ENGINEERING Private Limited

    An ISO 9001:2008 Certified Company

  • Maya High Efficient ACC Fan

    Conventional FRP ACC Fan

    “MAYA” FRP Air Cooled Condenser/ACC Fans Special Features

  • Introduction –

    There are two type of heat exchanger, wet cooling heat exchanger or dry cooling heat exchanger.

    Wet cooling heat exchanger use fluid media to take away the heat like cooling tower.

    Dry cooling heat exchanger do not use any additional fluid these are directly use air to condense the steam. These are often called heat exchanger or dry cooled heat exchanger these are also known as air cooled condenser (ACC) or fin fan cooler, and here in this presentation we may keep using any of above terms.

    Blade – is terms used for wing of fan used in this type of equipment.

  • Heat Exchanger Fans and Possibility of Power saving :‐

    Today due to increasing cost of water and serious concern about water pollution use of air cooled condenser getting much attention and been adopted by most of new project, in our observation we have found that majority of ACC/fin fan cooler are over design and having fan with significant possibility of power saving following are major point to we taken care while going for power saving in air cooled condenser fans:-

    » Reducing fan weight will not reduce power consumption of heat exchanger fan/ ACC Fan / Fin fan cooled fans.
    » Only converting metallic fan in to FRP dose not reduce fan power consumption.
    » There should not be any reduction in airflow while proving power saving.
    » There should not be any deterioration in performance of Heat exchanger/ACC during ACC fans power saving project.

    Achieving power saving is not too easy, it need great understanding on fan design and understanding of it’s application

    At MAYA fan we built a all new fan with most efficient aero foil which if similar to that of airplane wing to achieve significant amount of power saving. We also improve aerodynamic hub to optimized our air cooled condenser fan performance. In this presentation all these components are explained in detail.

  • Special Features of “MAYA” air cooled condenser/ACC Fans Design

    Heat Exchanger Fans "Blade"

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

    Heat Exchanger Fans Aerodynamic Hub

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

    Heat Exchanger Fans Selection

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

  • Detail about fin fan/ACC blade Design ‐‐

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

    Fig A – Conventional ACC Fan Blades

    Fig B – Maya High Efficient ACC Fan Blades

  • In few case of ACC fan replacement we clearly observed such recirculation:-

    In some case we clearly observed –iv velocity (by flag test) at centre of fan while collecting air velocity data.

    it is normally do not observed because air velocity is measured by anemometer which only provide amplitude of air velocity not direction of velocity thus what ever the direction of air it keep giving positive reading which is by default considered as air delivery by fan. To understand this deference we use flag test to find direction of flow along with its value.

    Flag Test –

    In this a small and very light strip of a cloth is tied near to the anemometer which keep flying along the direction of air. By this we get direction of air at the anemometer.

  • 2. individual 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 of ACC fan.

    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 (refer picture) Where as at MayaFan we do follow standard fan design principal and achieve more uniform airflow Fig ‐‐

  • 3. angle of the ACC fan 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 air cooled condenser fans 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 design software.

  • Fin Fan Aerodynamic Hub:

    The majority of ACC hollow FRP fan manufacturers do not provide any aerodynamic hub. And few of them have conventional aerodynamic hub which is shown in Fig C. non of solution provide close circuit between two different pressure plan thus recirculation continue.

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

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

  • Velocity curve of conventional ACC fans with turbulence at centre of fan

    Red arrow representing air turbulence

  • At Maya Fan we again refine design of our air cooled condenser/ACC fans aerodynamic hub to reduce the turbulence and achieving smooth airflow at the center of fan.

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

  • Smooth airflow through Maya Air Cooled Condenser Fans

    MAYA High Efficient ACC FRP Fan Air Velocity Curve

  • This is the non productive turbulence flow area in conventional fin 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 fan

    Fig - D

  • Air Cooled Condenser/ACC Fan selection:

    Selection of air cooled condenser/acc 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 -

    Power consumption.
    Low Noise.
    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 - ACC fans special feature

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

  • Summary - ACC fans special feature

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

  • Key Features of MAYA FRP Air Cooled Condenser Fans Fan

    » Free trial – we provide free trial with committed power saving
    » Energy saving – Our ACC 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

  • Case Study-1: Maya Vs Metallic Air Cooled Condenser/ACC Fans

    Practical example of comparison of ACC Fan with metallic Fan

    Observation 1 for Air Flow:

    Existing fan ‐ 1880779 CMH

    Maya Fan ‐ 1885751 CMH

    Airflow is higher than existing fan

    Observation 2 for Power Consumption:

    Existing fan ‐ 132.81 kW

    Maya Fan ‐ 93.72 kW

    Total direct power saving is 29.43 %

  • Case Study-2: Maya Vs Conventional FRP Heat Exchanger fans

    Practical example of comparison with conventional FRP fans

    Observation 1 for Air Flow:

    Existing fan ‐ 2265894

    Maya Fan ‐ 2432971

    Observation 2 for Air Flow: Existing fan ‐ 84.11 kW Maya Fan ‐ 60.53 kW

    Even with higher air flow power consumption is lower than the existing and our fan saves 28.8% power over the existing FRP fan.

  • 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