B1. Fan Laws and Fan Control - Robinson

Robinson Industries Fans
for You

The Beginning - 1892

Robinson Industries
Today
Heavy Duty Fan Manufacturer
4Global Support Capability w/ Intl. Representation

113 Years in Fan Industry (1892 - Present)
Four Locations:
4 4 Fabrication Facilities
4 1 Service Center
4 Corporate HQ
Zelienople, PA, USA

Abilene, TX
Robinson Product
Range
+Custom Built Special Purpose Centrifugal Fans
+Industries Served: Power, Cement, Paper, Chemical,
Ceramic, Steel, Aluminum, Mining, Fertilizer
+Combustion Air Blowers
+Baghouse I.D. Fans
+Material Handling Exhausters
+Repair/Rebuild/Retrofit

Gas Density Calculation
Density = f (Temperature, Pressure, Molecular
Weight)

One Calculation Method Is:
D = 0.075 x (460+70)/(460+T) x {(407-k*FASL+P
I
) / 407} x
MW/28.96

D = Density, lb./cu.ft. (note: standard air = .075 lbs/ft
3
)
T = Temp at fan inlet, F (note: standard temp = 70 F)
MW = Molecular Weight (note: dry air = 28.96)
k = Altitude correction (note: =.013)
P
I
= Fan inlet pressure, in-H
2
O gage ( could be + or -)

(Ref. Page 1 of Robinsons Fan Performance and Design Manual)
43
o
F wb
2
60
o
F db
0.002 lb H
2
O/lb da
3
1
Example: Tdry = 60 degF; Twet= 43 deg F; what is the
absolute humidity ratio? What is the density?
1. Enter the chart at the bottom at 60
o
F dry bulb.
2. Find 43
o
F wet bulb along the saturation line and read down
and to the right along 43
o
F until it intersects 60
o
F db.
3. Plot this point, then read horizontally to the right to the
read absolute humidity ratio W which is in pounds of
water per pound of dry air (= .002 lb H2O /lb dry air)
4. Read specific volume = 13.14 ft
3
per lb of dry gas
5. Determine density = (1 + .002)/(13.14) = .076 lbs/ft
3
Fan System Assessment Tool
(FSAT)
This tool developed by the US
Department of Defense and the Air Moving
and Control Association, International
helps evaluate fan and system efficiency.

It also includes a segment that is helpful in
determining gas density.
System Resistance
Volume (CFM x 1000)
500 450 400 350 300 250 200 150 100 50 0

S
t
a
t
i
c

P
r
e
s
s
u
r
e

(
I
n

H
2
0
)
60
50
40
30
20
10
0
40
0 BHP
ROBINSON INDUSTRIES
FAN : 83" x 14.38" FRD
FOR : Basic Fan Laws I
FAN SPEED : 1180
TEMP. : 70
DENSITY : 0.075
SYSTEM RESISTANCE
150,000 CFM
40 SP
Every system has
resistance to flow.
Most gas systems
can be approximated
by an equivalent
orifice. The flow is
turbulent and the
pressure (P) required
varies as a function
of the square of the
volume flow-rate (Q).
P = kQ
2
(k is a
system resistance
constant.)
(Ref. Page 16)
Fan and System Curves
Volume (CFM) x 1000
300 250 200 150 100 50 0

P
r
e
s
s
u
r
e

(
I
n

H
2
0
)
50
40
30
20
10
0
ROBINSON INDUSTRIES, INC.
FAN : 83" x 14.38" FRD
FAN SPEED : 1180
TEMP. : 70
DENSITY : 0.075
SP
SYSTEM RESISTANCE
150,000 CFM
40 SP
4 The actual
operating
point will
be the
intersection
of the
system
resistance
curve and
the fan
curve.

(Ref. page 17)
Fan BHP Curve
Volume (CFM) x 1000
300 250 200 150 100
50
0
B
H
P
2000
1600
1200
800
400
0
1,257 BHP
150000 CFM
FAN : 83" x 14.38" FRD
FAN SPEED : 1180
TEMP. : 70
DENSITY : 0.075
BHP
This shows the
power required
to drive the fan.
For most
centrifugal fans
the BHP
increases as
CFM increases.
A Non-
overloading fan
has a BHP curve
that peaks and
then drops off at
higher flow.
(Ref. page 17)
Fan Curves
Considerations for a Good Operating Point
Volume (CFM) x 1000
300 250 200 150 100 500
00

P
r
e
s
s
u
r
e

(
I
n

H
2
0
)
50
40
30
20
10

B
H
P
2000
1600
1200
800
400
40 SP
1257 BHP
150000 CFM
FAN : 83" x 14.38" FRD
FAN SPEED : 1180
TEMP. : 70
DENSITY : 0.075
E
f
f
i
c
i
e
n
c
y

%
100
80
40
20
0
SP
BHP
Eff.
Efficiency
Stability
Sound
Size
Lab Test Arrangement
Laboratory Air
Performance Test
Test Fan
Laboratory Air
Performance Test
Test Fan
Orifice Plate (Throttling Device)
Pitot Traverse in Outlet Duct
Fan Laws
Static Pressure, Velocity Pressure
(Dynamic Pressure), Total Pressure
Density Change
Speed Change
Size Change

Static, Velocity, and Total
Pressure
Pt = Ps + Pv
Consider two planes
1. fan inlet
2. fan discharge (after evase)
Fan Total Pressure: Pt
discharge
- Pt
inlet
Fan Static Pressure:
Ps
fan
= Ps
discharge

- Pt
inlet
or,

Ps
fan
= Ps
discharge

- (Ps
inlet
+ Pv
inlet
)
Fan Static Pressure Rise (or, Differential Static
Pressure):
P
Static Rise
= Ps
discharge
Ps
inlet
Density Change
Volume
CFM
2
= CFM
1
Static Pressure
SP
2
= SP
1
x (Density
2
/Density
1
)
Horsepower
HP
2
= HP
1
x (Density
2
/Density
1
)
Sound Power
L
w2
= L
w1
+ 20 log x (Density
2
/Density
1
)

(Ref. Page 25)
Density Change Example
Problem: Find the new performance at 600F and
0.0375 lbs/ft3 given the performance at
70F and 0.075 lbs/ft3:

Given: 880 RPM
Flow = 125,000 cfm
Density = 0.075 lbs/ft3 @ 70F
SP = 20 in-H2O
BHP = 525 hp

Solution
CFM2=CFM1=125,000 cfm; (Constant Volume Machine)
SP2 = (20 in-H2O) x (0.0375/0.075) = 10 in-H2O
HP2 = (525 hp) x (0.0375/0.075) = 262 hp
(Ref. Page 25)

Density Change Example Curve
Volume (CFM) x 1000
250 200 150 100 50

P
r
e
s
s
u
r
e

(
I
n

H
2
0
)
25
20
15
10
5
0
B
H
P
1000
800
600
400
200
10
20
262 BHP
525 BHP
125000 CFM
FAN : 83" x 14.38" FRD
FAN SPEED : 880
TEMP. : See Below
SP
BHP
T1 = 70 F
D1 = 0.075
T2 = 600 F
D2 = 0.0375
Speed Change
(incompressible flow)
Volume
CFM
2
= (RPM
2
/ RPM
1
) x (CFM
1
)
Static Pressure
SP
2
= (RPM
2
/ RPM
1
)
2
x (SP
1
)
Horsepower
BHP
2

= (RPM
2
/ RPM
1
)
3
x (BHP
1
)
Sound Power
L
w2
= L
w1
+ 50 log (RPM
2
/ RPM
1
)
(Ref. Page 23)
Speed Change Example
Question: Customer will change speed from 1180 rpm to 880
rpm. What will be the new performance?
Given: The existing fan has the following performance.
1180 rpm
100,000 acfm
20 in-H
2
O Static Pressure @ 70 degF
432 bhp
Solution:
acfm
2
= (100,000) x (880/1180)
1
= 74,576 acfm
Ps
2
= (20.0) x (880/1180)
2
= 11.1 in-H2O
bhp
2
= (432) x (880/1180)
3
= 179 bhp

Note: The new performance is still on the original system resistance curve.
The original efficiency is maintained.

(Ref. Page 23 of Robinson Fan Performance and Design Manual)

Speed Change Example Curve
Volume (CFM)
160 120 80 40

P
r
e
s
s
u
r
e

(
I
n

H
2
0
)
30
25
20
15
10
5
0

B
H
P
1200
1000
800
600
400
200
11.1 SP
20 SP
179 BHP
432 BHP
74576 CFM 100000 CFM
FAN : 64" x 12.94" FRD
FAN SPEED : 1180 & 880
TEMP. : 70
DENSITY : 0.075
SP
BHP
SYSTEM RESISTANCE
Size Change Fan Law
4Volume
CFM
2
= (Size
2
/ Size
1
)
3
x (CFM
1
)
4Static Pressure
SP
2
= (Size
2
/ Size
1
)
2
x (SP
1
)
4Horsepower
BHP
2
= (Size
2
/ Size
1
)
5
x (BHP
1
)
4Sound Power
L
w2
= L
w1
+ 70 log (Size
2
/ Size
1
)
Note: All fan dimensions change in proportion to the wheel
diameter. Used to size fans from lab prototype tests.
(Ref. Page 24)
Size Change Example
Fans with Geometric Similarity
What is the performance of a 90 inch dia radial
bladed fan, based on a 40 inch dia geometrically
similar test fan (at the same speed and density)?
Given: 40 inch diameter radial bladed fan
9,000 cfm
20 SP @ 70F, 0.075 lb/ft3
39 BHP
Solution: for 90 inch diameter geometrically similar
fan
CFM2 = (90/40)
3
x (9,000) = 102,516 CFM
SP2 = (90/40)
2
x (20) = 101.3 H2O
BHP2 = (90/40)
5
x (39) = 2249 HP
(Ref. Page 24)

Repairs and tip-outs
A worn out wheel can be not only be refurbished, but also tipped-
out to achieve a slightly higher volume and pressure capability.
Size Change: Tip-Out or De-Tip
Volume
CFM
Mod
= (Dia
mod
/ Dia
orig
)
2
x (CFM
orig
)
Static Pressure
SP
Mod
= (Dia
mod
/ Dia
orig
)
2
x (SP
orig
)
Horsepower
BHP
Mod
= (Dia
mod
/ Dia
orig
)
4
x (BHP
orig
)
Sound Power
L
wmod
> L
w
+ 70 log (Dia
mod
/Dia
orig
)

Tipped-out RB Wheel
Tipped-out RT Wheel
Tip-out and De-Tip Notes
Only the wheel diameter
changes.
Normal Tip-Out or De-Tip
is up to 5%
Maximum is around 10%
for some fan types
Increased Noise
Cannot De-Tip an Airfoil
Wheel

(Ref. Page 24)
Tip-Out Example
Problem: Customer ABC has a 100 diameter wheel and they would
like to tip it out by 5%, (new wheel diameter is 105). What would be
the new performance?
Given: 100 inch diameter wheel
100,000 CFM
20 H2O @ 70F
393 BHP
Solution:
CFM
mod
= (105/100)
2
x (100,000) = 110,250 cfm
SP
mod
= (105/100)
2
x (20) = 22.05 in. H2O
BHP
mod
= (105/100)
4
x (393) = 478 bhp


Fan Laws Summary
Q
2
= (Q
1
)(D
2
/D
1
)
3
(N
2
/N
1
)
1
(1)(Kp
2
/Kp
1
)
-1

P
2
= (P
1
)(D
2
/D
1
)
2
(N
2
/N
1
)
2
(
2
/
1
)
1
(Kp
2
/Kp
1
)
-1

HP
2
= (HP
1
)(D
2
/D
1
)
5
(N
2
/N
1
)
3
(
2
/
1
)
1
(Kp
2
/Kp
1
)
-1

Lw
2
= (Lw
1
)+70log(D
2
/D
1
)+50log(N
2
/N
1
)+20log(
2
/
1
)

Fan Curves
See reference document titled:

Modified Fan Performance Curve Calculator
Fan Control
Outlet Damper
Inlet Damper (various types)
Speed Adjustment
Considerations
Initial Cost
Energy Cost
Mechanical & Electrical Maintenance &
Reliability
Outlet Damper Control

Volume (CFM) x 1000
300 275000 250
225000
200
175000
150
125000
100
75000
50
25000
0

P
r
e
s
s
u
r
e

(
I
n

H
2
0
)

50
45
40
35
30
25
20
15
10
5
0
B
H
P

2000
1800
1600
1400
1200
1000
800
600
400
200
0
42.5 SP
1000 BHP
105000 CFM
FAN : 83" x 14.38" FRD
FAN SPEED : 1180
TEMP. : 70
DENSITY : 0.075
EF :1.03000000000065
SE :1.04000000000087
TF :1
SP
BHP
Turndown can
be achieved by
partially closing
a fan outlet
damper. In this
example, the
pressure drop
across the outlet
damper is 22.5
in-H
2
O (= 42.5-
20). The
system
performance is
20 in-H2O at
105,000 CFM.
(Ref. page 19)
Rated at
150,000 acfm
and 40 in-H2O
Pressure loss
= 22.5 in-H
2
O
Inlet Louvered Damper Control
1 The same
operating
point can
be
achieved
by
throttling
an inlet
louvered
damper to
20 degrees
open. The
BHP is
reduced to
880 due to
pre-spin.
1 (Ref. pages
20-21)
Volume (CFM x 1000)
300 275 250 225 200 175 150 125 100 75 50 25 0
P
r
e
s
s
u
r
e

(
i
n
.

H
2
0
)
50
45
40
35
30
25
20
15
10
5
0
B
H
P
4000
3600
3200
2800
2400
2000
1600
1200
800
400
0
20
Robinson Industries, Inc.
Fan : 83" x 14.38" FRD SWSI
For : Basic Fan Laws I
Fan Speed : 1180 RPM
Temperature : 70F
Density : 0.075 LB/FT
Date : 02/02/1999
Quote Number : 123456
RII FO # : 123456
EF :1
SE :1
TF :1
Note: Louvered dampered
curves are approximate
SP
20
40
60
BHP
20
40
60
Note: Inlet
P(s) Ratio = 0
880 BHP
105000 CFM
20 in. H20
Louvered Damper
15% leakage (typical).
Parallel blade operation.
Lower efficiency when dampered.
Good for dirty airstream.
Synchronized operation for
DWDI.
(Ref: Page 68)
Louvered Inlet Damper
Radial Inlet Damper Control
The same
operating
point can be
achieved by
throttling a
radial inlet
damper to
25 degrees
open. The
BHP is
reduced
further to
700 due to
the more
effective
pre-spin
than the
louvered
inlet damper
(Ref. pages
20-21)
Volume (CFM x 1000)
300 275 250 225 200 175 150 125 100 75 50 25 0
P
r
e
s
s
u
r
e

(
i
n
.

H
2
0
)
50
45
40
35
30
25
20
15
10
5
0
B
H
P
4000
3600
3200
2800
2400
2000
1600
1200
800
400
0
20
Robinson Industries, Inc.
Fan : 83" x 14.38" FRD SWSI
For : Basic Fan Laws I
Fan Speed : 1180 RPM
Temperature : 70F
Density : 0.075 LB/FT
Date : 02/03/1999
Quote Number : 123456
RII FO # : 123456
EF :1
SE :1
TF :1
Note: Radial dampered
curves are approximate
SP
20
30
45
BHP
20
30
45
Note: Inlet
P(s) Ratio = 0
700 BHP
105000 CFM
20 in. H20
Radial Inlet Damper
Radial Inlet Damper
10-15% leakage (typical).
Good dampered efficiency
Center-support or cantilever
design.
Good for open inlet SWSI.
Operating linkage outside
airstream.
(Ref: Page 68)
Vortex Damper
High efficiency in dampered
conditions.
Mechanism outside airstream.
Conical inlet pieces preferred.
Cannot be used without inlet
box.
Split design available
No need to extend bearing
centers for DWDI.

(Ref: Page 68)
Variable Inlet Vane (VIV)
Built as part of the inlet
piece.
Requires cone-shaped inlet
piece design.
High efficiency when
dampered.
No need to extend bearing
centers on DWDI.
Mechanism in airstream
for clean applications only.
(Ref: Page 68)
Variable Inlet Vane (VIV) Damper
Speed Control
Volume (CFM) x 1000
250 200 150 100 50

P
r
e
s
s
u
r
e

(
I
n

H
2
0
)
25
20
15
10
5
0
B
H
P
1000
800
600
400
200
20 SP
450 BHP
FAN : 83" x 14.38" FRD
FAN SPEED : 840
TEMP. : 70
DENSITY : 0.075
SP
BHP
SYSTEM RESISTANCE
105,000 CFM
The same
operating point
can be achieved
by reducing the
speed from 1180
rpm to 840 rpm.
The BHP is
greatly reduced
to 450 since
peak efficiency
is maintained.

(Ref. page 22)
Annual Operating Cost
Outlet Damper: 1000 HP = 313,000 $US
Louverd Damper: 880 HP = 275,000 $US
Radial or VIV Damper: 700 HP = 219,000 $US
Variable Speed Control: 450HP = 141,000 $US

Example Calculation (for variable speed control):
(450 HP) x (0.746 kW/HP) x (350 days/yr.) x (24 hrs/day) x (0.05 $/kWh) = $140,994/yr
Note: 1 HP costs about $313/yr
System Effects
System Effects
Fan Performance
can be affected
by the
configuration of
ductwork
upstream and
downstream
of the fan.

(Ref. Page 28)
System Effects Fan Outlet
(Ref. Page 28)
Reprinted from AMCA Publication 201-90
Effective Duct Length
(Ref. Page 29)
System Effect Factor for
Outlet Elbows
(Ref. Page 32)
System Effects (Pressure Losses)
(Ref. Page 33)
CFD Analysis of Non-Uniform
Flow in Fan Outlet Elbow
Forced Inlet Vortex -
(Counter Rotating Swirl)
(Ref. Page 30)
+Decreased Fan
Aerodynamic Performance
+Increased Fan Brake
Horsepower Requirement
+Fan Aerodynamic Surge
/ Pulsation may Result
Non-Uniform Flow Induced into
Fan Inlet by a Poorly Designed
Rectangular Inlet Duct
(Ref. Page 31)
+Most Common Cause of
Deficient Fan Performance
+Fan Aerodynamic Surge
/ Pulsations may Result
+Properly Designed Inlet
Box Provides a Predictable
Inlet Condition and
Maintains Stable Fan
Performance
Non-Uniform Flow into Fan Inlet
Induced by 90 Round Section
Elbow - No Turning Vanes
(Ref. Page 31)
System Effects (Pressure Losses)
(Ref. Page 33)
System Effects
(Ref. Page 34)
Non-Uniform Flow Induced into Fan
Inlet CFD Analysis of Flow
Fan Stability
The Mechanics of Surging
(Ref. Page 36)
(Ref. Page 36)
B
Desired Operating Point:

When operating volume
is reduced from A to B,
the fan responds by
generating more pressure.
As a result the system
remains stable with the
flow proceeding from the
fan down the duct.
B
(Ref. Page 37)
Undesirable Operating point:

When flow is reduced from
B to C, the fan responds by
generating less pressure. Then
the pressure in the downstream
duct is higher than the pressure
at the fan. The result is reverse
Flow commonly called
surging .
C
(Ref. Page 37)
We normally only think
About fan performance
in the first quadrant
i.e. positive flow and
positive pressure.
Flow reversal!
Inlet Damper Control
(Ref. Page 35)
Discharge Damper
(Ref. Page 36)
Eliminates the Helmholtz
resonator effect of a large
duct or plenum,
Blow-Off or Recirculation
(Ref. Page 35)
Blow-off
Recirculation
Loop
Robinson Surgeless Blower
(Ref. Page 38)
Robinson offers a
blower with special
surgeless characteristic
performance curve. The
peak pressure is at zero
volumetric flow.
Temperature Rise thru Fan
(Ref. Page 38)
Sound Considerations
Ref. Page 73
Community Noise Concerns
Ref. Page 73

B1. Fan Laws and Fan Control - Robinson

Uploaded by

Document Information

Original Description:

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

B1. Fan Laws and Fan Control - Robinson

Uploaded by

Copyright:

Available Formats

Robinson Industries Fans

You might also like