Cement Manufacturing Holcim Technology Phone +41 58 858 58 00

Quality & Process Control Im Schachen Fax +41 58 858 63 27

5113 Holderbank

TIS Fan Efficiency Report

Holcim Technology Ltd

Cement Manufacturing

The copyright for this document and all appendices are reserved by Holcim Technology Ltd
 Reference No.: CM-QPC 13/00050/E
TIS Fan Efficiency Report Revision No.: V2

TIS Fan Efficiency Report

Report Number: CM-QPC 13/50000/E

Date: March 17, 2014
Revision No.: V2

Holcim Technology Ltd

Cement Manufacturing

Prepared by: Hugo Escobar

Markus Rufle
Sergio Garcia
Vicente Camacho

Reviewed by: Carlos Pinzon

Approved by: René Zürcher

Holcim Technology Ltd

Cement Manufacturing
Im Schachen
CH-5113 Holderbank

Phone +41 58 858 58 00

Fax +41 58 858 63 27

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Introduction
This document describes the application of the Holcim Fan Efficiency Report in the Technical
Information System (TIS) according to the TIS Global Concept.
The following topics are documented:
 Description of functionality
 Specification of preconditions
 Description of configuration

Abbreviations
FET Fan Efficiency Tool
LIG Law of the Ideal Gases
Log Instance for data storage in TIS
TIS Technical Information System

Key words
TIS, Technical Information System, TIS Application Guideline, Fan Efficiency, Fan Efficiency
Tool, Air Flow, Power Consumption

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Table of Contents

1. INTRODUCTION 5
1.1 Project background 5
1.2 Fan efficiency basics 5

2. FAN EFFICIENCY ASSESSMENT 7

2.1 Fan curve 7

3. FAN EFFICIENCY ASSESSMENT WITH THE NEW FAN TOOL 9

3.1 Functionality and overview 9
3.2 Results and interpretation 9

4. TIS REPORT 10
4.1 Signals, logs and internal logs / calculations 10
4.2 Calculated logs 11
4.2.1 Volume flow 11
4.2.2 Estimated power consumption 15
4.2.3 Delta power 16
4.2.4 DeltaP 17
4.3 Report 18

5. REFERENCE DOCUMENTS 28

6. VERSION INDEX 28

7. ANNEXES 28

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1. INTRODUCTION

1.1 Project background

Due to the high increase of electrical energy cost there is a need to optimize the
efficiency of main equipment. As large process fans are responsible for about 30 –
50% of the electrical energy consumption in cement plants, improving their
efficiency has a high potential impact in terms of energy cost reduction.

A key parameter to determine fan efficiency is its volume flow rate which is in most
cases neither easy to measure nor to calculate. Many measuring devices based on
different technologies are available on the market. But for measuring mainly hot and
dusty gas streams in cement applications not every measuring equipment is
suitable. Furthermore, according to the respective predominating gas condition in
the cement process different principles have to be applied depending on
measurement’s location in the process.

There is also the need for a systematic approach to fan efficiency assessment and
monitoring which will lead to preventive and/or predictive actions on process fans.

The final aim of the project will be to implement a system for online fan efficiency
monitoring.

1.2 Fan efficiency basics

The efficiency of a fan determines the shaft power demand for a given operating
point. It can be calculated with the following equation:

Equation 1: Fan Efficiency

Being:
  = Fan efficiency [%]
 p = Pressure increase across the fan [mbar]
 This parameter can be calculated as the difference between the static pressure
at fan outlet and inlet
 = Actual volume flow at fan inlet [m3/s]
 In case is not possible to directly measure this parameter, it is possible to
measure the inlet flow and convert it to the conditions at fan outlet (temperature
and pressure) using the Law of the Ideal Gases (LIG).
 P = Power requirement at fan shaft [kW].

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 It is not possible to measure the power directly at the shaft. It can be calculated
from the electrical power consumption, considering the electrical losses of the
different equipment between the power reading point and the fan shaft.
 CDust = Dust concentration in the gas stream [kg/m3].
This parameter can be measured using special equipment (i.e. opacimeter).
As it depends on the separation efficiency of the dedusting equipment in the
plant (cyclones, bag filters, EP), in most of the cases it will be either constant
or the result of a correlation with the production rate. In the case of low dust
load, the dust term can be neglected for the efficiency calculation.
 Gas = Gas density [kg/m3]
This parameter can be calculated considering the gas composition, which can
be measured with a gas analyzer.

An important factor affecting fan efficiency is gas density, which will be determined
by gas composition, pressure and temperature [K]. The calculation of gas density
can be done according to the LIG:

Equation 2: Law of the Ideal Gases (LIG)

Where R (8.2058e-5 m3.bar/k.mol) is the constant of the ideal gases and n is the
number of moles in the considered gas volume which can be expressed as the ratio
between mass (m) and molecular weight (mw):

In a cement manufacturing process, the gases will be mainly composed by O2, N2,
CO2 and H2O, considering x,y,z and s as the corresponding mass fractions of each
component in the total gas, it is possible to calculate the corresponding mw:

Equation 3: Gas Molecular Weight

Now it is possible to express LIG as:

Considering

The formula can be solved for the density as follows:

Equation 4: Gas Density

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As mw and R are constant, once the initial gas density is known, it is possible to
calculate the gas density at any other temperature and pressure conditions:

Equation 5: Gas Density Variation

In order to calculate fan efficiency, inlet volume flow must be used. In case it is
easier to measure at the outlet, it is possible to calculate the volume at inlet by using
Equation 2:

Equation 6: Gas Volume Variation

Now getting all parameters together the current fan efficiency can be determined
according to Equation 1.

2. FAN EFFICIENCY ASSESSMENT

The aim of a fan efficiency assessment is to check the performance of a given fan
by determining its actual efficiency and comparing it with the expected (theoretical)
one and find potential improvement areas.

For this, according to chapter 1, it is crucial to determine temperature and pressure

in order to calculate the actual gas density as well as the pressure difference and
flow to finally get to the actual fan efficiency.

2.1 Fan curve

The fan curve is a graphical representation of the fan behavior provided by the
supplier.

The fan curve represents all the possible operating points of a fan at a given fan
speed or control damper position (depending on the fan control type) and certain
conditions of gas inlet pressure, temperature and density (reference conditions).
Knowing the fan speed or damper position and either the fan inlet volume, the
pressure increase across the fan or the shaft power demand, it is possible to
estimate graphically the other parameters.

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Figure 1: Fan curve with power and pressure indication in relation to volume flow

Once these values are known, it is possible to convert them to the actual conditions
of the fan, considering the equations:

Equation 7: Conversion of pressure

Equation 8: Conversion of power

It is also possible to calculate the volume flow at fan outlet (if temperature and
pressure are known at fan outlet) using Equation 6.
With the actual pressure increase, shaft power demand and fan inlet volume flow it
is possible to calculate the fan efficiency according to Equation 1.

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3. FAN EFFICIENCY ASSESSMENT WITH THE NEW FAN TOOL

In order to calculate the expected efficiency of a fan, it is necessary to use the fan
curves (as shown in chapter 2.1) provided by the fan supplier. The graphical
process to get the pressure and power requirement values and convert them to the
actual conditions could be tedious, even more considering it has to be repeated for
any different fan speed or control damper position.

In the past there were several attempts to develop fan assessment tools inside
HGRS. Since the tools were getting too sophisticated and were not easily
understandable for most of the users they were only rarely used.
The new Fan Efficiency Tool (FET) developed under the scope of the Fan Efficiency
Innovation project tries to give a simpler and faster answer to the need of a tool for
fan assessment. In the following subchapters a short overview of the functionality
and results of the tool are given. For detailed information refer to the FET manual.

3.1 Functionality and overview

FET adapts the fan curves provided by the fan supplier to actual gas density,
calculates the expected fan efficiency according to the fan curve at the respective
fan speed or control damper position and compares it with the actual fan efficiency
from manual measurements. By knowing the values for both actual and expected
efficiency, the user can easily estimate whether the fan is working properly or not.

With FET the time spent for fan assessment calculations is reduced significantly by
avoiding the repetition of the graphical reading of the supplier’s fan curves. Once the
fan curves for a given fan are implemented in the tool, it is only necessary to change
the process parameters to get the fan curves at actual conditions and speed or
damper position.

3.2 Results and interpretation

On the results sheet, the tool gives a comparison between actual and expected fan
efficiency, power and flow.

The tool has a built-in indication on the performance of the fan (traffic light), so the
user has already a hint about the fan behaviour. The traffic light indication is done
taking into consideration the fan accuracy class according to the norm DIN-24166,
which provides acceptance criteria for deviations of the fan properties from the
agreed operational parameters.

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Figure 2: Traffic light indication

The fan curve corresponding to the actual fan speed is also shown together with two
different system curves, the one calculated from the measured operating point and
the one calculated from the measured pressure increase and the corresponding
theoretical flow.
Both theoretical and measured points have a specific error range in pressure and
flow. This means, the real operating points can be located on any place inside the
area delimited by the error bars displayed on the chart. In case the areas of the
measured and theoretical operating point are overlapping in any point, the user
should consider the fan is working properly.

4. TIS REPORT
The fan efficiency tool, provides a good insight of the current efficiency of the fans,
however this is not an automated task, in addition, not all the plants have a flow
measurement device in each fan, hence, an ad-hoc calculation within TIS can
provide an approximation of the efficiency in real time.
Therefore, TIS presents the opportunity to incorporate the FET calculations, and
display them in a report which can be carefully monitored by the plant personnel.

4.1 Signals, logs and internal logs / calculations

Signals and Logs
The basic signals and average Logs that should be available to create the fan
efficiency calculations are.
 Fan inlet pressure (mbar)
 Fan outlet pressure or pressure difference (mbar)
 Fan speed (rpm)
 Temperature before or after the fan (°C)
 Fan power consumption (KW)

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4.2 Calculated logs

There are 4 calculated Logs that need to be set to properly report the fan efficiency.
 Estimated volume flow
 Estimated power consumption
 Delta power
 Delta pressure

4.2.1 Volume flow

This indicator provides an approximation of the air flow through the fan, and is
based on the fan curves and fan efficiency tool (described in chapter 2 and 3)
To create this Log, the equation representing the fan curve at reference conditions
and maximum fan speed (supplier curve) is needed.

Equation 9: Equation second order

This equation can be obtained copying in excel the extracted pairs of values for
volume flow (horizontal axis, m3/h) and pressure increase (vertical axis, mbar) from
the supplier curve.

Flow p
(m3/h) (mbar)
150000 99
250000 97
300000 96
500000 85
700000 65
800000 53

Figure 3: Relation Flow and p

After making the scatter representation of the values and adding the second order
polynomial trendline and its equation to the graph, the corresponding equation
coefficients can be copied

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Figure 4: Relation Flow and p

The coefficients (a,b,c) correspond to the following parameters in the report:

A Reference
B Reference
C Reference

These coefficients can also be obtained directly using FET, just by setting the inputs
in the section 1.2 of the tool to the values of the reference data of section 1.1 and
also setting the fan speed to match the one corresponding to the supplier curve
(maximum speed).

Additionally, the following information is required and should be extracted from the
fan documentation provided by the supplier:

Reference density
Reference temperature
Reference speed (fan speed related to the curve used for coefficient calculation)
Reference ambient pressure
Reference fan inlet pressure

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This information will help to build the quadratic equation (see general equation
below) to determine the flow:

Equation 10: General quadratic equation

This then will be used to estimate the power consumption.

Figure 5: LOG Volumenflow

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The actual code can be copy-pasted from below. Considering that all the necessary
changes will be done accordingly.

‘--FAN EFFICIENCY—Volume Flow Estimation

'The reference values are manual inputs entered by user

'this is an EXAMPLE values are different for each fan

A_ref= -1.6806 * (10^-10)

B_ref= -3.2685 * (10^-5)
C_ref= 63.918

'this is an EXAMPLE values are different for each fan

Density_Ref = 0.486 'kg/m3

Temp_Ref = 178 '°C
Speed_ref = 986 'rpm
P_amb = 960 'mbar
P_ref = -52 'mbar

'The following values are read from TIS

'The logs should maintain same order as below

P1_act = A*10 'A=Press act (before fan) mbar ‘ Factor needed to convert to mbar
P2_act = B*10 'B=Press after fan ‘ Factor needed to convert to mbar
Speed_act = C 'C=fan Speed
Temp_act = D 'D=Temp act

'CALCULATIONS

Delta_P = abs(P1_act - P2_act)

Density_Act = Density_Ref * ((P_amb + P1_Act)/(P_amb+P_ref))*((Temp_ref+273)/(Temp_act+273))

A1_act = A_ref * (Dens_Act/Density_Ref)

B1_act = B_ref * (Dens_Act/Density_Ref)
C1_act = C_ref * (Dens_Act/Density_Ref)

A_act = A_ref * (Density_Act/Density_Ref)

B_act = B_ref * (Density_Act/Density_Ref) * (Speed_act / Speed_ref)
C_act = C_ref * (Density_Act/Density_Ref) * (Speed_act / Speed_ref)^2

'These conditions are set to avoid ERRORS in TIS

if (Speed_act<(Speed_ref*0.4) or ( B_act^2 - (4 * A_act * (C_act - Delta_P))) < 0) then

X1 = null
X2 = null

'SECOND DEGREE EQUATION to find X (volume-flow)

Else
X1 = (- B_act + (sqr( B_act^2 - (4 * A_act * (C_act - Delta_P))))) / (2 * A_act)
X2 = (- B_act - (sqr( B_act^2 - (4 * A_act * (C_act - Delta_P))))) / (2 * A_act)

End if

'Selection of Highest ecuation value = CALCULATED VOLUME-FLOW

IF (X1 > X2) THEN

Y = X1
ELSE
Y = X2
END IF

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4.2.2 Estimated power consumption

This calculation gives expected power consumption for the calculated flow; also this
calculation is based on the fan curves and fan efficiency tool (described in chapter 2).

Figure 6: LOG power consumption

The actual code can be copy-paste from below. Considering that all the necessary
changes will be done accordingly:

‘--FAN EFFICIENCY-- Power Consumption Estimation

'The following reference values are manual inputs
'These values are obtain from the Fan Efficiency tool

'The reference values are manual inputs entered by user

A_ref = -2.927 * (10^-9)

B_ref = 2.8578 * (10^-3)
C_ref = -1.8743

Density_Ref = 0.486 'kg/m3

Temp_ref = 178 '°C
Speed_ref = 986 'rpm
P_Amb = 960 'mbar
P_ref = -52 'mbar

'The following values are read from TIS

'The logs should maintain same order as below

P1_act = A*10 'A = Press act (before fan) mbar ‘ Factor needed to convert to mbar
P2_act = B*10 'B = Press after fan ‘ Factor needed to convert to mbar
Speed_act = C 'C = Fan Speed
Temp_act = D 'D = Temp actual
Flow_calc = E 'E = Calculated volume-flow

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'CALCULATIONS

Density_act = Density_Ref * ((P_Amb + P1_act) / (P_Amb + P_ref)) * ((Temp_ref + 273) / (Temp_act + 273))

A1_act = A_ref * (Density_Act / Density_Ref)

B1_act = B_ref * (Density_Act / Density_Ref)
C1_act = C_ref * (Density_Act / Density_Ref)

A_act = A1_act * (Speed_act / Speed_Ref)

B_act = B1_act * (Speed_act / Speed_Ref)^2
C_act = C1_act * (Speed_act / Speed_Ref)^3

'CALCULATED KW

If Speed_act<(Speed_ref*0.4)then
Y=null
Else
Y = A_act * Flow_calc^2 + (B_act * Flow_calc) + C_act
End if

4.2.3 Delta power

This is a simple calculation that describes the difference between the actual
measurement and the calculated consumption, providing a good insight of the fan
performance.

Figure 7: LOG delta KW

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The actual code can be copy-pasted from below. Considering that all the necessary
changes will be done accordingly:

‘--FAN EFFICIENCY-- Power Deviation Estimation

'Calculation to obtain Power deviation

'A is the measure power

'B is the calculated power
'C is Speed

Speed_ref = 986 'rpm

If isnull(B) or B=<0 or isnull(A) or A<2 or C<(Speed_ref*0.4) then

Y=null
else
Y=((A/B)*100)-100
end if

4.2.4 Fan’s delta pressure

This log calculates the theoretical delta p.

Figure 8: LOG delta P

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The actual code can be copy-pasted from below.

‘--FAN Delta p--

'Calculation to obtain delta P (mbars)

'The following values are read from TIS

'A = Fan Inlet pressure

'B = Fan outlet pressure

If isnull(B) or isnull(A) then

Y=null
else
Y=abs(A - B)
end if

4.3 Report
Once the Logs have been created and verified, it is important to display the
information in a consistent arrangement. It is important to consider that not all fans
need to be incorporated to the report, as not all the information will be available for
all fans, however it should be created for all large process fans

The suggested report provides quick overview of the calculated efficiency and its
behaviour over time.

Figure 9: Fan Efficiency report

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For the proposed report, a dedicated template has to be created (importing template
file available as annex 1). The simpler way to setup the template is by using a HTML
table (3 columns and the number of rows will be determined by the number of
available fans).

It is only required to position one gauge, one spread sheet body and one chart body
in the first row, and then each element can be copied as required.

Figure 10: Fan Efficiency template

When the template has been creted a new report will be created using the new
template.

Figure 11: New report (template Fan Efficiency)

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The new report will open, apply the name and description.

Figure 12: Fan Efficiency Report Template

Once the report opens, modify the table size and cells formulas to be able to read
the LOGS.

Figure 13: Fan Efficiency Report Template detail.

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Adjust the scale of the gauge charts.

Figure 14: Fan Efficiency Report Template, gauge

Then it is important to setup the limits, to facilitate the overview of the gauge charts.

Figure 15: Fan Efficiency Report Template, limits

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And the last step is to setup the “chart-trend”.

Figure 16: Fan Efficiency Report Template, Chart

Once the report has been configured, save your changes, it should be clear and
easy to identify the key fans, in order to generate an automatic report, an autoprint
function needs to be enabled (for more information about autoprint, please refer to
chapter 5 in the configuration report R-CMS-ECT-12-1942-E-TIS Standard Reports).
You can use in order to generate an automatic report and send it by mail, in version
KM 6 the report annexe 2.

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The final report can be accessed via Internet explorer.

Figure 17: Fan Efficiency Report

 Use this kind report in order to be able to send it by email, in KM6

Figure 18: Fan Efficiency Report (mail)

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In order to create this report we must create a new template with the link of the Fan
Efficiency report. (The link must be changed in the template for the differents plants)
(Fiugre 19).

Figure 19: Template Fan Efficiency Report (mail)

Adjust the report

Figure 20a: Fan Efficiency Report (mail) configuration

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Figure 20b: Fan Efficiency Report (mail) configuration

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Once the report has been configured, save your changes, close the report and adjust
the Autoprint Definitions.

To set auto print definitions, follow the steps below:

 In the List View, right-click on the report that you want to view or set the auto print
definitions for and from the popup menu that appears click on the Auto Print
Definitions option.

 In the dialog that opens double-click on any of the rows shown.

 The Auto Print Configuration Dialog will open.

 Complete the fields in the Auto Print Dialog.

 Click on the OK button.

 Right-click anywhere in the Work Area and from the popup menu that appears,
click on Save.

 Save and close the report.

Result: In the List View, the attribute A will indicate the new report settings.

Figure 21: Auto Print Definitions

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The next step is complete the Auto Print dialog.

 In the Name field, type a name for your definition. It must be unique per report.
Should be short and explicit, but you can use up to 80 characters, including
spaces. Names are case sensitive.

 From the Period field drop down list select the period to be used for report
headers. This will specify the reporting period that the definition will use.

 From the Resolution field drop down list select the resolution for the report. This is
Autoprint execution interval, defines when you want to have the report printed, e-
mailed or transferred and specifies, when the definition will be activated.

 Select the target for the report output, E-mail - sends the report to an e-mail
address.

 Type the e-mail address/group that you want to receive the report, for example:
aaa.bbb@ddd.yyyy.com, bbb.ccc@ddd.yyyy.com

 Select whether you want this print definition to be active periodical

 Deselect active on even

 Once you have completed all of the fields, click on the OK button.

Figure 20: Auto Print Configuration Dialog

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5. REFERENCE DOCUMENTS

Document Description
R-CMS-ECT-12-1950-E_Process Fan Efficiency report and tool
Innovation Project Fan Efficiency
Final Report _v2
R-CMS-ECT-12-1942-E-TIS TIS standard reports configuration
Standard Reports

6. VERSION INDEX

Version Description of change Date, Responsible

V1 First issue 25.09.2013, ESH
V2 Format, and basic information 05.03.2014, CAV

7. ANNEXES

Document Description File

Annex 1 - Fan Efficiency Import file for Fan
Report_export.xml Efficiency report
Includes:
Fan Efficiency Report_export.xml
Templates,
Reports and Logs.
Annex 2 - Fan Import file for Fan
Efficiency_mail_export.xml Efficiency report
(by mail)
Fan Efficiency_mail_export.xml
Includes:
Templates,
Reports

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