FAN EFFICIENCY ANALYZER
barunsway
CEMENT INDUSTRY · PROCESS ENGINEERING · barunsway.com
⚙ General Fan Data
SELECT FAN
RPM
RPM
mm
mm
—
m²
mm
—
m²
%
Hz
⚡ Motor Power Input
kW
kW
p.u.
—
%
Fan Power (kW)
—
kW used
Shaft Power
—
kW
Motor Eff.
95
% (assumed)
🌡 Temperature & Gas Properties
°C
°C
°C
⚡ COMPUTED GAS DENSITY — LIVE
Standard ρ (0°C)
—
kg/m³
Actual ρ at inlet T
—
kg/m³ ← used in calcs
Correction Factor
—
ρ_actual / ρ_std
Method 1: ρ = MW_mix × P / (8314 × T_K) | Method 2: ρ = ρ_std × (273/(273+T)) × (P/101325)
kg/m³
kg/m³
🏔 Altitude / Barometric Correction
m
Pa
Standard Atmosphere Equation
P = 101325 × (1 − 2.25577×10⁻⁵ × h)^5.25588 Pa
P = 101325 × (1 − 2.25577×10⁻⁵ × h)^5.25588 Pa
Calc. Baro. (Pa)
—
Pa
Density Correction
—
factor
Corrected ρ
—
kg/m³
Density Correction Formula
ρ_actual = (P × MW) / (R × T) | R = 8314 J/(kmol·K)
Correction Factor = ρ_actual / ρ_standard
ρ_actual = (P × MW) / (R × T) | R = 8314 J/(kmol·K)
Correction Factor = ρ_actual / ρ_standard
⚙ Fan Inlet Measurement Method
SELECT METHOD
For large fans (RABH, ESP, ID Fans): Direct inlet draft measurement is frequently unreliable due to turbulent flow,
non-uniform velocity profiles, and limited straight duct length. Use Option 2 to back-calculate inlet conditions from stack measurements.
📊 Pressure Measurements
OPTION 1 — DIRECT
mmWC
mmWC
mmWC
mmWC
mmWC
Conversions
Inlet (Pa)
—
Outlet (Pa)
—
Static ΔP (Pa)
—
Total ΔP (Pa)
—
🔬 Dynamic DP Readings (Pitot Traverse)
Pitot Traverse Method
Multiple VP readings at equal area traverse points. Q = Cp × A × √(2 × VP_avg / ρ)
Multiple VP readings at equal area traverse points. Q = Cp × A × √(2 × VP_avg / ρ)
| # | Point | VP Reading (mmWC) | √VP |
|---|
Min VP
—
mmWC
Max VP
—
mmWC
Avg √VP
—
Avg VP
—
mmWC
💨 Flow Calculation Methods
Method 1: Pitot Traverse
mmWC
mm
⚡ PITOT FLOW RESULT — LIVE
Area (m²)
—
Density (kg/m³)
—
Velocity (m/s)
—
Flow (m³/s)
—
v = Cp × √(2×ΔP_Pa/ρ) | Q = v × A
Method 2: Direct Velocity
m/s
DUCT AREA (from inlet setup above):
—
m²
Flow (Velocity) — Real-time
—
m³/s (actual)
Method 3: Design / NM³ Input
Nm³/hr
°C
Pa
Actual Flow
—
m³/s (actual)
Flow Summary & Density Correction
Selected Flow Q
—
m³/s
Flow (m³/hr)
—
m³/hr
Density-Corr. Flow
—
Nm³/hr
Gas Velocity
—
m/s
🏭 Process-Specific Parameters
SELECT FAN TYPE FIRST
ℹ Select a fan type in the Fan Configuration tab to see process-specific parameters.
🏭 Raw Mill Fan — Process Parameters
mmWC
°C
TPH
%
RPM
%
%
m³/t
%
MW
Fan Loading Analysis: Higher moisture → more drying required → higher gas volumes → increased fan loading. Circulation load affects separator resistance → affects DP → affects fan duty point.
⚠ Coal Mill Fan — Safety-Critical Parameters
%
°C
%
%
mmWC
mmWC
m³/hr
mmWC
m/s
🚀 Booster Fan Array
🌫 RABH Fan — Reverse Air Bag House Parameters
°C
mmWC
min
mg/Nm³
m³/hr
⚡ ESP Fan Parameters
°C
mmWC
kV
%
🏭 Common Process Inputs — Entire Cooler Section
GLOBAL PARAMETERS
These values apply to all cooler fans and update all calculations in real time. Clinker Output = (Kiln Feed × 1000) ÷ Clinker Factor.
TPH
ratio
°C
kg/m³
kg/m³
—
kg/hr
= (KF × 1000) ÷ CF
—
kg/m³
= ρₙ × 273 ÷ (273 + T)
❄ COOLER FAN CARDS
📊 Overall Cooler Summary — Live Dashboard
REAL-TIME
Fans Active
0
Total m³/hr
—
actual
Total Nm³/hr
—
normal
Σ Sp. Air (Nm³/kg)
—
Nm³/kg clinker
Σ Sp. Air (kg/kg)
—
kg air/kg clinker
Avg Efficiency
—
%
Total Motor kW
—
kW
Flow Imbalance
—
%
| Fan | Mode | Velocity (m/s) | Flow (m³/hr) | Flow (Nm³/hr) | Sp. Air (Nm³/kg) | Sp. Air (kg/kg) | Motor kW | Efficiency % | Motor Load % | Status |
|---|
📈 Fan Laws — Interactive Module
Q₂/Q₁ = N₂/N₁Flow varies linearly with RPM
P₂/P₁ = (N₂/N₁)²Pressure varies as square of RPM
W₂/W₁ = (N₂/N₁)³Power varies as cube of RPM
RPM
m³/s
Pa
kW
N₂
900
RPM
Q₂
—
m³/s
P₂
—
Pa
W₂
—
kW
Power Change
—
%
Deviation
—
from design
RPM vs FLOW
RPM vs PRESSURE
RPM vs POWER (Cube Law!)
Engineering Insight: A mere 10% increase in RPM increases power by ~33% (1.1³ = 1.331). This is why overspeeding fans leads to motor overloads. VFDs save enormous energy by reducing RPM when full flow is not required — a 20% RPM reduction cuts power by ~49%.
🎯 Fan Efficiency Results
AWAITING INPUT
📐 Calculated Parameters
Flow Q
—
m³/s
Total Pressure ΔP
—
Pa
Static Pressure
—
Pa
Velocity Pressure
—
Pa
Shaft Power
—
kW
Fan Efficiency
—
%
Specific Power
—
kWh/1000m³
System Resistance
—
mmWC
Gas Velocity
—
m/s
Motor Loading
—
%
⚖ Fan Law Deviation Analysis
RPM Ratio
—
Expected Flow
—
m³/s
Actual Flow
—
m³/s
Flow Deviation
—
%
Fan Law Performance Deviation: If actual flow significantly differs from fan law prediction at the same RPM ratio, it indicates system resistance change (dirty filter, damper position, air leakage) or fan mechanical issue (blade wear, inlet vortex).
🔍 Automatic Diagnostics
Run diagnostics after calculating all parameters to get engineering insights.
💡 Plant Recommendations
Recommendations will appear after diagnostics are run.
📏 Instrument Uncertainty & Calibration
Pitot Tube
%
Pressure Transmitter
%
Power Meter / CT
%
—
📚 Engineering Reference Notes
Static vs Velocity vs Total Pressure
Static Pressure = Energy stored in gas as pressure. Velocity Pressure = Kinetic energy of moving gas. Total Pressure = Static + Velocity. VP = ½ρv². Fans develop Total Pressure; the system converts it into useful static pressure.
Static Pressure = Energy stored in gas as pressure. Velocity Pressure = Kinetic energy of moving gas. Total Pressure = Static + Velocity. VP = ½ρv². Fans develop Total Pressure; the system converts it into useful static pressure.
Density Correction Importance
Fan flow Q (m³/s) is volumetric — same volume at high temperature has lower mass. For process purposes, Nm³/hr matters. Always correct: Q_actual × (273+T)/(273) × (101325/P_baro) = Q_normal.
Fan flow Q (m³/s) is volumetric — same volume at high temperature has lower mass. For process purposes, Nm³/hr matters. Always correct: Q_actual × (273+T)/(273) × (101325/P_baro) = Q_normal.
Why Altitude Affects Fan Performance
At higher altitude, lower air density means lower mass flow for same volumetric flow. Fan develops same ΔP in Pa but lower mass flow. Motor may seem underloaded but process gas is deficient — always correct to actual operating density.
At higher altitude, lower air density means lower mass flow for same volumetric flow. Fan develops same ΔP in Pa but lower mass flow. Motor may seem underloaded but process gas is deficient — always correct to actual operating density.
Pitot Traverse Accuracy
Single-point pitot reading can have ±15% error. Proper traverse (log-Tchebycheff) across 16-20 points at equal area intervals gives ±2% accuracy. Use average of √VP (not √(avg VP)) — this gives true mean velocity.
Single-point pitot reading can have ±15% error. Proper traverse (log-Tchebycheff) across 16-20 points at equal area intervals gives ±2% accuracy. Use average of √VP (not √(avg VP)) — this gives true mean velocity.
System Resistance & Fan Efficiency
Fan efficiency alone does not determine system performance. A 90% efficient fan driving through a badly sized system wastes energy. System resistance ∝ Q². If resistance doubles, same fan delivers ~30% less flow. Check duct sizing, bends, and obstructions.
Fan efficiency alone does not determine system performance. A 90% efficient fan driving through a badly sized system wastes energy. System resistance ∝ Q². If resistance doubles, same fan delivers ~30% less flow. Check duct sizing, bends, and obstructions.
Why Actual Flow Differs from Design
Temperature deviation from design → volumetric flow change. Air infiltration/leakage → extra flow. Worn impeller → lower head and flow. Changed system resistance → new operating point on curve. Incorrect RPM → fan law deviation.
Temperature deviation from design → volumetric flow change. Air infiltration/leakage → extra flow. Worn impeller → lower head and flow. Changed system resistance → new operating point on curve. Incorrect RPM → fan law deviation.
📄 Report Generation
🔐
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barunsway.com · Engineering Tool
— CEMENT PLANT —
Advanced Fan Efficiency Analysis Report
Date: —
Engineer: —
Equipment: —
Report No: —
Fan Efficiency Status:
—
Fan Type: —
1 · Fan Configuration
| Parameter | Value | Parameter | Value |
|---|---|---|---|
| Fan Type / Category | — | Fan Name / Tag | — |
| Actual Running RPM | — | Design RPM | — |
| Impeller Diameter | — | Fan Arrangement | — |
| Inlet Duct Area | — | Outlet Duct Area | — |
| Damper Position | — | VFD Frequency | — |
| Pitot Tube Constant (Cp) | — | Drive Type | — |
2 · Motor & Electrical Data
| Parameter | Value | Parameter | Value |
|---|---|---|---|
| Motor Rated kW | — | Motor Efficiency | — |
| Actual Power Consumed | — | Drive Efficiency | — |
| Motor Loading | — | Shaft Power | — |
barunsway.com — Fan Efficiency Report
— | —
3 · Process & Gas Conditions
| Parameter | Value | Parameter | Value |
|---|---|---|---|
| Fan Inlet Temperature | — | Ambient Temperature | — |
| Barometric Pressure | — | Plant Elevation (MSL) | — |
| Gas Type / Composition | — | Gas Density Method | — |
| Standard Gas Density ρₛ | — | Actual Gas Density ρₐ | — |
4 · Pressure Measurements
| Parameter | Measured Value | Unit | Pa Equivalent | Note |
|---|---|---|---|---|
| Fan Inlet Draft | — | mmWC | — | Negative = suction side |
| Fan Outlet Pressure | — | mmWC | — | |
| Static Pressure Rise | — | mmWC | — | |
| Velocity Pressure (Pitot) | — | mmWC | — | Avg of traverse readings |
| Total Pressure Rise ΔP | — | mmWC | — | Static + Velocity |
| Measurement Method | — | |||
5 · Gas Flow Measurements
| Parameter | Value | Unit | Remarks |
|---|---|---|---|
| Measurement Method | — | — | Selected by engineer |
| Gas Velocity | — | m/s | At measurement point |
| Actual Gas Flow Q | — | m³/s | Actual volumetric |
| Gas Flow (m³/hr) | — | m³/hr | |
| Normal Flow (Nm³/hr) | — | Nm³/hr | Density corrected @ 0°C, 101325 Pa |
barunsway.com — Fan Efficiency Report
— | —
6 · Calculated Performance Results
Fan Efficiency
—
%
Gas Flow
—
m³/s
Shaft Power
—
kW
Motor Load
—
%
| Calculated Parameter | Value | Unit | Assessment |
|---|---|---|---|
| Fan Total Efficiency η | — | % | — |
| Total Pressure Rise ΔP | — | Pa | Static + Velocity |
| Static Pressure Rise | — | Pa | |
| Velocity Pressure | — | Pa | |
| Specific Power Consumption | — | kWh/1000m³ | Lower is better |
| System Resistance | — | mmWC | Total duct + equipment loss |
| Gas Flow Status | — | — |
7 · Engineering Assessment & Diagnostics
Generate report after running diagnostics to populate this section.
barunsway.com — Fan Efficiency Report
— | —
8 · Fan Law Deviation Analysis
| Parameter | Value | Parameter | Value |
|---|---|---|---|
| RPM Ratio (Actual / Design) | — | Fan Law Expected Flow | — |
| Actual Measured Flow | — | Flow Deviation | — |
Note: Significant deviation from fan law prediction indicates system resistance
change (dirty filter, damper adjustment, air leakage) or fan mechanical degradation
(blade erosion, inlet vortex, shaft misalignment).
9 · Site Remarks & Observations
—
10 · Authorisation & Sign-off
Prepared By
Name & Signature
Date: ________________
Reviewed By
Name & Signature
Date: ________________
Approved By
Name & Signature
Date: ________________
barunsway.com ·
Advanced Fan Efficiency Analyzer · Cement Industry Engineering Tool
Generated: — ·
This report is confidential and proprietary to barunsway.com