-.

I

;,

—

18

L!,1

1,

,.-:.. .J.. !.!

,—

‘1

,-i-

i‘—

,.

.

< ,,..1

~.

1““:?..*—’”‘–— C $’!{)])l),)’!llt$

.— ——_-._-_..—-

App -eh df’~p

,’. .

.,.. ., .,, .

:,. ,.,,..,,...

“STATE-OF~THE-ART OF INDUSTRIAL, ,. ,’ ... ,,, .

TECHNOLOGY OF”ROTATING,,..,.,

,,, .,,,, ,, ,,,

,. ,.,,.,,,”~%, DIFFUSER (RD) FANS ~

i

..

[ 1 “’‘“---2-*c ~@ijwcs— .——— ..—

—

—

—

—

—

.

—

—

.—

—

—

,

—

I

,.

,,

.,

TABLE OF CONTENTS

Page No.

lNTRODUC’I’ION

THE PROPOSED MPS LIFT FAN (10,000 MD 15,000 TONS) 4

s’~N~l;-01~-’~llE-AlVf01~ INDUSTRIAL RI)FANS IN THE MPS(10,OOO-TON) DUTY RANGE 11

IL.

1.. Custolnc!rw’List of Recent Industrial RI)Fan Instal-lations

2. PhotographSof Typical RD Fan Wheels

11

16

“ 163. Performance of Two Typical RI)Fan Wheels,.,,

BROAD STATE-OF-THE-ART OF INDUSTRIAL RD FANS,INCLUDING LARGE FANS OPERATING AT lIIG1{URTHAN THE MPS (15,000 TON) LIFT FAN

VERY ”HIGH-PRESSURE RD BLOWERS FOR FUTURE

PRESSURES

SES LIFT

FAN APPLICATIONS

CONCLUSIONS

,,

,, ,. .,,.

..-.,,.,.

—: ;’

.,.

. . .. ...... ..,,. ,,, ,,.

,., ,,

,:,,,.,,.... . ....

,,. .

,..,, . .

ii

\<~.. .,. .. J, ,:7 -----—- —-

:: L.. ,, ,,, y:., . . . .. .. . .. . . . . . .,, ,., ,.. . . . . . . ., .,. :, 1. . . . .. . .

—

.

—

—

—

—

.

—

—

—

.

[i—

~,. ,

i—

:,LIST OF FIGURIJS

,.:..>~_yre No. Pag& No;

1.

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

Major ACV and SES Lift I?anSystems, and Comparisonwith Required MPS Lift Fan System

General Performance of Full Size RD Wheel(MPS 10,000 and 15,000-Ton Missions)..

MPS,;/’ypeLift Fan During Installation

Rotary Diffuser Fan During Assembly (Porchevilleon Figure 17) .

MPS Lift Fan - Side View

Pressure-Flow Duty Points of Operational NeuHeavy-duty Industrial RD Fans Compared with SESMPS Lift Fans

Close-up Photograph of Inlet of RD Fan Wheel307-.55-1.3 (Fan No. 12 on Table III)

Overall Photograph of RD Fan Wheel 307-.55-1.3(No. 12 on Table III)

Side Photograph of RD Fan Wheel 307-.55-1.3(No. 12 on Table III)

Photograph of Two RD Fan Wheels, Model 307-.55-1.3,Original on the Ftight (1970), Improved Version Left

Photograph of Stainless Steel Fan Wheel, 280-.5-1.3(S),(NO. 15 qn Table III)

Photograph of UNIPEL wheel, 17 ft;Diameter(Duty Point Shown on Figure 17)

Overall Photograph of 17-ft UNIPEL Wheel +.

2

5

8

9

10

14

17

18

19

20

21

22

23

Photograph of RD Fan Wheel 200-.65-1.3 ‘(No. 8 on Table III) 24

Full-Scale Performance of RI)Fan 307-.55-1.3 s-(No. 12 on Table”III, and Figures 7 to 9) ‘ 25

Full-Scale Performance of RD Fan 280-.46-1.2(Figure 11) 26

7.

.

.

,,”

.,

..

,.

k-’ . ..!.. .! ...,,.,.4 . . .. . ..—.— .—..— -...----.—- -------- ---- . . . . .. .

~,-i -?-

-

,.

.

—

.

—

—

-—

—

—

iLIST OF F’lGURES (cent’.d)

~.

Fi~ure No.’-- —— .,

t

Page No.

Pressure-Flow Duty Points of Typical Industrial RD Fans’ z~17

Photograph of RD Fan Wheel 100-0.7-1.2 DuringFabrication (Model Fan for MPS Lift Fan System) “ 27

Selection Curves for High-Pressure RD Blowers forFuture SES Lift Fan Applications 3~

Performance of RD No. 92-.55-1.09 Neuair Blower 32/

General Arrangement Drawing of Neuair Blower RD 33

20

21No. 92-.55-1.09

,.

.“

i,!

11, . ....—

Table No.-—

MPS Lift System Performance l~equirements—

MPS Lift System Performance Requirements2. (15,000 LT) 7

RD Fans 123. Reference List of Typical Neu Heavy-Duty—

—

.

. .. ... . ,.. . .,,

—

,, iv—.—

‘5” —.- --.--.-..,.....-.--—..—.-.,——.-—-......—.,.—,-. .. . . . .. . ., .>... ..... ...

—

—

-—

—

—

—

.

—

.

—-

—

!,,_

.

() ... ---)

I.NTRODUCTION,..

:,

.,

The Naval Sea Systems Command of the U.S. Navy is currently taking anew look at Surface Effect Ships (SES), for a range of missions and sizes(!xtcl~diL~~from patrol ships (under 100-ton displacement) to large logistictransports (10 to 15,000 tons).

The Navy’s interests are addressing foremost tilesl~ort- to mid–termLime-frame and searching questions are being asked about technical risks ofSES development programs, especially for large ships. What distinguishestileSKS from the conventional ship is the presence of the air bubble “on whichjt ri.dcs. To many traditional naval engineers, tl~e.develo[jllle~~t,fabricationand installation of the air moving machinery which creates and maintainsthis air bubble is an unfamiliar technology, which they view with apprehen-sion, because of the lack of experience in this area in the Navyts past:JIId present fleet.

For example, in the MPS study performed by the Navy a couple of yearsago , AcIT()~liysIcs colllpilIly/N~u L_!Cll~~~[U~Lll l.LfL filllS of 11)(J!{OLilL~l)~ 1)1[].’USC!~

type were proposed and,presented as being low-risk, state-of-the-art techno-logy . These fans, witk an outside diameter of 8.3 ft, are absorbing 7,000Horsepower, and delivering 350,000 cubic feet per minute at a pressure riseof ‘1O(Iinches W.G. (520 potinds per square foot). By comparison, existingIi[”[I’;J1]systems for SES (the 100-A, the 1OO-B, the 111]-200,the LCAC, for

example) operate at cushion pressures one-quarter that of the PIPS fans andat powers that are an order’ of magnitude smaller, as illustrated in Figure 1.It is interesting to note that all current ACV or SES machines operate nearthe upper limit of the state-of-the-art of backward-inclined centrifugal fans.Therefore, questions have been asked about the “low-risk” statement concern-ing RD lift fans, made in the MPS study. :. ;.,

‘I’hepurpose of this report is to s~pplement the information providedin the MPS report about the “credibility of the MPS lift fan system. Theopportunity is also taken to show the higher limit of pressure” rise currentlyavaili.lble, using RD fans; over the MPS duty point. It is shown that fanpressures twice as high ‘as the MPS (15,000 ton)duty point, can be obtainedfrom off-the-shelf fans.

In the first section of the report, the required characteristics ofEhe ML’S lift fan are recalled, and how they are met by using an Aerophysics/Neu RD 195-.55-1.3-90° fan. In the second section, a list of over one hun-dred industrial fan wheels installed by Ets Neu in the past fifteen yearsi.nsteel plants around the world is presented and summarized in table 111.‘1’lleduty point for each of these fans is shown on figure$6 and comparedwith the 10,000-ton MDC fan duty point; most importantly, each of the 14fan systems shown on figure 6 (for which a total of 98 wheels were furnished)belong to the same class of fabrication as the MPS fan (referred to by Neu——.onclAerophysics as Class 111s).

Photographs of a few of the fan wheels listed in table III, which hap-pened to be in the Neu-Lillq shop for overhaul at the time of the latest

Novcnher 1983 visit by Navy representatives, are also shown. Also shown iss

,,

:,,

,.

.,,

.,.,.

1

i “’ ‘“” ‘; :--:,..,..,. ,, . . . .. . . .... . .— .. ..— -—----- ~,.---.-— --— ~.,,:.. . . .

‘—

,.

,—

+,..

4000

“\

) 2$..T FA.- -. ..

.

.... . . .

.

,..,.

. .. .

.

--- /

\

. .... ... .,.. .

.. ....

—...- . -.

,.

.. . .

.. .-..

+’--- --

\\

I‘\

~..4“‘ ‘O. i

~\0(

Ffifvs ( t.) ’-,———,

ISKS Es(t#..... ... . ..

,“VOK SES I\

‘“\”’ i ‘“, \, ,, ,’ -.. :.

\

\

.SES IOOA’

I

—.-~~ >

JzF.F ~ /-.

TEFF B

“-=+-=.-. .3ZN 0 ... .

. . . . . . . 4------, v&~:: ~

,. .\

“\

. . . . . ---

\. . . . — .. . .—.

.—.. _.

\

)00

.

u R— .

--T..-.\‘L

. .

. .

—. .

Es.-\\

..

.

..

,.

\‘\

—

-----

. .

-.—..

\ \

$kj

\

—

P5.

Ml

.

‘-’%.----&----.-:.,

\\—

-.

1000

. .- . .. . .

., -. . ..\

\

“\-7 V’WD .lZLHUoLOqY.

\--___

,— it!. .

. ....

‘)4\~\..

.-—

.....-

-----.Q’—-,.

‘\

---

.— ------..-

.-—-. —.—.

-HM :

. . . . ● .

\.

“. ..-.

\

-- . . .- .-—-

,—

—

.- \o ,0

FLOW, CFS.I

I

(

—’

.-.

—

-.

—-

—

.

—

.

.

.

.

..—

—

—

.—

—

---

LI]Cfull-scale performance of two of the typical fans of table III. In the ‘,”,third section (figure 7), a list of Neu fan wheels is shown , which extendsto pressures in excess of those required for the MPS lift fan (15,000 ton).However, this chart (figure 7) must be used with caution, because it does11OLshow fans of the same class of fabrication as the proposed MPS fans.111tilefourth section pressure-flow maps of offi-the-shelf RD blowers ~per-:It.i]lgat pressures twice those required for the ME’S duty are shown (figure 18).T]lisextends the avafJa’ble family of RD blowers usable for RD fans to totalpressures in excess o’f1,500 pounds per square foot.

It is therefore concluded chat the statements made earlier in theMI’S report about the availability of industrial RD fan technology to,meetlarge SES fan needs are fully justified.

. . .. . ,, .’,,’, .,

.. . ,,.

,., ., .,

,.

,,

.3 ,..

“

...--— .... . . . . ; .— . .._—-.__. . ., ..... .. . . . ... .. ........ ..... ... . ....,

—“

.

—

—

—

—

—

.

“-

—

—

. .

—

:-—

It

1. ‘1’klEPROPOSED MPS LIFT FAN (10,000 AND 15,000 TONS)

,.

The Aerophysics-proposed RD fan system for the MPS ship was presentedin Aerophysics Company Report 80-93-1 and later incorporated into a Navyreport. One of the interesting problems of the MPS mission, as stated in1980, was to have a common fan for a 10,000-ton and for a 15,000-ton ship,the increased pressure requirements of the 15,000-ton ship being accommo-dated by an increase in fan RPM and the increased flow by a greater numberof fan modules, if necessary.

The proposed Aerophysics fan was a Double Width Double Inlet (DWDI)series 195-0.55-1.3-90° fan. The nomenclature is as follows:

195 stands for the blade diameter of the fan, in centimeters

0.55 is the ratio of the inlet eye diameter to the b.lade diameter

1.3 is the ratio of the rotating diffuser (or overall diameter) tothe+blade diun]cter

90° is the blade angle at its tip of discharge (~z). In this case, theblade is radial.

The performance of the proposed RD wheel is shown, in non-dimensionalpressure-flow coefficients, as figure 2, where it is shown that the same fan

can accommodate, with good efficiency, both the 10,000-ton and the 15iOOO-ton duties. For a definition of the non-dimensional pressure and flow co-efficients Cp and Cd, the reader is referred to Aerophysics Company Report80-93-1.

The lift system requirements for the MPS are shown on’table I for the10,000-ton ship and table 11 for the 15,000-ton ship.

TWO pictures of Neu industrial fans vith duties similar to that of theMPSfan wer> shown in the Navy report and are reproduced here as’figures 3and 4? Note that the first one operates at a pressure rise similar to th?tof the MPS, while the second one-,aforced draft fan for an electrical- ‘

generation power plant - operates at a much lower pressure rise than the!IPSfan (47 in. W.C. against, 107 in. W.G.).

A side view of the MPS lift fan is shown as figure 5.

,,

,,

.,k, ..

,.., 4

,-~. .,. - . ...-T—- -—— —— --.- .—------- -------- - ------ -- —. -:- —,----- --- ;. . .7

1, *,

—

“>. . ,,..

!,

,.

;,, .’. . .

GENERAL PERFORMANCE OF FULL SIZE RD WHEEL

: .06-3mm2 .04-(L-1

2s’ .02-

15,0$)0 T DISPLACEMENT 10,000 T DISPLACEME)JT# . . AH’

,1

,“

...,

&4ik”8:’’-.80

-+---

1 -—-<o~o,.-,~_ -——

\ ~ W’=”45.I ‘k ,4

IGV SETTING ‘- -60° “50°,$

.30= ‘

S = SEALSC = CUSHION

L

&I 1

0t I [

.10I

.20 .30I

.40I

.50 .60 .70 .80

,,,

,.,

1,,

,..,

....,4

....:.

.,,

,.

:,.

,,

.,

i.5“

.. :,’;..’ — .—,- ~ ,---......... . . ..:,.,..,,, ‘. ./,. “’., .,,. .!’, .-! t.. .--. —.. .-...——-. -_,, r

-...... . .

(

—

—

—

.

.

—

—.

—

—

.

—

—

.

—

m’S LI??T SYS TM PE.XFOWCE PJQUI~~S

‘(lo,000 LT)

:,. ”

:,,. .....

,. ... !

:’. , !: . . .

sIj~-:;y~’r~.(I SEALS

7CUSHION

J1O. OF DWD1 R,DLIFT FANS4“ 2

>:0. OF IN~TS8 4

,!lo[{:;E POWR AV+;~u/IlmT43500 3500

PS STATIC, FSF . 514 467‘T TOTAL, PSF ;55.

504 ~DELIVEUD FLOW/I~T, ‘CF$ .

291.7 ~ 3120TOTJU FLOW IN “CUSHION, ‘CFS

12480TOTAL FLOW IN B& SE&S, CFS “

23336 .-TOTAL FLOW/ SHIP , CFS

35815 ‘

>t , TOTAL PIU?SS~ COEFFICI~.0970 .0881

cd‘ FLOW COEFFICIENT:551 ,584

x~, TOTAL Efficiency.865 .825

XGV BLADE SEmING, DEfJ~Es ,. .“-9 -16 ~

SLOP E OF pERFOW~ c~~ .STABLE STABLE

I

TIP SPEED, FT/sECO~ ‘

< * 549 “

R?>l, ENGINE - FAN1350 - 1639

GZ.IR lUiTIO REQUIUD* a. ,

,.

J.. L14I

. . 1

,.

.,.. . .,,, . . .L.., .,,,. .,

,.’

TABLE I, -’

1 ‘ - ~~~~~~

., ,., ..’ ., W,:,.’, ,

-.., .,., .,, .,’, ., .. . ,. .,,. , .,L r 1. ....- .,,.!> ‘.,’!) !!.;,,:. ., ./ .,. . , ,-, --,.-, --- ,—----------- .--. ..-.---., .-?” -.-- *:.— ---y ~

.< .”’” . . ,. , ,, f

>,. .,.

,..,.

,.7

,.,

,,”’, ,<

.

‘—

,,.

—

—

.

,.—

—.

—

1

-

.

—

—

---

.-

q .-, —

. .,,

MPS LIFT SYSTEkfPERFOWCE REQUI~NTS ‘(15>000 LT)

“

,., ., ,:,,’, ...

‘, .,,

.;., .,. ,

. . . . . .i.,.!

,,. .

‘,.,, .,

<..

.-’, . . . . . . ., ....,,. .---. —...._ ,.

. . . .. . ..—. --- , ‘—- .--.—. .—

TABLE 11........_

,,.,

. .,.7

..- --y -7:..,,,,,~,1.,.,,., ..:,,,,.,,.....,,, ---,:,...’ ...!.,.. ...-., ,., .:,. . .

; .. . --...—.—— , .— .... .~! -. ~.” ,

,,—

—

—

—

1

—

.“)1

‘,\.,’

‘.”

M[~s’JypELIFT FAN DURIPJG

.,

,.

.,

NSTALLAT ON

., .,.,,,. ,,,,,,.,.

.,. ”

FIGURE; 3— .

i

..:,..-. . .. ..... ...... .-.., ..

~..hd

*.4

I

/.. .

,

,:.!.,,

;.,.”!,,

,,

,... ,.-,.— 8.—

/

.,,

.:,.

,,’, ,

‘..,.

.,1,!,.

,’

i ——. . . . ... ... 4 ,,, ,,, : ,,, ,.,, .l ,.,. .,, ,. ..,.,;..,.. . . .. . . . : , :, . —.

,.:.. . ,, ..,. !. . ...”. ..,, ,,. ; ,,

‘}.

—

—

—

—

—

.

—

.

.

—

—’

—

t,.”

.,,,, ....’ .,.

—-- .,,. ...,. . . .

,.!“,

#\ RO”rARY D FFUSER

,.

. ..4

FAN DUR

.,, . .‘: .’

NG ASSEMBLY t

,.

,, .,. .

,

. .,

,.,.

!.

—

,.:,{

%.“>

!0,.— 9 ,’

.....‘, ........ . ..., -------,, ----.............-~..,.—...-.-,=----.7,.

,..,+-...+...--, c-~ -.——.

j$

i

7

‘,.,,,.,

.’

.,, . ,.

,..

MPS LIFT FAN – SIDE V[EW ‘

,,,., ...,.. .

,,. ..,, ,.11 FT.51N.

., !

,.~

,’ ,’

,, .::;,4, .:,:,..,,.,.,.”,!:..s.

., ,.

/cET%’i“’\’

,—.I. =L-7--. L. .lJ-LA_iiL. -.L -——kf=-l -- I I

. . ------- ---------+ #/“I ---

------ -------

//

,. -----

.-

- ““”--’10

,,.>

,.,,,

.,

.,,,.

:-;.1’:.,..>i ...

..

..,.,

.$)

!. ;

;

-----n-_--_, .,— .— ---- .——... ..... . ------ ... .... . . ,-.,..-. .—=—

—

—

—

—

.

!,

,—

—

—

—

—

—

—

—

.

—

—

—

—

—

‘J -’>. —...— -— _——.-.—. — —...——

II.. STATE-OI?-T1lE-ARTOF INDUS’lRIAL RI)FANSIN THE MPS (lo,ooo-’roN) Dufry RANGE

,,.

:1. Customersl List of”Recent Industrial RD fan Installations

During a trip to Ets Neu, in Line, France, in November 1983, by

G. Boehler of Aerophysics, and W. White of NAVSEA, a review was made of thelist of references of Neu industrial RD fan ~.nstallation of the last 15 years.A table, shown here as table III, was prepared of fan installations withpressure and flow characteristics similar to those of the MPS, e.g. pressurer.L:;cs aroun 100 in. W.G. and flows around 300 to 400,000 cfm., Sixteen suchinst{ll.1.atl.onsare listed in table III. They cover sizes between 185 and307 cm. blade diameters (the MPS fan blade diameter is 195 cm), pressurebetween 75 and 130 in. W.G. (the MPS pressure rise is 107 in. W.G.) and flowsl)utwc~cn100,000, CFM and about 800,000 CFM. ,.

‘I’heindustrial fans listed in table III were designed for variableoperating temperatures, which could be as high as 1000”F. The pressure

rise of a fan is proportional to the density of the fluid which it handles.‘1’l]c.rcfore,if at high temperature the density of the fluid is only halfthat at standard conditions, the pressure rise at 1000”C is twice thatrequired under standard conditions. Therefore, the performance of variousfans can only be compared meaningfully under the same inlet flow conditions.Therefore, the performance of the 16 ,fans bhown on table 111 was recalculatedfor “standard” conditions (corresponding to a fluid density of 1.2 kg/m3),for the point of’maximum efficiency, and is based on the performance curvesof each fan developed by Ets. Neu”over the last 30 years,

Each of the fans of table III is a so-called “heavy duty” fan, e.g.one operating in a difficult environment: high temperatures, with flyingashes going through.the fan, large temperature gradients> etc”> and underfull-time duty conditions: 24 hours a day, usually 360 days of the year.As far as is known, every one of the 16 fans of table 111 is currentlyoperating, and none has ever failed during operation. For Example, No. 12(Arbed) and No. 13 (Solmer) have been operating continuously for 10 years,except for yearly shut-down of the plant. These two installations arealso the largest RD wheels ever built by Neu (307 cm. dia., 57% largerthan the proposed MPS “lift fan) and operate at a higher pressure rise thanthe MPS fan (120 in. W.G. against 107 in. W.G.). The 307-cm wheel is theone that is shown on figure 2 of this report. Figure 6 shows a pressure-

flow duty point (at the design point) for 14.of the 16 fans shown in tableTTT. It compares these duty point with thos& of the MPS 10,000 ton lift

fan (and, for further comparison, of the Ml}S 15,000-ton and of the oldRohr 3KSES). . Most importantly, all fans shown on figure 6 are,wdesignedto identical structural and fabrication criteria, corresponding to RD fanheavy duty. In the Neu-Aerophysics nomenclature, this corresponds to theclass of fabrication III-s and the class of quality Q1. Because of the

importance of this point, it is elaborated on further here.

,.

.. . .,.,1

11

JOBNUMBER

1.E3.74

L3.E3.76

8.E3.75

3.V3.79

!l.E3.76

:4.E3.77

:0.V3.79,,

5.E3.76

3.E2.74

8.E2.74

9.E2.75

~09x2,71

4LE2.71

27.E3.77

l&”E3.75

13.E3.77

LOCATION OFINSTALLATION

HUTA KATOWICI

ITALSIDERTARENTE ;..

METALLURGIENOWDY

USINORDUNKERQUE

HBL-CARLING(COKE PLANT)

V.Z.K.G.

SACILORROMBAS

SACILORJOEUF

POSCO KOREA

TAIW&T

TMM CHARLEROY

ARBED BELVAL

SOL*~R FOS

USINORDUNKERQUE

SOLLACKNUTANGE

HAINAUTSAMBE

1

TABLE III: P&FERENCE LIST OF TYPICAL NEU HEAVY-DUTY RD FANS

FAN TYPE NUMBER DATE OF CLASS T3:PE

r

ROT

OF WHEELS INITIAL OF OF Rylj

DELIVERED FABRIC- FABRI- STEEL

RD 218-.65-1.2

‘RD 200-.55-1.3

RD 185-.5-1.3

RD 220-/55-109

RD 185-.38-1.2

RD 220-.38-1.2

RD 200-.6-1.2

RD 200-.65-1.3

RD 260-.6-1.3

RD 240-.6-1.3

RD 307-.5-1.3

RD 307-.55-1.3

RD 307-.55-1.3

RD 185-;55-1.2

RD”280-.5+..3(S)

RD 280-.53-1.2

18

10

6

2

3

2

10

8

2

4

4

8

8

4

6

6

,.

@f?L@Tg&!_1976

1977

1976

1979

1977

1962

1962

1969

1976

1976

1977

‘1973

1973

1973

.1965

1975

111s

111s

11s

111s

111s

111s

111s

111s

111s

111s

111s

111s

111s

111s

111s

11s

18M5f

A42c1

18$fif

18M5f

A42C1

A42C1

A42C1

A42C1

A42C1

A42c1

A42C1

A42C1

A42C1

A42Cl

A42c1

A42Cl

PJ-1500

1500

1500

1500

1500

1500

1500

1500

1200

1200

1000

1000

1000

1450

1000

1000

Blad{Tip

%

171

186

165

170

154

174

160

155

160

159

173

171

181

142

152

153

.TIONAL SPEEDS PERFOFWWCE,Diffuse STD CTip

1#==-

eed

203

203

186.

186

171

190

188

203

211

193

209

209

209

171

189

175

AP>in. 1

105.

127.

100.

106.

88.

112.

93.

86.

93.

92.

110.

107.

120.

74.

85.

86.

. ... .. . .

NDI.TIONS

Q.:.ave.,Fl cfm*

489,000

331,000

208,000

373-,-000

103,000

147,000

351,000

214,000

574,000

485,000

610,000

727,000

770,000

213,000

225,000

502,000

‘1...

In the design of RD fans, there are 4 “classes” of fabrication:11s, 1.1s,.IVS and I.VC,this for a wheel of given geometry and size.class Is corresponds to “light” duty and Class 111s to “heavy duty”, asclefine above (continuous operation for a year, adverse environment, etc.).Classe IVS and IVC are applicable to “compressor” duty, meaning pressurer:ises etween 200 and 300 in. W.G., which are currently way above anyrange f interest for SES. All RD fans are bent sheet metal welded struc-tures The class of fabrication therefore depends upon two major elements:tl~ebasic material used and the quality control of the manufacturingoperation, especially of the welds (a derivative element is the strengthof the structure, i.e. the thickness of blades and shrouds). It iS ofgreat interest to note in table 3 that the material used in the majorityof Neu heavy-duty fans is ordinary steel (A42c1, which corresponds toASTM A515. gr. 60, in the U.S.). In fact, the highest-performance fans,i.e. No. 12 (Arbed) and 13 (Solmer) are made of ordinary steel. Theother steel used is 18 M 5 f, which is a relatively high strength steel,

CCIUIVUleiIt to the CORTENC in ~11~Us.. Both are very easy to weld.

The detailed quality control characteristics of class 111s fabri-cation for an 10 fan are available from Aerophysics and are summarizedhere, as follows:

1. Materialsi

All materials’ entering into the fabrication of the fan are identi- “fied and controlled individually when received. The supplier isrequired to provide a certificate of chemical analysis and ofmechanical characteristics for each lot, as well as an overalll’control certificate’t. Weld materials are subjected to strictspecifications , which must also be certified in writing by thesupplier. Suppliers must meet a particular specification forforged materials. ~

..--— ,.-,.—..— . ... .... ---- ..... ,.-.-—.

#“ I,.,.. -

. .I

..—.

I I

200

.,,“.

.

,.

,,

. . .

. .

NOTE:w“~

I [ I

p=l.2 kg/m3

hLL FAN SYSTEMS SHOWN HERE AREHEAVY DUTY, CLASS III-S FANS

I I

.—

—

—

—

—

,—

—

.

—

—

,—

—

—

..

.

,_

i~ ~.

I

i-—

—.

2.

.

.

.

.

3.

.

.

.

4.

.

.

5.

.,~,,.. .. ...{. ,,, ,; ,,/,, ..”

Fabrication processes

any subcontracted ”item requires from the subcontractor submissionof detailed procedures , which must be approved by us ,,

,..,.When a new fan goes into the shop, a meeting between engineering,quality control and shop personnel (welders) must take place andwelding procedures approved for that particular job.

.,,. “All welders are certified by a State organization. In addition,each welder must be certified individually, in-house, for eachclass of fabrication. Only a fraction of the welders are certi-fied for Class 111 fabrication.

.,,,. .,. *.All,welders must comply with a detailed specification about thequali’t’yof welds (minimum number of passes as a function of metalthicknesg, etc.).

Quality Control .,,,‘,....-’,’ ,’. ,~.,

All welds are: ‘.,7..,, ..,‘,

,.’.:)’;:“.. ,.:.., I .. ,’:..,.

,v>$aually’”.$nspected;:“ ‘“‘,..,?;~.,.,>,..

.,,.,. ,,. ,,,.-.~fi,,:.’:,. .:,: ‘.’ ‘!. . :.‘subject to sweatingY in accordance with a specification, preceded ‘by sand blasting, if therb has been previous heat treat. A writtenreport is required,,:’:.,...:,~::.’,(,..., I

,:, ,) {, :., . . .

X-rays, both before and after assembly.’ A written report is ‘required

.,, ,,..:::::.},::,,!

., .,.,,.,,

,’,.. .,

‘Vi6ualcheck-Of’””surfaceconditionsand’ofcleanlinessOf the air “passages ,,\,:’”,,,:./,. ,’,./.......”!. .,.., ,.,.,;;,,,,. ..’,..,4,.,s..check dimensions’ against’ drawings: check direction of rdtation.Awritten report must show actual measured dimensions.,,,.., ,: ,,;,;,.

Heat treating ‘,,,;:,;,’;l:., : ,“ ,’ ,,.’,

The heat treating cycle is as”’follows::<{...:,,.’......,;

,:.,,”:‘;”!>,:,,,~,.., ‘,’,.::......““ ,’,.,,..Increase heat~at 150°C/hr -“’up to ’600°C*”““Stayat 600”c * 10for:one ’hour ,“ ,,

::,,.,.:4,.,..:.,.,..:..>,,,,!,!:<<.,$:‘[., ,

Cooling unitl 300°C in the oven at the rate of 50°/hr, then coolingin’ambient air. A report on the heat treat cycfe must be furnished.

.,, .,. ,,, ,, .,, ,,:,,.., . ..,,,,,. .,:2.,.. ,,” ,$ .,, !, .: ‘,,’1,., .’.- .,:,, ,, .:, ”

Dynamic balancing”is performed”in accordance with the Companyspecification (not reproduced here). Balancing masses must beadded in accordance with Company Specification. A special formmust be filled up,.,

, !,,., ,,..?;.:{.,l..., ..’,:..,,,.,.:,,,..... ,.:.i,:,f:il;Y,,Tf,,. , .,.L,,.,,.,;’;’ “,>.,~,,..:.:..,, ,..$<!... .. . 1.:,<,<;,,(,.~\,(..,. . t,:.......-l.:},’~ .,,.,+..,,,,.,’; ,’‘,..,,),!,}.,..:*..,. !.,

,....:<,,.,,:.,.

!.

,

I

—

.

.

.

—

.

.

.

—

—

—

—

—

i.

—

:,.

c1 .-’----3/ D —- .—r’---Lql’()[>llyslcs

!,,.. ,

,. .,:

Based on the showings of figure 6, it is’clear that the technology “embodied in our class 111s fabrication is fully adequate for SES lift fansystems for the 10,000-ton SES ship, as currently contemplated. Again,every single fan shown on figure 6 was built ‘to the same structural and en-vironmental s~andards as the proposed MPS fan and forty (40) of the fansshown on figure,6 have duties, in both pressure and flow, that equal orexceed the duty of the,10,000-ton MPS fan.

2. Photographs of Typical Fan Wheels

During the trip to Ets Neu,.h Li.lle, France, in november,1983,Mr. W. White of NAVSEA had the opportunity to photograph severa~” RD wheels,which happened to be in the Neu shop for repair or overhaul or as spares.Some of these photographs are shown here, with the other visitors, Mrs.White and G. Boehler, to show the “scale” of the fans.

:.

As sta~ed earlier, the most interesting RI)fan in terms of the MPSduty, is the ,jUl307-.5-1.3, ‘lArbed-Belval” shown as No. 12 on table III.‘1’hreephotographs of this fan wheel are shown, as figures 7, 8 and 9.Another earlier version of the same fan (Rombas) is shown on figure 10.The rusty-colored fan of figure 10 has about 50,000 hours of operation ina hot, dusty,environment. Shown on figure 11 is a slightly smaller fan(11 ft outer diameter, instead of 13 ft, forthe Belval fan), which issingle width, instead of double width. This fan is of interest becauseit is built entirely of stainless steel. It is not shown on table III,which includes fans made of ordinary steel.

., ,.,.The fan shown on figures 12 and 13 is interesting, because it repre-

sents a sery advanced technology. It is not an RD fan, but a “pellet” fan,designed as an induced-draft blower for chains of pelletization (the manu-facture of pellets of iron ore, in such places as the Mesabi range inMinnesota). Its diameter is 17 feet and it weighs 15 tons. It is designedto operate continuously at high temperatures and under high temperature

.,,

gradients.;,:...‘“’!,,: / ,?’,,.,.

Finally; the fa~”wheel shownSacilor Joeuf. It is of’interest,with the fan chosen as the Rohr 3K

3. Performance of two typical fan

,,

on fi”gure 14 is No. 8, on table III:because it is of identical geometrySES back-up lift fan.

wheels:

The full-scale’ performance of the Belval fan (No. 12 on table 3 and

figures 7, 8 and 9) is shown on figure 15, which is a pressure-flow mapfor various Inlet Guide vane angles (0° is fully open, 90° fully closed),together with constant-efficiency curves.

@

The performance of the SWSI stainless steel fan of figure 11 (Saulnes-Uckange) is shown on figure 16.

...

i.,.,—

—. ....T‘5 ~..--,- \-:,T-:.,.....,-,,.,.... ....7 “---~~~;-;-. ~. .k,

—

,

—

.

.—

.

.-.

—

.

—

—

—

.

—

—

—

.,

i.’

Fi}j[lr(: ~: Close-u]> l’liotograpl~of Inlet of RD F~n Wllecl 307-.55-1.3(Fan No. 1.2oq Table 111)

17,.

.. -&t,;

.—.. .

———.

—.——.—..———.

—

f)““=

2-.c

(&-ll)J,yhJc&

—,

—

,,;;..,,,,-.J;’““

‘~..,.!,

,,,,,,

..,

\,.

.,

-..+,

.,.,

.Me#?

??

’w

“’,,

.,‘1

--

,.,.

/

m.r+

tiu-l.

w01+aJ

!-l

.3x

...

...

..—

.,.

,

>.>

——‘———.———————I/

—’

.’..’....,

,,”.:...-

;..:

,..;:,..’ ‘-..

,,...

....

,......

.

Y .: ”..

.nuHH.

m.

%-+

Cn

,“

.,

m

,,,,.10

t.’”.L

7...

,.,

i~.

,.,,’.

”.’.

~-.-—.

—----

r

-—,

—,

—,

—.

—-

————.————————

r

.,,

..

,,

,,

,...,,

+$m’.

.r-l

,..,,

G.,

,.

.my“mIn

.

,1

hom.

J

.....

J,<.,

.,

,\,

..0l-l

..—.

.._.,___

20.—

=%

__..,

.,

.

!I I [ [ I 1 I [ I I [ I I j { I 1.

r

Figure ’11: Photograph of Stainless Steel Fan Wheel, 280-.5-1.3(s) ( .~zfb-l%ea~

(, U&.t.c.)

!

i

I

Mm

Figure 12: r4..y’Photograph of UNIPEL Wheel, ~ ft Diameter (Duty Point Shown on Figure 17).

?’+, 7,

(

I1 { { / i i I I

Figure 13:!.

Overall Photograph of =fi Diameter UNIpEL;’wheel

IL

I I

r-

..

=.

‘q,.

,,.,.

I1----1

,;I

,....

.”:.,”,

.,.

—

—.

—.4.,

.,.

—,—,

\ \IIII{

1I--

-.---”---

----

;I

-.-..-—

–..–--

-i..L

–--–_

t

-----------

-.,

\ 1

-..—

—

““\~

\\

—.—

-—‘,

\

k“

...

.....

,,‘k—

——

._—_

_______

__

—.-

\

‘\\

.—’\\

“:

\

\c

\o

!

\.-

~--—

\~

I

\1

-—\\

$II 1 -—

—

i

\/\v/—

.—

____,/ /’\,

,i

,/”‘,

.—.

-,/

Ii-,~

--~\

-..

——

---

—.—

____

\

k,--Q

.’%!

it””..

+2

.....

r,

..

,,.,

,“,,-’

,..

——

#.

...-.—..

...

...

——

—

........

..-—-

.-—

----

1\

.,,,....

...

........:‘

72.

.,..

....-

Cm-

-1

1-

,,,..

—.

—‘321

,1

1.!

.,..

!.

23C’

-3 —

I I { { { ( [ [ i’

Figure 14: photograph of RI)Fan Wheel 200-.65-1,3 (No. 8 on Table III).

7

I

...

.-4—

—(’.-

-------..A

-...-

-.-~

~.

...-_

..

I1I

.———

——

—w

_-

—-~

—-

-

—.-”

.-.——-——-

—.

—-

—-

1;.

,,..

t,,’,

”:’

bj:,.’,

,1

$I

,,“’

;.

.....;

.,.,

II

‘+’

;//]>

PI”

‘m!

.Q

1““:~

/$”:’i.P

1~

W..

...1.

,..,

.;.,,,,.-

y-.

:’.:’

.,....

1“,,.

,.’,.

.’.

.,,,.,

..i

,.’j,.,:.,!.,

,:~@

,,:+<1

fj.

?s.

H“

HH“

i-o

+

u-lo

.,

._.

L,—,..—“

—’

.—

,,....

,

.’:!.’,

..,

. Q,,

,-

/

,, ’.,’..,,,,,, ,,,,,, ...... ’.,,,,,,,f? w. .,: -,:”., !, ,, t

~ ,,,

,“’.-,. ,,1~1: :,

.,!.

.:,~’,: ; ;:, :i ; :’1 *,’.,, .:.. .... .. . .’ z .% ‘? ’.. “) ,.

‘..’

1:.:,:’

~........$’..!’.. f<,,’,,,,.,

.... .... ...

As’”faas the design of ~he 15,000-ton SES f~~,,~,sconcerned (a fan’”‘ ,“8:.

that could m et”the 10,000-ton requirement, but alsc!.,a”pressure rise ofL50 IN. W.G., instead of 10~ in. W.G. at a somewhat keduced flow),~4+am&;:hereare n ,fans in the steel industry $a}]rcssure ..‘ The reapon is no~ that ~ .;~;;r~~’~~~~~r~~~ $~~~~~e:;tcci Industry has no need for ~ heavy-duty fan~requiring that~pris’surerise. However, the chemical industry has needed higher pressures for along time, usually with smaller airflows than those in the steel industry.‘therefore,figure~ was~~~~~~ed. It shows a range of operational Neu fans,and includes w types tha-nheavy-duty steel fans, to show what has beenbuilt to date altogether! The following points relevant to figure% l%cullbe made: ,,

....,.,,, ,,.

,.There exists a number of RD=fan installations, which have operated,,’-for a nuWber of.years, that nave higher pressure ratios than che ‘. :.15.000-ton SES lift fan: ..,,” .“;..,

.. . ...---—● Orenbourg, 23,000 cfm● Ach4res,. 41iOO0 cfm ... APC Rouen, 115,000 cfm

,.!,. Prahovo, 150,000 cfm ‘.

., .. ,,.., INote that the.Prahovo unit”is a Single-Width-Single-Inlet (SWSI) “

fan> producing 150,000 cfm. All that is needed is to build the sameunit as a Double Width-Double-Inlet (DWDI)fan, and the cfm will be 300,(,)C)O”Cfm, which is more than the required duty for the MPS 15,000-ton Iif”t~an.

.,. ,~,’,..It may also be noted that ’technology of RD fans allows, fabrication “’

of wheels Up to 4-meter. diameter (the largest’ ones built to-day beingModel 307). They were .not builtj because industry has had no need for it.What industry preferes to do is to put two fans in parallel, for a givenduty, und shut down one fan when the plant is operating at re~ced load.In addition, transportation and installation problems becoke more severe~ur frill sizes much above 3 meters in diame~er.

.,

,,,,.,x,.,

.’.,:,. i,,

,.

\

‘,

i

i

.

Ir

.4

----.-.

:@=

---

h’

1I:-1’

It-m _..

I

,-— —-

[ I I I ( I [ I I I I [ I I I I 1’ l-’. .

>

>.

:.. .

1.. .

“..

Figure 18: Photograph of RD Fan Wheel 100-.7-1.2 (Model Fan for MPS Lift Fan System) During Fabrication

..:.

,.. ”... . ,, ., ., .:,... ,,, ... .,

,,.. , ,, .,.

For planning purposes, the U.S. Navy is interested In cushion(and therefore fan) pressures much higher than those proposed for theMPS (for example, for catamaran SES configurations). A brief set ofselection curves is shown on figure 19 to show the available range ofNeu RD “blowers”. ?

\

,,,..’It is useful to mention here that, in standard rotating’machinery

termin logy’ ‘pressure-rising equiFaent at low pressure ratios (between1 and ,#or example) is called “fans”; for intermediate pressure ra-

/

ties (between and 2) it is called “blowers”. Above a pressure ratioof 2, it i called “compressors”. Therefore, strictly speaking, thefans ,$j&5ussed in this report in connection with the MPS should bec~l.1-edblowers. However, the above definitions are rather loose, and it3s felt that to introduce the name of “blower” for current SI%Slift fanapplications could be confusing.

However, one is talking in this section of pressure ratios above1.5. Therefore, it would be stretching the convention a little’ tocall the equipment “fans”. Also, to avoid the use of.large numbers, itis conventional to express pressures in pounds per square inch, insteadof pounds per square ‘foot (1 pound per square inch equals 144.pounds persquare foot).

: ,, .’

. ..”.

About eight years ago, the decision was made by Neuair, Inc., ajoint subsidiary of Aerophysics Company and of Ets. Neu, to sponsor thedevelopment of a family of modular blowers. Ten sizes were selected,with blade diameters between 55 cm (labelled ’’’No.55”) and 120 cm.All wheel. were of the RD type and were aerodynamically identical, witha proportion ‘of 0.55 and a diffuser ratio of 1.09.

“,1 ..!, *A summary chart of the pressure-flow characteristics of the 10-

blower family is shown on figure 19. It can be seen that the familycovers airflows between and pressures :b”etween6:psig[?~~~t 900 pounds’pe’r sq &~;;--16fiO’”psf)’~”’A=nual.— .-.-—..is available from Aerophysics, showing the performance of each blower..—.

As an example,. suppose that a blower is to be chosen to supplya total pressure rise of 1300 psf (about 9 psig) with a correspondingflow of 45,000 cfm. This is shown as point A on figure 19. Therefore,an RD blower No. 92 is chosen. In turn, the detailed performance of

blower No. 92,is show,on figuye 20. The general configuration of thisblower is shown’on figure 21. It can be seen that t~e No. 92 fansized for the above duty rotates at 5440 ~pm and absorbs approximately2,250 Horsepower.

.. .. ,,

,(; .

,.:,

— “ [—-a&F ““‘I ,,,.,,.. ,,,

—

—mm C

8000

7000

6000

—5000

. 4000

I 3000—

I

t

2000

I000

—

,,.

6—--+XV+XV’ Yw Y

- ..__... ,-

> .,. -

‘i: ...

\,!

;, ...4 ,4 !’.’

II !., ,, I:,, ; ,,., , ,. , ;,,;.,: , !4; .,,:,,.,.,,:.,‘,,:,:. ; ‘,!::.,4,. !’,,, ,.

~,’,.; ,. .,, ~, L-’; > .:,:,;.:!. ,. ,.:. ... , ,,,’,,“4!;. : :,.;:”<,-,.,:].. ,: .”!’.,, ,’.. ,:/, ,, ,,..., ,;

2—...—_.., ., .’,,:,... ,,

1!,,,,:.‘: , ‘~: , ;,:j;!’.’, ,“

:’:; (. < ,,/ ,,.,;. ;;i.n,,,.,, f’ ,; ;:’;:’1 “,::,)..,,, ,.~,,!! 1 ;,:..!, ... ..(!,, I

10 .:”:,, 20;’::, ,, 30“:1: Y;;:;’ ’40 [~~ ~o ; To 80 9i ,, ‘jdI I 9 t

o -. % o,- j. “:;;. “ ;.’: .,... wis’

‘“~ i ‘“’-’~’.’”.’.””,;. ,,, . . . . .,.,,,.,, ,?+W4?

.-...—.. .?.:,,, ,. .:

--.— -— .“.‘.”hdetflow ~

.:

,.,..,

.,1

,,

..:

.’r

r.

=-2+,~~ysic5 .“ ,, .

mm CE

8000

6000’

Sooo

4000!,

,,

3000

2000

iooo

,,

::,,,,,.p

,,>

Psig,—/

,10—

q ,.

,8——.———

.,,

)6—

‘,, ,:, ,j>:.,:. .):,...7 ,’,,,.,,

, ;,,,.,.,,

.4-

,, )i.,,“ 1

.2-

,..,, . . .,, .’. :, ’’,,.,, ., . .,. ‘. .:,., -! r.,. .

Other operating points can be obtained by changing the angle of the inlet guidevunesorby reducingthespeed.

.,,. ...

v

..

,,,.

,,’.

—

—

;.—

—

—

.

-

—

t.-

!,

—

,.. ,

f-/-1 ........L

,,.,,,’.

“H

.,. ,., ’,..

.%77=?i.

i“ti”)\ ‘t--’imim

Dram M. NPIOND W

., , ,:. ... . . ,.,, ,,. ,... .”,,”, ‘J:, .’.,, ., ’.:.. ,,, .,, L v ,.

., ,”...... .. ’’.,,.,, ,. ,,, , .; .,,,, !,,

Figure 21’:“ General Arrangement Drawing’ of’Neuair Blower RD 92-.55-1.09

,..,,,:

.:!,,+

,,.,

;,.:.

,,, ---- ... ... ... .... . . . ,-T--?-.,., ,,, - . . .,,-

,,.-

.. -

.,

I.

I—.

.

1,

I

L

,

.1,’

i.’ -

1 -L

i.

;1

,. .

;:,1

,. -.. . ....~! $

f , ::; “ :;, \ - .-.>.’ ,*‘i? .

d*

‘14.4.6Lift System Risk Assessment

Lift fans - No risk. Rotating Diffuser fans have been built for dutypoints that meet those required for the MPS.Successful fan operation has demonstrated theirreliability “

,.. .,

It is believed that the information contained in this report fully

documents the above claim. It is therefor~ sound to make development plans

for large SES, assuming that the technology base for lift fans exists and

is acceptable.

,.

.,

(. :-4.- —- —.-— .. .._ ——. -.. . .——-. —