• MAYA FAN AIR


    ENGINEERING Private Limited


    An ISO 9001:2008 Certified Company

  • Maya High Efficient Fan


    Conventional FRP Fan


    Special Features of “MAYA” Cooling tower Hollow FRP Fans

  • Myth Related To Power Saving & Cooling tower Fans Performance



    Today several types of hollow FRP fans are available in cooling tower fan industries and there are many users using these fans but majority are not satisfied with the performance and power saving because of following reason.

    - Reducing cooling tower fan weight will reduce power consumption of fan. (Wrong)
    - Converting metallic cooling tower fan in to Identical FRP fans will reduce fan power consumption. (Wrong)
    - Reduction in cooling tower fans airflow while proving power saving. (Cheating)
    - There is power saving and no reduction in airflow but cooling tower performance reduce. (Cheating)
    - Illogical power saving achieved 50%, 90% or even more after replacement of cooling tower fans. (Myth)
    - Improving flow & power saving are directly related and either of one is possible to similar value while replacing cooling tower fans. (Wrong)
    - After achieving power saving in cooling tower fan replacement project, problem faced in peak season. (Reality)

    We do agree that these problems in the FRP cooling tower fans exists and these are due to improper fan and aerodynamic hub design and also due to falls and non practical commitment.

    Thus to overcome all these issues, MAYA fan have built a new ladder in the field of power saving by introducing a overall new design. It even strengthens by our “application specific selection”, and most advanced manufacturing processes. Details and impact of all these is described in this presentation.

  • Special Features of “MAYA”FRP Cooling Tower Fan Design

    Cooling tower fan "Blade"


    -Sealed circuit (recirculation prevention)
    - Widen toward head
    - Full length twist


    Cooling Tower Fan Aerodynamic Hub

    - Aerodynamics hub prevent recirculation, prevent eddies generation as well as smooth path of air till the exit.


    Cooling tower fan Selection

    - To prevent any wrong doing we provide final selection of CT fans by our designer only

  • Blade Design Of Cooling Tower Fans ‐


    The most important requirement of a CT fan wheel is that it must impart to the air stream a uniform velocity and pressure over its entire area. Any well‐designed axial flow fan wheel is sure to have following characteristics:


    1. CT Fan wheel should clearly separate two different pressure plain.


    a. Suction plain or (‐iv) pressure plain.

    b. Delivery plain or (+iv) pressure plain.

    2. individual cooling tower fans blades will be narrow at the tip, where the blade velocity is high, and will widen toward the hub, where more blade area is required due to lower blade velocity.


    3. angle of cooling tower fan blades to the plane of rotation will be minimum at the tip and increase as the hub is approached.

    Above three are explain in next few slide.

  • 1. Cooling tower Fan wheel should clearly separate two different pressure plain.
    a. Suction plain or –iv pressure plain b. Delivery plain or +iv pressure plain.


    Today most of the conventional cooling tower fan blades are prepared as per Fig A, having blank Portion of about 15 to 20% of total blade length. This blank portion provide a clear path to connect two different pressure plain thus recirculation of air start in this portion of the blade. few of the global fan manufacturer already avoid such design but it is still in practice by most of Indian and international cooling tower fans manufacturer.


    Fig A – Conventional CT Fan Blades

    Fig B – Maya High Efficient CT Fan Blades

  • A Case study from vedanta – Jharsuguda :-
    a. Suction plain or –iv pressure plain
    b. Delivery plain or +iv pressure plain.


    In this case during velocity data collection it was clearly observed that the inner most velocity reading comes –iv (we observed this by flag test)


    But as anemometer give only velocity, not direction Therefore by objection of our competitor this reading is also consider as normal reading.



  • 2. individual CT fan blades will be narrow at the tip, where blade velocity is high, and will widen toward hub, where more blade area is required due to lower blade velocity.


    Because of production process restriction most of metallic blade as well as fibre (pultrusion ) blades are having constant cross section through out the blade thus there blade dose not follow one of the very basic rule of blade design. Where as at MayaFan we do follow standard fan design principal and achieve more uniform airflow Fig ‐



  • 3. angle of the CT blades to the plane of rotation will be minimum at the tip and increase as the hub is approached


    Because of production as well as transportation restriction none of fan manufacturer follow twist provided by the designing software and original design edited to suit there high production manufacturing process and to reduce Transportation cost. Where as we are following exact output of cooling tower fan design software.



  • Cooling Tower Fans Aerodynamic Hub:


    The majority of cooling tower hollow FRP fan manufacturers do not provide any aerodynamic hub. where as few of them have conventional aerodynamic hub which is shown in Fig C.
    Non of solution completely close the circuit between two different pressure plain thus recirculation continue.



  • So in there conventional design without aerodynamic hub or with conventional aerodynamic hub recirculation near hub is observed, which diversely effect cooling tower fan performance as well as increase possibility under fatigue failure.


    3‐5% of air volume is turbulated in operating condition due to this in conventional cooling tower fan



  • Velocity curve of conventional cooling tower fan


    Red arrow representing air turbulence



  • At Maya Fan we again refine design of our cooling tower fan aerodynamic hub to reduce turbulence and achieving smooth airflow at the center of fan, representing below:


    Due to this overlapping of fan blade to aerodynamic hub, there is no provision of air turbulence at all. Maya cooling tower fan offers smooth air flow in this area as shown in next slide.



  • Smooth airflow through the CT fan


    MAYA High Efficient FRP CT Fan Air Velocity Curve



  • This is the non productive area in conventional fan which is considered as productive as the remaining blade (we observed it by flag test as anemometer do gave only velocity not direction of flow)


    For 28’ diameter CT fan


    Fig - D



  • Cooling Tower Fans selection:


    Selection of cooling tower fan is considered as most useful task in the field of power saving.


    We at Maya Fan design CT fans as per the preference given by the customer it could be any of the below –


    Cooling tower fan optimized for "low power consumption"
    Cooling tower fan optimized for "low noise level"
    Cooling tower fan optimized for "low initial cost"


    based on the customer feedback we designed or select fan with our proprietary software “MayaBladeSelect” with it we have developed more than 1000 different duty point and all are performing very well.


  • Summary - Cooling tower fans special feature


    Switching from conventional FRP to MAYA fan will save 10‐30 % power

  • Summary - Cooling tower fans special feature


    Switching from conventional metallic to MAYA fan will save 20‐40 % power

  • Key Features of MAYA FRP Cooling Tower Fans

    » Free trial – we provide free trial with committed power saving for cooling tower fan replacement*
    » Energy saving – Our fans are 10‐15% more efficient compared to other metallic fans.
    » Proprietary Aerodynamic High Efficient Designs
    » Vibration and turbulence free operation.
    » Corrosion resistant
    » Low noise level
    » Zero maintenance

  • Cooling tower fans Case Study-1

    Practical example for replacement of cooling tower fan at SAIL (BSP)(METAL to FRP))

    Observation 1 for Air velocity range ‐ Air velocity range of Maya fan is more uniform compared to the existing fan.

    Ideally air velocity across the whole blade should be equal thus the range of airflow across the blade length should be zero.

    Observation 2 for Fan Air Flow: Existing fan ‐ 526867 Maya Fan ‐ 578337

    Airflow is higher than existing fan

    Observation 3 for Power Consumption: Existing fan ‐ 20.73 Maya Fan ‐ 15.22

    Even with higher air flow power consumption is lower than the existing and our fan saves 26.57% power in comparison to the existing CT fan.



  • Cooling tower fans Case Study-2

    Practical example for replacement of cooling tower fan at KRIBHCO (FRP to FRP))

    Observation 1 for Air velocity range ‐ Air velocity range of Maya CT fan is more uniform compared to the existing fan.

    Ideally air velocity across the whole blade should be equal thus the range of airflow across the blade length should be zero.

    Observation 2 for Air Flow: Existing fan ‐ 987476 Maya Fan ‐ 1029472

    Airflow is higher than existing CT fan

    Observation 3 for Power Consumption: Existing fan ‐ 55.30 Maya Fan ‐ 43.40

    Even with higher air flow power consumption is lower than the existing and our CT fan saves 21.52% power over the existing FRP fan.

  • Our one of the prestigious projects Summery Report for 10M (33’) size cooling tower Fan At IPCL Nagothane


    Average power saving in 14 fans is 28.63% that translates into 209.34 kW saving per hour.


  • Based on all the above special features Maya Fan has become the First and only company having the ISO 9001:2008 Certification for:


    “Manufacturer and Supply of Energy Saving Industrial Fan and Fans Equipment”



  • Thank You For Watching this Presentation

    For any query or sugestation feel free to contact at
    info@mayafan.in, mayafan.in@gmail.com