Sybrand J. van der Spuy

An evaluation of simplified CFD models applied to perimeter fans in air-cooled steam condensers

Modelling air-cooled condensers (ACCs) incorporating hundreds of fans, necessitates the use of simplified fan models when performing a computational fluid dynamics (CFD) analysis of the condenser. The perimeter fans in these ACCs are subjected to distorted inlet flow conditions. This paper compares the accuracy of three different simplified fan models and proposes an improved model, based on numerical and experimental results from representative fan configurations. Three different fan configurations are tested as perimeter fans in a three-fan test facility, and their results compared to CFD results. The experimental evaluation by particle image velocimetry (PIV) reveals the shape of the velocity profiles immediately upstream of the perimeter fan. The accuracy of the CFD-predicted flow field directly upstream of the perimeter fan varies according to the model used to represent the fan as well as the configuration of the specific perimeter fan. The paper indicates a discrepancy of as much as 30% between experimental and simulated volumetric effectiveness values for a specific simulation model and fan configuration. The standard and extended actuator disc fan models perform better than the pressure jump model in predicting the volumetric effectiveness of the perimeter fans, and the extended actuator disc model performs best at predicting fan inlet velocity profiles.Modelling air-cooled condensers (ACCs) incorporating hundreds of fans, necessitates the use of simplified fan models when performing a computational fluid dynamics (CFD) analysis of the condenser. The perimeter fans in these ACCs are subjected to distorted inlet flow conditions. This paper compares the accuracy of three different simplified fan models and proposes an improved model, based on numerical and experimental results from representative fan configurations. Three different fan configurations are tested as perimeter fans in a three-fan test facility, and their results compared to CFD results. The experimental evaluation by particle image velocimetry (PIV) reveals the shape of the velocity profiles immediately upstream of the perimeter fan. The accuracy of the CFD-predicted flow field directly upstream of the perimeter fan varies according to the model used to represent the fan as well as the configuration of the specific perimeter fan. The paper indicates a discrepancy of as much as 30% between exp...

Numerical and experimental investigation into the accuracy of the fan scaling laws applied to large diameter axial flow fans

The cooling effectiveness of air-cooled steam condenser units is impacted by the performance of the large diameter axial flow cooling fans, which ultimately affects the overall efficiency of the power plant. Because of the large diameters of these fans, performance tests are carried out at test facilities with smaller, standardized diameters and measuring equipment. The performance of the large scale fans can be predicted based on the small scale test results using the similarity laws and scale-up formulae. This article details the results of small scale experimental tests and numerical simulations that were performed on a pair of 1.25 m diameter axial flow fans. Full scale, 10.360 m, diameter simulations of the same axial flow fans were subsequently performed and compared with the experimental results that were scaled up using the fan scaling laws.

Experimental Investigation of the Blade Surface Pressure Distribution in an Axial Flow Fan for a Range of Flow Rates

Numerical modeling of the flow field in the vicinity of large axial flow fans finds application in various engineering investigations, whether for fan design purposes, fan induced flow fields or fan system modeling. These three-dimensional fan models generally require verification with experimental results to establish validity. For this purpose a comparison is generally made between the numerically and experimentally obtained fan performance characteristics (fan static pressure and static efficiency curves) to verify the model. Although this method provides a means to validate the numerical model on a global flow level, some uncertainty on the accuracy of this validated model on a local flow level (flow structures close to the fan blade) might still exist. In the present study an experimental technique is presented to measure blade surface static pressures that can be used to validate numerical fan models on a local flow level. These measurements are obtained for a specific fan by means of piezo-resistive pressure transducers mounted in a capsule on the fan axis and connected to pressure taps in specially manufactured fan blades. The transducers are also coupled to a telemetry system that samples the measured pressures and enables wireless communication between the fan and a laptop/PC. Blade surface pressure measurements are obtained for a series of volumetric flow rates through the fan and compared to the numerical data simulated using a RANS approach. A good comparison between the experimental and numerical blade surface static pressure data exists, with the largest discrepancies occurring near the hub as well as the leading and trailing edges of the blade. The reason for this discrepancy could be attributed, amongst others, to low y+ values (y+ < 30) on the blade surface in these regions, leading to errors in the calculation of the wall condition by the wall function. The experimental technique therefore provides CFD engineers with an additional tool for numerical fan model validation on a local flow level.Copyright

The Determination of Fan Blade Aerodynamic Loading From a Measured Response

Large-scale cooling system fans often operate under distorted inlet air flow conditions due to the presence of other fans and the prevalent wind conditions. Strain gauge measurements have been used to determine the blade loading as a result of the unsteady aerodynamic forces. However, these measurements are of the blade’s response to the aerodynamic forces and include the deformation as a result of the first natural frequency being excited. When considering the dominant first natural frequency and bending mode of the fan blade, one can approximate the fan blade as a cantilever beam that acts as a single degree-of-freedom system. The response of a single degree-of-freedom system can be calculated analytically for any excitation if the system’s properties are known. The current investigation focuses on using these equations to create an algorithm that can be applied to the measured response of a fan blade to then extract the aerodynamic forces exciting it. This is performed by using a simple non-linear, least-squares optimization algorithm to fit a complex Fourier series to the response and using the coefficients of each harmonic term to determine the Fourier series representing the excitation function. The algorithm was first tested by applying it to the response of a finite element cantilever beam representing a simplified model of the fan blade. Good results were obtained for a variety of excitation forces and as such the algorithm was then applied to the measured response of a full-scale fan blade. The full-scale blade was excited with a shaker where the forcing function could be accurately controlled. Once validated, the algorithm was applied to a set of strain gauge measurements that were recorded at a full-scale fan while in operation. The reconstructed aerodynamic loading showed increased forces when the blade passed beneath the fan bridge as well as when it approached the windward side of the casing.Copyright

Investigation of Large-Scale Cooling System Fan Blade Vibration

Fans operating at the edges of large-scale air-cooled steam condensers often do so under distorted inlet air flow conditions. These conditions create variations in the aerodynamic loads exerted on a fan blade during rotation which causes it to vibrate. In order to isolate the sources of the unsteady aerodynamic loads as well as their effects on blade vibration, a potential flow fluid dynamics code was written to determine the aerodynamic loads exerted on a fan blade as a function of its rotation. The lift and drag forces were exported to a finite element code approximating the fan blade as a cantilever beam. With these two sets of code the response of the blade when subjected to varying aerodynamic loads could be determined. Furthermore, the effect of changing certain parameters such as blade stiffness or damping can be investigated. It was found that the blade’s response closely resembles that which was measured at the full-scale facility and that slight changes to the blade’s stiffness can potentially reduce the vibrational amplitude but may also lead to resonance.© 2014 ASME

Prediction of axial compressor blade excitation by using a two-way staggered fluid-structure interaction model:

A vibration excitation system has been developed to excite the rotor blades of an axial compressor, in the specified nodal diameter mode and at the specified frequency, by injecting additional compressed air into the compressor flow path. The system was fitted to the Rofanco compressor test bench at the University of Stellenbosch in South Africa. A two-way staggered fluid–structure interaction (FSI) model was constructed that was capable of simulating the vibrations of the rotor blades excited by the vibration excitation system. The results of the FSI simulations were verified using available experimental data. It was concluded that the FSI model is able to recreate the vibrations of the rotor blades with sufficient accuracy. The results of the FSI simulations also indicated that the vibration excitation system should be capable of exciting the blades in the selected mode shape and at the selected frequency, provided the excitation frequency is close to the natural frequency of the first bending mode of each rotor blade.

Investigation of the Flow Field in the Vicinity of an Axial Flow Fan During Low Flow Rates

Large axial flow fans are used in forced draft air cooled heat exchangers (ACHEs). Previous studies have shown that adverse operating conditions cause certain sectors of the fan, or the fan as a whole to operate at very low flow rates, thereby reducing the cooling effectiveness of the ACHE. The present study is directed towards the experimental and numerical analyses of the flow in the vicinity of an axial flow fan during low flow rates. This is done to obtain the global flow structure up and downstream of the fan. A near-free-vortex fan, designed for specific application in ACHEs, is used for the investigation. Experimental fan testing was conducted in a British Standard 848, type A fan test facility, to obtain the fan characteristic. Both steady-state and time-dependent numerical simulations were performed, depending on the operating condition of the fan, using the Realizable k-e turbulence model. Good agreement is found between the numerically and experimentally obtained fan characteristic data. Using data from the numerical simulations, the time and circumferentially averaged flow field is presented. At the design flow rate the downstream fan jet mainly moves in the axial and tangential direction, as expected for a free-vortex design criteria, with a small amount of radial flow that can be observed. As the flow rate through the fan is decreased, it is evident that the down-stream fan jet gradually shifts more diagonally outwards, and the region where reverse flow occur between the fan jet and the fan rotational axis increases. At very low flow rates the flow close to the tip reverses through the fan, producing a small recirculation zone as well as swirl at certain locations upstream of the fan.Copyright

The design of an axial flow fan for application in large air-cooled heat exchangers

The heat transfer characteristics of industrial air-cooled heat exchangers (ACHEs) are dependent on the ability of the fan system to deliver sufficient cooling air. However, under normal operating conditions, variable flow direction and strength often subject peripheral fans to distorted inlet conditions with an attendant reduction in overall volumetric flow rate and cooling capacity. In this paper, a design methodology for single-rotor axial flow fans, appropriate for use in large industrial ACHE’s is presented. The primary motivation for this work was to address the issues of robust off-design performance, in particular, distorted inlet flow tolerance. Using this methodology, two 8-bladed prototype fans (B1 and B2) were designed, built and tested in accordance with BS 848 (Type A) standards. The two B-fans have a hub-tip ratio of xh = 0.4 and employ the Clark Y and NASA LS airfoil profiles respectively. Measured performance characteristics were compared to commercial fan designs (V-, DL- and L-fan) used in existing ACHEs. Results indicate that the B-fans have a higher design point operating efficiency. The B-fans also show a steeper fan static pressure rise characteristic compared to the commercial fans, except for the DL-fan, implying a greater tolerance to pressure fluctuations caused by distorted inflows.Copyright