Air Fin Cooler Discharge Temperature Control Options
Air Fin Cooler Discharge Temperature Control Options
Air Fin Cooler Discharge Temperature Control Options
by R.C. Monroe
Hudson Products Corporation, Houston, Texas
Orlando, Florida
Consider variable pitch fans use in the USA. Its advantage is that critical
components are accessible for easy adjustment or
maintenance from the walkway.
By R. C. Monroe
Fig. 3 shows the electrically operated hub for a 28 ft.
Presented is a detailed analysis of the control and (8.5m) diameter fan that will be used in a large air
energy saving advantages of variable pitch fans. cooled steam condenser. The thrust bearing above
Basic mechanical and operating principles are the gear box is lubricated by the gear box oil pump.
also covered.
Operating and Control Characteristics
R.C. Monroe, Hudson Products Company,
Houston Variable pitch fan operators used in air coolers can
be described in general terms as very similar to
Variable pitch fans provide the precise amount of diaphragm operated, spring return valves. Instead of
airflow to control process temperature and save moving a valve stem up and down the operator
substantial amounts of energy at the same time ... controls fan blade pitch. A force diagram is shown in
automatically. This article discusses their ability to Fig. 4.
control, to conserve energy, and their basic
operating characteristics and mechanical aspects. As the blade moves the air, the aerodynamic
Economic comparisons with other type air flow moment (CW) tries to feather the blade. The hub
control systems for axial fans are made. spring creates an opposing moment (CCW) to make
the blade do work. This is a fail-safe mechanism so
Auto-variable®, controllable pitch, or variable pitch that if the air pressure on the diaphragm fails, the fan
are words usually used to describe axial fans with operates as a fixed pitch fan providing design air
blades that change pitch in operation, so that the flow. Fans can be assembled to move to maximum
precise amount of airflow is furnished to meet the or minimum air flow on loss of air signal. The initial
requirements for a particular heat exchanger or spring preload has to be sufficient to keep the blade
cooling tower. from feathering.
In the years of low cost energy, the impetus to use To reduce the air flow, or even reverse the air flow
variable pitch fans has been for precise temperature direction, air pressure is exerted on the diaphragm to
control, generally to within four percent or less of oppose the hub spring and decrease blade pitch.
the set point. However there is new interest in
variable pitch fans for the energy saving potential as When the blade pitch is about minus 10º, no work is
well. done and essentially "zero" flow is attained.
Minimum air velocity obtainable is approximately
This article will discuss characteristics of variable 50-100 fpm (.25-.50m/s). If the hub has its pitch
pitch fans under 30 feet (9.1 in) in diameter and less stops adjusted for reverse flow, the air is directed
than 150 horsepower (112 Kw). The most typical downward and can be as much as about 60 percent
sizes would be 10 to 14 feet (3.04-4.3m) in diameter of the upward flow at the same horsepower. The
consuming up to 40 horsepower (30 Kw). Shown in decrease in flow capability is because of poor
Fig. 1 through 3 are several different types of efficiency in the reverse pitch mode.
variable pitch fans. Fig. 1 shows the typical type
found in air coolers. Fig. 2 shows an inverted A typical variable pitch hub requires a 3-15 psi
actuator type popular in Europe but not in general (21103 kPa) control signal and operates the blades
Let's examine a typical case of an air cooler with a Step 3. For a fixed pitch fan, flow is a direct
fixed pitch fan and a means of throttling air flow, function of speed. Make a plot of fan output versus
such as a shutter, at its design point and several ambient temperature for each scheme to be studied.
other operating points of' reduced air flow. This yields hp-hours per temperature range.
For example, consider a 14 ft. diameter fan Once the cfm is defined for each range, the fan
operating at 14º pitch at its design point 1 (Fig. 12). horsepower for any point (i) can be approximated by
The system resistance line, shown as a dashed line, is the following relation:
the locus of points obtained by a summation of the
static and velocity pressure losses vs. flow through Hpi = ( cfmi )2.8 ( pi ) hpdes
the bundle. The pitch angle line for 14º represents cfm des pdes
the delivery characteristics to the fan. Assume
density remains constant and the decreased air flow Where hpi = Horsepower at cfmi
is a result of decreased duty. pi = Density at point i lb/ft3
cfmi = ft3/min flow at point i
The louver throttles air flow to control the outlet hpdes = Design horsepower
temperature. From Fig. 12 the points shown as 1, 2', pdes = Design density
3' and 4' are the total pressure output and
horsepower consumed by the fixed pitch fan. If we or: kWei = ( m3/si )2.8 ( kg/m3i) kWdes
were controlling the airflow with a variable pitch fan m3/sdes kg/m3des
instead of a throttling device, the total pressure
output would exactly match the system requirements Step 4. Using hp-hours for each temperature range,
as shown in points 2, 3 and 4 and the horsepower tabulate the total for the year. The power required
requirements would be significantly reduced. The would be kWe = hp (.746). Arrive at an energy cost
savings in horsepower can easily be seen. In this per year for each scheme.
case the variable pitch fan saved 26, 51 and 73
percent of the horsepower required by the fixed This is a very simple approach but a useful tool.
pitch fan at points, 2', 3' and 4'.
As an example consider the following: a 20 by 36 ft.
Energy comparison. A typical case study to (6 by 11 m), 4 row, forced draft air cooled heat
evaluate cost differentials between fixed pitch (single exchanger, with 2-14 ft. (4.3 m) fans each having
or dual speed) or variable pitch fans would be 40hp (30kW) motors. The unit is a propane
prepared as follows: condenser, item 126C to be located in West
Virginia, close to Charleston. Power cost is
Step 1. Thermal studies would be made to determine $0.035/kW-hr.
the total airflow required as a function of ambient