
blades higher than radial fans, power rises
dust laden air/gases
continuously

High pressure, high flow, high


HVAC, vaious industrial
Backward efficiency, power reduces as flow
applications forced draft fans
curved blades increases beyond the point of
etc
highest efficiency
Same as backward curve type, Same as backward curved, but
Airfoil type
highest efficiency for clean air application

06a M.S. Ramaiah School of Advanced Studies 12


PEMP

Fan/Blower Blade Types RMD 2501

Impeller blades are manufactured either laminar (flat, constant


thickness) or aerofoil shape and generally hollow
Aerofoil blades have greater efficiencies (up to 90%) compared
to constant thickness blades,
blades with the advantages of efficiency
spread over the characteristic and lower noise generation
However with careful attention to design of blade curvature,
inlet eye detail and impeller shrouding, comparable efficiencies
can be achieved with constant thickness blades
Aerofoil blades are freelyy used pparticularlyy when blade stresses
are high and extra stiffening is required

constant thickness blades Aerofoil blades


06a M.S. Ramaiah School of Advanced Studies 13
PEMP

Axial Flow Fans RMD 2501

L efficient,
Less ffi i t large
l i fl
airflow
and low speeds

Vane axial fan


Tube axial fan

Propeller fan

Higher speeds than


propeller fans, high- Pressures upto 500
pressures 250 400 mm mmWC and are highly
WC and efficiency up to energy-efficient
65%.

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PEMP

Axial Flow Fans Applications RMD 2501

Ventilation Fan
Airscrew Fan
Wall mounted Supply
pp y Fan
Wall mounted Exhaust Fan
Bifurcated Fan
Roof Exhaust Fan
Inline Fan
Spark proof Fans
Inline Fans
Freshh Air
Ai Unit
i
Ventilation Unit
Air washer Unit
Smoke Exhaust Unit
Toilet Exhaust Fans
CPU Fans

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PEMP

Propeller Fan RMD 2501

Propeller fan also known as panel fan is commonly used to exhaust hot or
contaminated air or corrosive gases from factories, welding shops, foundries,
furnace rooms, laboratories, laundries, stores or residential attics or windows

24propeller fan with belt drive

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PEMP

Axial Fans RMD 2501

Type Characteristics Typical Applications


low pressure, high flow, low Air circulation,
efficiency peak efficiency
efficiency, ventilation
ventilation,
Propeller
close to point of free air exhaust
delivery (zero static pressure)
M di
Medium pressure, high
hi h flow,
fl
HVAC,
higher efficiency than
drying ovens,
Tube Axial ppropeller
p type,
yp dipp in pressure
p
exhaust systems
flow curve before peak
pressure point
Highh pressure, medium
Hi di flow,
fl
High pressure
dip in pressure-flow curve,
Vane Axial applications including
use of guide vanes improves
HVAC systems
efficiency exhausts
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PEMP

Mixed Flow Fan RMD 2501

Mixed flow fan with barrel shaped spun housing for small
diameters of inlet and outlet ducts. Direct drive, the fan wheel
has a conical back plate. Outlet guide vanes prevent excessive
p at the small outlet diameter.
air spin

06a M.S. Ramaiah School of Advanced Studies 18


PEMP

Axial-Centrifugal Fan Types RMD 2501

Single inlet single


width impeller

Double inlet
double width
impeller Single inlet single width
fan wheel with six radial
blades welded to a back
plate
l

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PEMP

Belt Drive versus Direct Drive RMD 2501

Belt drive Direct drive


Flexibility in operating Lower number of components
speeds resulting in lower costs
The air stream passing over Requires no regular checkups for
the motor cools it adjustment of belt
Large size fans can be Higher fan efficiency since no
operated at low speeds while slippage due to belt drive
motor is operated at higher Results
R l in i more flow
fl since
i motor
speeds resulting in does not obstruct flow
economical operation Performance flexibility of belt
drive can be obtained by adjustable
A 30 increase in blade angle will pitch blades and increasing number
result in 10-15% increase in fflow
of blades

06a M.S. Ramaiah School of Advanced Studies 20


PEMP

Blower Types RMD 2501

Centrifugal blowers typically operate against pressures of 0.35 to 0.70


kg/cm2, but can achieve much higher pressures
Also used to produce negative pressures for industrial vacuum systems
Major types are; centrifugal blower and positive-displacement blower
The impeller is typically gear-driven and rotates as fast as 15,000 rpm
Efficiency drops with multi
multi-staging
staging due to the path taken from stage to stage
One characteristic is that airflow tends to drop drastically as system pressure
increases
Positive displacement blowers have rotors,
Positive-displacement rotors which "trap"
trap air and push it
through housing.
Positive-displacement blowers provide a constant volume of air even if the
system pressure varies.
varies They are especially suitable for applications prone to
clogging,
They turn much slower than centrifugal blowers (e.g. 3,600 rpm), and are
often belt driven to facilitate speed changes.
changes

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PEMP

Fan Laws RMD 2501

Fan data for geometrically similar fans can be collapsed onto a


single curve using dimensionless numbers
Q = volumetric flow rate
D = ffan di
diameter
t
N = fan rotational speed
W = fan power
= fluid density
P = fanpressurerise

N 10% Q 10% or N 10% Ps 19% N 10% HP 27% or


N 10% Q 10% or N 10% Ps 21% N 10% HP 33%

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PEMP

Fan Laws RMD 2501

Law 1 relates to effect of changing size, speed, or


density on volume flow, pressure, and power level

Law 2 relates to effect of changing size, pressure,


or density on volume flow rate, speed, and power

Subscript 1 and 2 denotes the variable for the fan


under consideration and for the tested fan respectively

For all
F ll fan
f laws
l (
( t)1 = (
( t)2 and
d ((point
i t off rating)
ti )1 =
(point of rating)2

Law 3 shows effect of changing size, volume P equals


q either pt or ps
flow, or density on speed, pressure, and power

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PEMP

Fan Laws RMD 2501

O ti Point:
Operating P i t Fan
F curve andd system
t curve intersect
i t t

Move to flow Q2 by
closing damper
(increase system
resistance)

Flow Q1 at pressure
P1 and fan speed
N1

Move to flow Q2 by
reducing fan speed

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PEMP

Efficiency or BEP RMD 2501

Peak
Type of Fan Efficiency
Range
Centrifugal fans:
Airfoil, 79-83
Backward
curved/inclined
Modified radial 72-79
R di l
Radial 69 75
69-75
Pressure blower 58-68
Forward curved 60-65
Deviation from BEP results in inefficiency Axial fans:
and energy loss Vane axial 78-85
y
Increased system resistance reduces fan
efficiency T b axial
Tube i l 67 72
67-72
Propeller 45-50
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PEMP

Fan Efficiency Calculation RMD 2501

f
Before l l i ffan efficiency
calculating ffi i i parameters
measure operating
Air velocity, pressure head, air stream temp, electrical motor
input etc.,
input, etc
Ensure that Is efficiency
Fan is operating at rated speed the onlyy
Operations are at stable condition criteria for fan
Methodology selection?
1 Calculate air/gas density
1.
2. Measure air velocity and calculate average
3. Calculate the volumetric flow in the duct
4. Measure the power drive of the motor
5. Calculate fan efficiency (Mechanical and Static efficiency)

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PEMP

Performance Characteristics RMD 2501

The theoretical pressure-quantity curve of an ideal fan (no


g line between zero volume and zero p
losses) is a straight pressure

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PEMP

System Resistance RMD 2501

Configuration of ducts,
Sum of static pressure losses pickups, elbows
in system
Pressure drop across
equipment

Increases with
square of air volume
Long narrow ducts,
many bends: more
resistance
Large ducts, few bends:
less resistance

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PEMP

System Resistance Curve RMD 2501

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PEMP

Fan Characteristic Curve RMD 2501

The fan curve is a graphical representation of a number of inter-related


parameters under a specific set of conditions

Typically a curve
will be developed
for a given set of
conditions
di i usually
ll
including: fan
volume, system
static pressure,
pressure fan
speed, efficiency
and BHP required
to drive the fan
under the stated
conditions

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PEMP

Impeller Types and Performance RMD 2501

Non
overloading
Efficiency power
limited to 60% characteristic.
to 70% at most. (i.e. power
Steeply rising input does not
power peak at either
characteristic free flow or
no flow)

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PEMP

Centrifugal Fans RMD 2501

Schematic sketch of a typical centrifugal fan wheel with ten backward-curved airfoil blades

d1 = blade inner diameter = blade angle


d2 = blade outer diameter U = blade velocity
b = blade width
i W = relative air velocity
l = blade length V = Absolute air velocity

1 is usually
10o to 30o

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PEMP

Scroll Casing RMD 2501

Schematic
S h i sketch
k h off typical
i l scroll
ll housing
h i assembly bl for
f
a 36.5 inch centrifugal fan with airfoil, backward curved
blades for general ventilation

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PEMP

Airflow versus Blade Width RMD 2501

Airflow versus blade width for a centrifugal fan with airfoil blades

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PEMP

Blade Angles and Diameter Ratios RMD 2501

g 2, as a function of the inlet blade angle


Tipp angles g 1 and of the
diameter ratio d1/d2 for straight blades
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PEMP

Control of Fan/Blower Airflow RMD 2501

Speed change by pulley change


Dampers
Inlet guide vanes
V i bl pitch
Variable it h fans
f Flow control Pulley Driven
dampers
Variable speed drives (VSD)
Multiple speed drive
Disc throttle
Operating
p g fans in pparallel
Operating fans in series

I l t vane dampers
Inlet d I l t guide
Inlet id vanes

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PEMP

Control of Fan/Blower Airflow RMD 2501

Pulley change: reduce motor/drive pulley


size Speed Change
Permanent speed
p decrease
Real energy reduction
Fan must handle capacity change
Only applicable if V-belt system or motor
Dampers: reduce flow and increase
upstream pressure
Inexpensive
E
Easy to install
i ll
Limited adjustment
Reduce flow but not energy consumption
Higher operating and maintenance costs Dampers
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PEMP

Control of Fan/Blower Airflow RMD 2501

I l t guide
Inlet id vanes
Create swirls in fan direction
Reduce angle air and fan blades
Lowering fan load, pressure, air flow
Improve efficiency: reduced load and airflow
Cost effective at 80-100% of full air flow
Less efficient at <80% of full air flow
Variable pitch fans: changes angle incoming
airflow and blades Axial fan only Lets look at this
High efficiency at range of operating conditions in detail in
No resonance p problems subsequent
slides
No stall problems at different flows
Applicable to axial fans only
Risk of fouling
fo ling problems
Reduced efficiency at low loads
06a M.S. Ramaiah School of Advanced Studies 38
PEMP

Control of Fan/Blower Airflow RMD 2501

Variable speed drives (VSDs): reduce fan speed and air flow
Two types; Mechanical VSDs and Electrical VSDs
((includingg VFDs))
Most improved and efficient speed control
Speed adjustments over continuous range
high costs
Variable frequency drives (Change motors rotational speed
by adjusting electrical frequency of power)
Effective and easy flow control
Improved efficiency over wide operating range
Can be retrofitted to existing motors
Compactness
No foulingg pproblems
Reduced energy losses and costs
06a
M.M.S.
S. Ramaiah School
Ramaiah of Advanced
School Studies, Studies
of Advanced Bangalore 39
39
PEMP

Control of Fan/Blower Airflow RMD 2501

Multiple speed drive (Changes fan speed from one to other)


Efficient control of flow
Suitable if onlyy 2 speeds
p required
q
Need to jump from speed to speed
High investment costs
Disc throttle (Sliding throttle that changes width of impeller
exposed to air stream)
Simple design
Feasible in some applications only
Operate fans in series
Lower average duct pressure
Less noise
Lower structural / electrical support required
Not suited for low resistance systems Fans in series
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PEMP

Control of Fan/Blower Airflow RMD 2501

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


High efficiencies at varying demand
Less expensive
p and better performance
p than one large
g fan
Risk of downtime avoided
Can be equipped with other flow controls
O l suited
Only i d for
f low
l resistance
i system
Comparing Fans in
Parallel and Series

Comparing the
impact of
different types
of flow control
on power use

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PEMP

Solidity Axial Flow Fans RMD 2501

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PEMP

Blade Pitch (angle) Setting RMD 2501

Adjustment using pitch plates Adjustment using pitch markings

Performance control is achieved by altering speed, adjusting


impeller blade pitch angle or adjusting variable inlet guide vanes
Performance is enhanced by installation of inlet cone, inlet or outlet
guide vanes, tail fairings, and diffusers
On-load or off load blade pitch adjustment is possible

06a M.S. Ramaiah School of Advanced Studies 43


PEMP

Blade Pitch (angle) Setting RMD 2501

Adjustment
j usingg a protractor
p Variable pitch blades

Impellers without markings require the use Each setting has a different performance
of a protractor to set the appropriate angle characteristic

Some manufacturers specify the blade pitch angle in terms of the tip chord. Those
who refurbish fans often incorrectly set these angles as the at the blade root rather
than the tip of the blade.
blade Depending upon the twist of the blade this could be as
much as 30 resulting with the fan performance less than expectations

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PEMP

Start Up Single Fan Variable Speed RMD 2501

On start up the fan goes


from standstill to full speed
Will follow path 1,2,3,4 if
equilibrium is reached
instantaneously
Will follow path 11, 2
2, 2
2,
4 if equilibrium is not
established instantaneously
In any case all points are
on the negative part of the
curve and therefore stable

Single fan - variable speed

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Start Up Single Fan Damper Control
PEMP
RMD 2501

Dampers set to open when a


predetermined pressure is
reached (i.e no flow until
operating pressure is reached)
Fan must follow the parabola
over the hump and the fan may
become unstable during this
stage
It is
i found
f d by
b experience
i that
th t
fans with long lengths of lay-flat
duct reduces excessive power
d
draw andd prevents the
h fan
f from
f
shaking violently
Single fan Damper Control

06a M.S. Ramaiah School of Advanced Studies 46


Start Up Two Fan in Series
PEMP
RMD 2501

If started simultaneously they will


act in the same manner as a single
fan
If one fan is started the operating
fan sees a higher resistance
caused by the non
non-operating
operating fan
At the start-up of the second fan
the system resistance is lowered
andd th
the first
fi t fan
f comes down
d the
th
curve whilst the second fan
moves from a free flow (air from
the
h first
fi fan)
f ) situation
i i untilil both
b h
fans are at the same speed and
contributing to the combined fan
Two fans in series
curve

06a M.S. Ramaiah School of Advanced Studies 47


Start Up Two Fan in Parallel
PEMP
RMD 2501

If started simultaneously they will act


in the same manner as a single fan
When one fan is started it will run up
and settle on the system
The second fan (no flow) will start
and when acceleration is sufficient it
will move to the right at the same
time that the first fan is moves up its
curve until
til both
b th fans
f are att the
th same
speed and contributing to the
combined fan curve
Note that the second fan must move
over the hump and could cause
serious instability if the curve has a Two fans in parallel
dip as well as a hump

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PEMP

Merits of Axial and Centrifugal Fans RMD 2501

Axial fans offer better efficiency over a wider range of duties whereas
the centrifugal fans can have a higher efficiency, albeit over a smaller
range, on a single performance curve.
The performance of a single speed axial fan can be altered simply by
adjustment to the impeller blade pitch angle.
The
Th performance
f off a single
i l speedd centrifugal
t if l fan
f requires
i theth
installation of variable inlet vanes.
Axial fans are ggenerallyy considered to be more easilyy accessible for
maintenance.
Axial fans generally run faster than centrifugal as a consequence are
much
h noisier.
ii
Axial fan impellers are generally manufactured from aluminum in an
effort to keep weight to a minimum. As a consequence the potential for
erosion is greater, particularly if there is water in the shaft.
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PEMP

Merits of Axial and Centrifugal Fans RMD 2501

The light material used in the blades along with the high rotational speed
of axial fans make them prone to erosion, and even in good (dry)
conditions it is reasonably expected that this erosion will have
significantly reduced the fan performance within five years.
Centrifugal fan impellers are fabricated from plate and are generally
hollow. As a consequence when there is water in the shaft the nose of
the blade is prone to pitting allowing water to enter the hollow section.
Sufficient water in this section will cause the impeller
p to become
unbalanced, and if allowed to continue it will result in high vibration and
eventual failure of the impeller shaft.
Centrifugal
C if l fans
f traditionally
di i ll require
i the
h construction
i off large
l concrete
foundations for the motor and ductwork. The cost of these foundations
significantly increases the capital cost of the fan.

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PEMP

Merits of Single and Multiple Fans RMD 2501

Single fan installations are generally less expensive than multiple fan
installations.
installations
Multiple fan installations have the advantage of airflow redundancy,
i.e. a percentage of airflow will always be available whilst a fan is off
line for maintenance or component change out.
Single fan options do not provide any capacity for redundancy
airflow. The purchase of spares (motor,
airflow (motor impeller
impeller, shafts
shafts, bearings
bearings,
blades etc) is good management and should be included as upfront
capital expenditure.

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PEMP

Session Summary RMD 2501

Various types of axial and centrifugal fans and blowers have


been described
described.
Fans and blowers are low speed machines with low pressure
rise, and the flow through them is treated as incompressible.
Fan / blower characteristics have been discussed.
Fan starting characteristics have been explained.
explained
Fans and blowers follow affinity laws which help in scaling of
the machines.

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PEMP
RMD 2501

Thank you

06a M.S. Ramaiah School of Advanced Studies 53

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