High efficient FRP cooling tower fans

The Cooling tower is a type of heat exchanger it transfers process waste heat to the atmosphere.
Circulating water used to reject heat by the airflow generated by cooling tower fans.
At Maya, we manufacture a broad range of FRP cooling tower fans. These fans are energy-efficient and achieve up to 40% power saving.

The cooling tower is Key equipment in all its application.

  • In refineries, equipment use flowing water to cool fluids and absorb process heat. The heat load of such equipment is very high, and operation is not possible without proper disposal of it. So This process water-cooled by Cooling towers for reuse.
  • In power plant cooling tower is large equipment. It required high operating power.
  • In-process and chemical industries machines depend on the tower to maintain is temperature.
  • Building and malls, having cooling tower to reject the heat of airconditioning equipment.

Therefore we should know how efficient is our cooling tower fans? And how to get the best fan for the tower?

We know the operating environment of the cooling tower fan is full of corrosion. It prove fibre-reinforced plastic “FRP” is the best material for cooling tower fans. FRP is light in weight and high in strength as well as it is having excellent resistance to corrosion. So it must be a primary focus to use FRP fan for high efficiency.

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Specification of our cooling tower fan 

Up to 40% power saving in CT fan

Fan Diameter range in foot

Airflow range Up To

Number Of Blades Up to

RPM range up to

Static Pressure in mm of wg

Cooling tower fan Key Feature

Efficiency and performance

  • Fan blades use high-grade fibre reinforced plastic (FRP).
  • High efficient airfoil blade design.
  • Reduction in cooling tower operation cost.
  • High ratio of the coefficient of lift to the coefficient of drag.
  • The aerodynamic hub provided with the fan. It functions like an aeroplane nose.
  • High airflow delivery due to zero re-circulation.
  • The fan surface is mirror finish it delivers laminar flow over the blade length.
  • The option is available for high to the very high-pressure fan.
  • Less power consumption to deliver the same airflow.
  • Low payback period in case of replacement of existing fan.
  • High performance in all weather and environment.
  • Zero Cost Solution for power saving opportunity.

Quality and construction

  • Hollow blade construction Reduce fan weight which reduces starting torque.
  • Lightweight FRP blade increased life of mechanical component i.e. cooling tower fan gearbox, driveshaft, motor, and bearings.
  • Excellent corrosion resistance with consistent performance even after a long time of operation.
  • Cooling tower fan assembly is statically balanced as per ISO 1940 grade 6.3 or 2.5 if required.
  • Small fans of up to 10 feet diameter are dynamically balanced.
  • The fan has reduced vibration due to closed-circuit operation.
  • Long life of fan due to reduced vibration and fatigue.
  • Low noise operation due to laminar flow and less vibration.
  • Updated fan manufacturing Facility and no outsourcing thus better control on quality.
  • The latest technologies used to improve the product and manufacturing process of fans.
  • The option is available for low to very low-noise cooling tower fan, with the blade of up to 1.2-meter chord width.

 

Considering the fan advance feature. We serve for 3 main categories of Mechanical draft cooling tower:

  • Forced draft cooling tower fans.
  • Induced draft crosses flow cooling tower fans.
  • Induced draft counter flow cooling tower fans.

It is also categorized by cooling tower construction –

  • FRP Cooling towers
  • Timber cooling towers
  • Concrete cooling tower
  • Latest introduction Pultrusion cooling tower.

We have our installation in each type of tower on the list.

We are India’s largest fan supplier to the cooling tower manufacturer (OEM).

All the major cooling tower maintenance and repair companies are our associates.

We have expertise in the axial fan blades design we develop more than 100 customized fans.

We have proven track record for power saving in metallic cooling tower fans as well as in conventional FRP cooling tower fans.

Among the fan performance, The blade has the greatest contribution. So to have energy-efficient cooling tower fan it is must to have outperformed fan blades. At Maya, We have more than 100+ different blade design. And the following are the

KEY FEATURE of our FRP BLADES:

Performance

  • Airfoil fan blades (same as aeroplane wing made)
  • We use the most efficient airfoil for blade manufacturing.
  • The blades having hollow construction to reduce the weight.
    The aerodynamic profile in its full blade length. (unlike conventional blade having up to 30 % blank area)
  • Excellent surface finish.
  • High-quality UV protection to achieve a long life of the blade.
  • Single-piece Jointless moulded and Pultruded FRP blades.
  • Uniform air velocity throughout the fan blade.
  • The blade is broad at the shank and reduced toward the tip. It maintains the constant air velocity throughout the length.
  • Excellent twist to width combination achieve high-efficiency.
  • Blades overlap to the aerodynamic hub. It closes the circuit to block the reverse movement of air.
  • Many blade designs are available for different duty points. Each blade design helps to achieve high efficiency at a specific application.

 

Quality

  • Blade having leading-edge protection to avoid erosion.
  • The option is available for stainless steel leading edge.
  • Blades tested for structural stability.
  • Blades can have FR material if required.
  • Replaceable leading edge. (Where leading-edge damaged due to faulty cooling tower drift eliminator.)
  • Blades use anti-static fibre to prevent static charging.
  • Full proof structural design of blade that pass 4 times load test.
  • Blades tested for the proof load.
  • The blade is moment balance so that it can replace when required.
  • Blades tested for track variation.
  • Every new blade design tested under an in-house wind tunnel. A full evaluation of fan performed before launch.

Aerodynamic hub

  • This maintains laminar airflow at the centre of the fan and avoids eddies generation.
  • It is having a high surface finish for smooth airflow.
  • It is having anti-static properties.
  • It seals the fan circuit and avoids air recirculation.
  • It gave freedom to reduce the mechanical hub dimension.

Fan hub / Boss

  • Heavy-duty MS fabricated.
  • Hub is dynamically balanced as per ISO 1940 grade 6.3 or 2.5 if required.
  • The individual part of hub is moment balanced.
  • All the MS part are hot-dip galvanized
    Option for different grade of ss plate is also available.
  • Nut bolt used are of coated HT or stainless steel series.
  • For sea weather application Solvent Free, Self-levelling Coatings are available.

Construction of cooling tower fan component

Blade –

  • Jointless construction with E glass fibre and epoxy resin.
  • The anti-static fibre used for blade manufacturing.
  • All the blades made with core for high load capacity.
  • A combination of various fibre used to achieve superior strength.

Fan Hub/boss –

  • Hot-dip galvanized MS plate or SS plates.
  • FE – 200 cast iron block or Aluminum block.
  • FE – 200 cast iron central bush.
  • Hardware SS163, SS304.

Aerodynamic hubmade of E-glass anti-static fibre, having UV protection. it is available in the segment for ease of transportation.

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Power saving opportunity and scope with energy-saving FRP fans

In power plant cooling tower fans are among the highest energy consumption equipment so even small saving in a fan power is an achievement.

The fan is a cooling tower part that is easiest and cheapest to modify and having a high impact on the performance.

  • Power Saving Against metallic fan is up to 40%
  • Power Saving against conventional FRP fans is up to 25%
  • Power saving against our own fan installed before 2015 is up to 20%

Payback period is as low as 8-3 month

Zero cost solution

FEW OF OUR PRESTIGIOUS COOLING TOWER FANS CUSTOMER

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Frequently Asked Question

Cooling tower definition.

The simplest definition could be, it is a type of heat exchanger which cools water flowing in it.

How does cooling tower works ?

Cooling tower work on the principle of evaporation where a high energy molecule leaves the system and resultant energy of the remaining molecules reduced.

How cooling tower fan works ?
The working principle of the fan is the same as an aeroplane.
the only difference is in-plane lift use to push the plain upward whereas in fan lift used to through the air.
Evaporative cooling tower fan.

Cooling towers work on the principle of evaporation, so the fan used in such a tower called an evaporative cooling tower fan.

Cooling tower fan blade angle calculation

Blade angle of any fan cannot be, calculated it is an outcome of the fan design and it can be, selected from the fan performance curve as per the required performance of fan (i.e. airflow, static pressure, RPM, and power).

Cooling tower vibration cause and solution

The source of vibration in a cooling tower is a fan, and the biggest reason for fan vibration is an imbalance, despite this fan tracking, higher tip clearance, and various frequency resonance can also cause high fan vibration.
Imbalance and tracking can be addressed at the site, whereas tip clearance is the property of fan shroud, whereas other frequency related issues need high technical knowhow to find the cause.
And these issues can solve by changing the number of blades in a fan or the blade profile.

Reason for cooling tower fan failure

In general FRP cooling tower, fans are very robust and strong enough to carry any load if the structural design is OK.

So the reason for fans failure are 

  • Manufacturing fault.
  • Improper design.
  • Improper selection – This is the main reason we observed most of the manufacturer having limited blade design, so they force those blade for all the application but over a while cooling tower pressure increase very much, and the old fan blades are not able to fulfil the duty point and prone to fail )
Cooling tower fan specification

The main parameter for fan selection are –

  • Air Flow requirement.
  • The static pressure of the system.
  • RPM in case of existing motor/gearbox (or let the manufacturer suggest)

These are the key parameter other than this air density, fan diameter restriction, motor rating, number of blades, operating temperature, recovery height, type of installation direction of rotation is also an important parameter.

Effect of fan on cooling tower water temperature !

Initially during cooling tower design fills media is having a maximum effect on the water temperature but once the tower is installed and working the fan is the only device that affects the performance of the tower.

What are various cooling tower operating cost ?

Electricity for fan and motor.
Makeup water.
Cooling tower water treatment chemical.

Maintenance cost.

Mainly cooling tower jobs include cleaning of different components and maintenance of fan significantly reduced by installing the robust fan.

How to measure cooling tower fan performance

For performance measurement, cooling tower institute code 143 are used.
We recommend cooling tower cold water temperature should be considered while comparing two different fans, in case of common sump rainwater temperature should be considered.

What are various application of cooling tower ?
  • Cooling tower in the power plant is the largest equipment by space.
  • A cooling tower for ac or HVAC
  • Cooling tower with any types of machine which need cold water to maintain temperature.

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