LECTURE 10.09.

2014

By
P. Kanthasamy
Principal Technical Officer
Environmental Technology Division
CSIR- Central Leather Research Institute
Adyar, Chennai- 600 020
Email:samyji@gmail.com

Mobile:9445587722

ENERGY AUDIT OF FANS

TERMS USED IN FAN

TERMS
Cfm-Cubic Feet Per Minute. A measure of airflow.

c
f
m

P
sPs-

s
o
n
e

Static Pressure. Resistance to airflow measured in inches of water gauge.

Sone-A measure of loudness. One sone can be approximated as the loudness of a quiet
refrigerator at a distance of 5 feet. Sones follow a linear scale, that is, 10 sones are twice as
loud as 5 sones.
BHP-Brake Horsepower. A measure of power consumption. Used to determine the proper
motor horsepower and wiring.

B
h
p

Horsepower. Used to indicate a fans motor size.

h
p

RPM- Revolutions Per Minute. Measure of fan speed.

r
p
m
T
S

TS- Tip Speed. The speed of the tip of a fan wheel or prop measured in feet per minute.
AMCA- Air Movement & Control Association. A nationally recognized association which
establishes standards for fan testing and performance ratings. AMCA also license air volume
and sound certified ratings.

A
M
C
A

BACKGROUND
Thermal power plant has several fans such as Induced draft
(ID) fans, Forced draft (FD) Fans, Primary air fans (PA
fans). These fans contribute to significant auxiliary power
consumption. ID fans alone contribute to about 12% of total
auxiliary power consumption
Steps Involved
Data collection
Observations and
Analysis
Exploration for energy
conservation measures
Report preparation
ID Fan System

DATA COLLECTION
Collect detailed design specification & operating parameters
Fans Parameters ( FD, ID and PA Fan )

DATA COLLECTION
Collect detailed design specification & operating parameters
Fans Parameters ( FD, ID and PA Fan )- contd

DATA COLLECTION
Details of the fans and ducting system:
Collect the schematic diagram / network of the

ducting system
Collect Performance characteristics of all fans
Compile design, Performance Guarantee Test,
previous best and last energy audit values with
respect to fans and draft system which include
excess air
If the fans are operated in parallel then it is
advised to collect the performance curve for the
parallel operation
Air quality and pressure equipments at the users
as per the design requirements

INSTRUMENTS REQUIRED
Power Analyzer: Used for measuring electrical parameters such as
kW, kVA, pf, V, A and Hz
Temperature Indicator & Probe
Stroboscope: To measure the speed of the driven equipment and
motor
Sling hygrometer or digital hygrometer
Anemometer
On line instruments (calibrated)
Digital Manometer of suitable range and appropriate probes for
measurement of pressure head and velocity head.
Pitot tubes
Additional pressure gauges with appropriate range of
measurement and calibrated before audit.

MEASUREMENTS & OBSERVATIONS TO BE MADE

Energy consumption pattern of fans
Motor electrical parameters (kW, kVA, Pf, A, V, Hz, Total
Harmonic Distortion(THD) of fans
Fan operating parameters to be measured/monitored for
each Fans are:
1. Discharge / flow rates
2. Pressure (suction & discharge)
-Static pressure
-Dynamic pressure
-Total pressure

MEASUREMENTS & OBSERVATIONS TO BE MADE

3. Damper position / guide vane position/ VSD Setting

4. Temperature of fluid handled
5. Load variation
6. Power parameters of fans
7. Fan operating hours and operating schedule
8. Pressure drop in the system (between discharge
and user point)
9. Pressure drop and temperatures drop across the
equipment
10. Fan /Motor speed

MEASUREMENTS & OBSERVATIONS TO BE MADE

Oxygen content, flow, temperature and pressure

measurement across in exhaust gas path
- Before and after air pre heater
- Before and after economizer
-Before and after ID fan
- Before and after ESP
- In case where flow measurement (for air pre heater
and ESP) is not possible, it can be estimated based on mass
balance principles, stoichiometric analysis,

ENERGY CONSUMPTION PATTERN

If the plant is monitoring the energy consumption, it is suggested
to record the data and monitor the daily and monthly consumption
pattern. (Collect data for 12 months)
Work out the total consumption of fans to arrive at percentage to
the total consumption of the auxiliary consumption
If the energy meters are not installed to fans, instantaneous
measurements can be carried out, based on the loading pattern the
daily consumption can be worked out as per following tableEnergy consumption pattern

FAN OPERATING EFFICIENCY

EVALUATION
The parameters to be studied in detailed are:
Air /gas rates of fans / main ducts
Static pressure and dynamic pressure and total
pressure
Power consumption of fan (for estimating the
operating efficiency of the fans)
Monitor present flow control system and
frequency of control valve operation if any (for
application of variable speed drives)
Fill up the following data sheet for every fan

FAN OPERATING EFFICIENCY EVALUATION

Performance parameters for fans

FAN OPERATING EFFICIENCY

EVALUATION

FAN LAWS
Flow ?x Speed

Q1 N 1

Q2 N 2
Varying the RPM by 10%
decreases or increases air
delivery by 10%.

Pressure ?x (Speed)2

SP1 N 1

SP 2 N 2

Varying the RPM by 10%

decreases or increases the
static pressure by 19%.

Power ?x (Speed)3

kW 1 N 1

kW 2 N 2

Varying the RPM by 10%

decreases or increases the
power requirement by
27%.

Where Q flow, SP Static Pressure, kW Power and N speed (RPM)

FANS PERFORMANCE ASSESSMENT

Static pressure
Potential energy put into the system by the fan

Velocity pressure
Pressure arising from air flowing through the duct. This is
used to calculate velocity

Total pressure
Static pressure + velocity pressure
Total pressure remains constant unlike static and velocity
pressure

TRAVERSE POINTS FOR VELOCITY

MEASUREMENT

FAN OPERATING EFFICIENCY

EVALUATION
3

Fan static kW = Q in m / s x static pr. developed by fan in mmwc

102
Fan static efficiency % = Fan static kW x 100
Input
kW
to motor x by
m fan in mmwc
3
Q
in
m
/
s
x
total
pr.
developed
Fan total kW =
102
Fan mechanical Efficiency = Fan total kW x 100
Input kW to motor x m
Parameter

Details

Unit

Air flow rate

m 3/ s

Static pressure

Difference between discharge & suction pressure

mmwc

Fan static/ total kW

Static / total power consumption of the fan

kW

Input kW to motor

Measured power consumption of the motor

kW

Efficiency of the motor at operating load

Total pressure

Difference between discharge & suction pressure

mmwc

FAN OPERATING EFFICIENCY EVALUATION

Corrected air density, =

Velocity in m / s =

273 X 1.293
273 + Air temperature in 0 C

Cp x 2 x 9.81 x Diff. velocity pr. in mmwc x

Parameter Details

Unit

Cp

Pitot tube constant

0.85 or as given
by manufacturer

Density of air or gas at test condition

Kg / m3

Volumetric flow (Q), m3/s = Velocity, m/s x Area, m2

FAN OPERATING EFFICIENCY

EVALUATION

In case of gas flow measurement of ID fans, where it is not

possible to measure the gas flow, then the mass flow method
can be adopted, provided the oxygen content and actual coal
flow measurements are available. For flow estimation through
this method, the following are required:
Stoichiometric air requirement (work out based on the coal
composition)
Oxygen content at ID fan inlet (measured)
Excess air (estimate)
% Excess air = (%O2 in flue gas x 100) / (21 O2 in flue gas)

Coal flow (based on actual measurement or on average

basis)
Fly ash content (assumed based on past data)

FAN PERFORMANCE ANALYSIS

While in case air flow measurement for FD and PA fans the
following instruments (which ever are suitable) can be used
Thermal anemometer
Vane type anemometer
Pitot tube along with micro manometer can be used
Online measuring instrument
If the fans are operating in parallel, it is advised to measure
all above parameter for every fan separately to evaluate the
individual performance. However combined parameters of
flow and head need to be verified with Performance curve for
parallel operation

FAN PERFORMANCE ANALYSIS

Compare the actual values with the design / performance test
values if any deviation is found, list the factors with the details
and suggestions to over come.
The investigations for abnormality are to be carried out for
problems.
Enlist scope of improvement with extensive physical checks /
observations.
Based on the actual operating parameters, enlist
recommendations for action to be taken for improvement, if
applicable such as- Replacement of fans, Impeller replacement,
VFD application.
Cost analysis with savings potential for taking improvement
measures.

FAN PERFORMANCE ANALYSIS

Flow control
Recirculation
Damper

100

P
o
w
e
r

IGV

75
50

VFD

25

Ideal

25

50

75

Flow

100

FAN PERFORMANCE ANALYSIS

Impact of speed reduction

System characteristics and Fan curves

FAN PERFORMANCE ANALYSIS

Visual survey of insulation & the ducting system:
Insulation status (measure the surface temperature with the
aid of surface thermocouple / infrared pyrometer or by using
thermal imaging cameras)
Bends and ducting status
Physical condition of insulation
Identification of locations where action is required to improve
the insulation (provide with detailed techno-economics)
Improvement options for ducting systems if any
Sources of air ingress

FAN PERFORMANCE ANALYSIS

Study of air ingress in to the system:
Before and after air preheater
Before and after ESP
Before and after ID fan
The difference in the oxygen gives the extent of air ingress in to the
system. Measurements of oxygen content across all units in flue gas
path, indicates the locations where ingress is occurring

EXPLORATION OF ENERGY
CONSERVATION POSSIBILITIES
Improvement of systems and drives:
Use of energy efficient fans
Change of impeller with energy efficient impeller
Correcting inaccuracies of the fan sizing
Use of high efficiency motors
Fan speed reduction by pulley diameter modifications for optimisation
Option of two speed motors or variable speed drives for variable duty
conditions
High Performance Lubricants: The low temperature fluidity and high
temperature stability of high performance lubricants can increase energy
efficiency by reducing frictional losses
Use of energy efficient transmission systems (Use of latest energy
efficient transmission belts)

EXPLORATION OF ENERGY
CONSERVATION POSSIBILITIES
Improvement in operations:
Minimising excess air level in combustion systems to reduce FD fan
and ID fan load.
Minimising air in-leaks in hot flue gas path to reduce ID fan load and
cold air in-leaks
Minimising system resistance and pressure drops by
improvements in duct system / Insulation aspects

Deviations in air flow rates

Measures to up keep the performance
After the identification of energy conservation measures,
detailed techno-economic evaluation has to be carried out

PROBLEM

A particular coal has the following ultimate analysis on a dry

basis percent by mass:

Component

Percent by Mass

Sulfur

0.6

Hydrogen

5.7

Carbon

79.2

Oxygen

10.0

Nitrogen

1.5

Ash

3.0

This coal is to be burned with 30% Excess Air. Calculate the Airfuel ratio on a mass basis.

SOLUTION

One approach to this problem is to write the combustion equations for

each of the combustible elements per 100 kg of fuel. The molar
compostion per 100 kg of fuel is found first

Kmol S/ 100kg fuel

= 0.6/32
= 0.02
Kmol H2/ 100kg fuel
= 5.7/2 = 2.85
Kmol C/ 100kg fuel = 79.2/12
= 6.60
Kmol O2/ 100kg fuel
= 10.0/32
= 0.3
Kmol N2/ 100kg fuel
= 1.5/28
= 0.05

The combustion equations for the combustible elements are now written
which enables us to find the theoretical oxygen required.
S+ O2
SO2
0.02S + 0.02 O2
0.02 SO2
H2 + 1/2O2
H2O
2.85H+2.85/2 O2
2.85 H2O
C+O2
CO2
Total Oxygen Required
6.60C+ 6.60O2
6.60CO2
=0.02+1.42+6.60=8.04
8.04 kmol O required /100kg of fuel
For S = 0.02
Total Oxygen required
0.31 kmol O is available in fuel /100
H2 = 1.42
kg
8.04-.31= 7.73 kmol
C = 6.60
2
2

SOLUTION

Air-Fuel Theo = [7.73 +7.73 (3.76)] x 28.97/100

= [36.7948x 28.97]/ 100
= 10.659 kg air/kg fuel
For 30% excess air the air fuel ratio is
AF = 1.3 x 10.659= 13.856 kg air/kg of fuel