Stall & Parallel Operation. Witt&Sohn AG Oct-14
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1 Stall & Parallel Operation
2 CONTENT Stall & Parallel Operation 1. Definition of Stall 2. Requirements for Parallel Operation 3. Operation of Parallel Fans 4. Stall-free Fans & VSD 2
3 Definition of Stall, Stall Definition Stall means: status of non-uniform flows, two air flows at one pressure value, Typical Axial Fan Curve, Single Operation: Stall area: forbidden for operation. Operation range 3
4 Definition of Stall, Stall Definition Stall means, status of non-uniform flow, two air flows at one pressure value, Typical Axial Fan Curve (2 Fans Parallel Operation) Stall area: forbidden for operation. Operation range 4
5 Definition of Stall Stall means, status of non-uniform flow, two air flows at one pressure value, Typical Axial Fan Curve (4 Fans Parallel Operation) Stall area: forbidden for operation. Operation range The more fans run in parallel the larger the stall area the smaller the operation range The STALL zone for axial fans in parallel often is much larger than expected! 5
6 Definition of Stall Disturbance causes the air flow to separate from one or more of the blades. This blocks the air flow through the corresponding blade cell. 6
7 Definition of Stall Curve of one fan Summary curve of two fans Max. allowed system resistance without any saftey margin Several fan suppliers do not show or do not know in detail the STALL area of their fan curves Stall area of one fan Stall area of two fans (summary curve) pd-line Always ask for fan curves starting at 0m³/s! 7
8 Definition of Stall Possible Consequences: - rupture of air stream lines at blade edge - high vibrations with low amplitude at blade - damage of bearings - fatigue break of impeller 8
9 Definition of Stall Reasons: Turbulent inlet or outlet flow at the fan System resistance too high because of unexpected aerodynamic behaviour (wrong system design) Short-term pressure pulses (due to Piston Effect of by-passing trains) 9
10 Piston Effect Axial Fans (none stall-free) Stall operation likely for none stall-free fans due to piston effect of by-passing trains (Metro/Railway application) Piston effect stall! +610Pa - 610Pa 10
11 Piston Effect Axial Fans (none stall-free) Stall operation likely for none stall-free fans due to piston effect of by-passing trains (Metro/Railway application) Piston effect stall! +610Pa - 610Pa 11
12 Detection of stall Stall detection probe by WITT&SOHN Stall detection is done by a Petermann probe in combination with a pressure sensor Probe located radially in the area of blade tip During normal (stable) operation the probe detects a negative or no pressure difference. - + Stall is detected if the pressure difference exceeds a predefined value NOTE: A stall detection probe does not eliminate the stall area of the fan. It only detects that the fan is not running in a stable area. Operation of fans in such conditions shall be avoided! 12
13 CONTENT Stall & Parallel Operation 1. Definition of Stall 2. Requirements for Parallel Operation 3. Operation of Parallel Fans 4. Stall-free Fans & VSD 13
14 Requirements for Parallel Operation For System: High volume flow (Q design > Q single fan ) Moderate pressure drop Restricted space Heat resistance Reversibility (up to 100%) Cost-effective solution Robust design 14
15 Requirements for Parallel Operation For Fan Maker: None stall-free fan curve with shown stall area Cumulative fan curve of parallel fans INFO: Most fan makers do not know/ show the STALL area characteristic of their fans! (stall control impossible) 15
16 Requirements for Parallel Operation For Fan Maker: None stall-free fan curve with shown stall area Cumulative fan curve of parallel fans or Stall-free fan curve 16
17 CONTENT Stall & Parallel Operation 1. Definition of Stall 2. Requirements for Parallel Operation 3. Operation of Parallel Fans 4. Stall-free Fans & VSD 17
18 Operation of Parallel Fans Installation: Keep distance between fans to prevent disturbance and interference of fans Bad Good 18
19 Operation of Parallel Fans Installation: Connect to plenum with separation walls Ensure symmetric openings Use shut-off dampers at one side Bad asymmetric opening symmetric openings Good short circuit separation of flow wall 19
20 Operation of Parallel Fans Installation - Samples: 20
21 Operation of Parallel Fans Parallel Fan Operation I. Start in cascade (DOL, weak supply net) synchronize fan start with opening of damper 1. ensure all dampers are initially closed 2. start-up 1 st fan 3. wait for signals 1 st fan: full speed and 1 st damper: open 4. start-up next fan (step 2. to 4.) stop procedure with any notice of failure But: 21
22 Operation of Parallel Fans Problem: Switch on an additional fan might lead to Asymmetry of individual air flow Moving of duty point of remaining fans into stall area Uncontrollable pulsing of system System performance problems Fan damage 22
23 Operation of Parallel Fans Parallel Fan Operation II. Start in parallel (DOL, strong supply net) synchronize fan start with opening of damper 1. ensure all dampers are initially closed 2. start-up all fans simultaneously 3. wait for signals all fans: full speed and all dampers: open stop procedure with any notice of failure But difficult to achieve Requires strong supply net 23
24 Operation of Parallel Fans Parallel Fan Operation III. Start-up in parallel (VSD) synchronize fan start with opening of damper 1. ensure all dampers are initially closed 2. start-up all fans simultaneously: use 1 st VSD as master, others as slave (AO master : actual speed AI slave : speed set point) 3. wait for signals all fans: full speed and all dampers: open stop procedure with any notice of failure But expensive 24
25 CONTENT Stall & Parallel Operation 1. Definition of Stall 2. Requirements for Parallel Operation 3. Operation of Parallel Fans 4. Stall-free Fans & VSD 25
26 Stall-free Fans & VSD Stall-free fans by WITT&SOHN : 1. Fans with truly STALL-free fan curve No limitation during parallel duty (trouble free) Max. stability against pressure pulses 26
27 Stall-free Fans & VSD Stall-free fans by WITT&SOHN : 2. Fans with Anti-Stall Device and quasi STALL-free fan curve Anti-Stall Device Still limitation during parallel duty: Anti-stall device reduces effect of stall, but continuous operation in stabilized area not recommended High stability against pressure pulses Provides a significant higher level of reliability of the ventilation system Parallel operation (trouble-free) 27
28 Stall-free Fans & VSD Stall-free fans by WITT&SOHN : 3. Fans with STALL-free fan curve and VSD Multiple duty points achievable with one blade angle Constantly high efficiencies No complex pitch-in-motion impellers required 28
29 Summary Axial flow fans should not be operated in STALL or in the stabilized STALL area Piston effects have to be taken into account Stall can be detected by a Petermann probe Parallel duty is restricting the operation range of fans with none stall-free characteristics For parallel duty it is required to know the characteristic of the stall area The plant layout should be symmetrically designed Fan isolation dampers have to be installed for parallel duty With stall free fans curves parallel duty is no problem anymore 29
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