Edge protection for a fan blade

Abstract: A protection element (20) containing a spring steel strip (22) is bent to have a tighter curvature than the curvature at the leading edge of a fan blade (10). The protection element 20 is then fixed to the leading edge of the fan blade (10) over an area of maximum erosion. Rubber or another elastomer (24) can be extruded over the strip (22) before or after it is fixed to the fan blade (10) or the strip (22) can incorporate an outer hardened layer to resist erosion. Attachment of the strip (22) to the blade (10) is advantageously accomplished using rivets (30) or screws at spaced locations along the blade (10) at the leading edge of the blade (10).

Description: The invention relates to edge protection for a fan blade. Steam generating units or petrochemical process plants require large numbers of wet cooling towers to cool water used in steam condensing or other heat exchange applications. This water is typically cooled by evaporation, such as by co-mingling with air supplied by large multi-bladed fans. In this process, some water droplets are entrained in the air and come into contact with the leading edges of the fan blades. These fan blades will generally be moving at a very high velocity, typically 200 kmph (125 mph) at the outer-most radius of the blade, and thus, over time, damage to these blades will occur. The most troublesome problem with the fans used in these wet cooling towers is leading edge erosion which is caused by impact with the water droplets entrained in the air stream. Severe erosion by such impact can result in the loss of these fan blades costing $1,000 or more in replacement costs. One technique for preventing such erosion is to apply a rubber "boot" to the leading edge of each blade in order to absorb the impact energy of colliding with the droplets. The cost of this rubber boot is approximately $200 to $500 per blade with this cost including about four hours labour for installation. Thus, when considering the vast number of blades to be corrected, the cost and effort involved is quite substantial. Another type of edge protection is disclosed in US-A-4 895 491 on which the preamble of Claims 1 and 6 is based. There is also an ongoing debate as to whether the erosion problem is due to faults in the blade or due to excessive water droplets in the air which compounds the difficulty of correcting the resultant problem. According to one aspect of the invention there is provided an edge protection arrangement for a fan blade having a leading edge with an area of maximum erosion and a selected curvature, the arrangement comprising: a. a continuous strip of spring steel bent to a tighter curvature than the curvature of the fan blade leading edge and fixed over the area of maximum erosion on the fan blade leading edge; and b. anti-erosion means on at least one surface of the spring steel strip to prevent erosion of the leading edge. Such an arrangement can provide improved leading edge protection for fan blades, can be inexpensive and can be effective in reducing leading edge corrosion. The low cost and effectiveness of the arrangement of the invention can avoid the debate concerning whether erosion is due to faults in the blade or excessive drift since the arrangement of the invention can be economically applied to solve the problem without addressing which factor causes the erosion. The spring steel strip can be of stainless steel and be shaped to conform to the leading edge profile of the blade. Holes can be punched at uniform distances along the centre of the strip and a coating of rubber or other elastomer can be extruded around the strip with the thickest dimension at the position of maximum erosion on the blade. The holes can be utilized to fasten the strip to the leading edge of the blade in a quick, economical and effective manner. An arrangement according to the invention can provide improved leading edge protection for fan blades which is simple in design, rugged in construction and economical to manufacture and install. According to another aspect of the invention there is provided a method of protecting the leading edge of a fan blade having an area of maximum erosion and a selected curvature, comprising the steps of: a. bending a continuous strip of spring steel to have a greater curvature than the curvature of the leading edge of the fan blade; b. applying anti-erosion means over at least one surface of the strip to prevent erosion of said at least one surface; c. pressing the strip onto the blade by at least partly biasing the strip so that when released it tightly grips an outer surface of the blade; and d. permanently fixing the strip to the leading edge of the blade. The invention is diagrammatically illustrated by way of example in the accompanying drawings, in which: Figure 1 is a partial sectional view of the leading edge of a fan blade illustrating the area of maximum erosion; Figure 2 is an exploded view showing the leading edge of a fan blade and illustrating leading edge protection of an arrangement according to the invention before it has been installed; Figure 3 shows the leading edge of a fan blade with the edge protection arrangement of Figure 2 installed; and Figure 4 is a view similar to Figure 3 showing an alternate of leading edge protection arrangement according to the invention. Referring to the drawings, and firstly to Figure 1, there is shown a typical leading edge construction of a fan blade 10. A leading area of approximately 25.4 mm (1 inch) in arcuate length at 12, is exposed to maximum erosion during the useful life of the blade 10. Figure 2 illustrates an edge protection member which is generally designated 20 and comprises an elongate continuous thin gauge stainless steel spring strip 22 surrounded by an extruded covering of rubber or other elastomer 24. The curvature of this stainless steel strip 22 is selected to match or be greater than the curvature of the leading edge of the blade 10 so that with the protection member 20 installed, the spring steel strip 22 will squeeze or be biased tightly against and thereby grip the leading edge of the blade 10. Holes 26 (one shown) are also punched through the protection member 20 at spaced locations along its length, this length being normal to the plane of Figure 2. The holes 26 can be punched into the spring steel 22 before the rubber 24 is extruded, followed by pilot holes or alignment markings on the surface of the rubber 24 to indicate the location of the underlying holes. Alternatively, the holes 26 may be punched after the rubber 24 is extruded over the stainless steel strip 22, whichever is desired. An area of high erosion protection 14 provided by the member 20 is selected to match the area of high erosion 12 on the blade 10, with the width of the strip 22 on opposite sides of this high erosion area as shown at 16, being selected to be approximately 50 to 75 mm (2 to 3 inches). Figure 3 illustrates the installed position of the protection member 20 on the blade 10. The stainless steel strip 22 is expanded slightly to accommodate the curvature of the blade 10 and at the same time firmly to hold itself and the extruded rubber coating 24 against the blade 10 so as to avoid rattling or any other displacement. Connectors 30, for example blind monel rivets or screws, are fastened through the holes 26 and the corresponding aligned holes in the leading edge of the blade 10. Ideally, the holes 26 would be drilled during blade assembly to provide an entrance for the rivet through the blade laminate. Advantageously, the holes 26 are provided every 200 to 250 mm (8 to 10 inches) (or so) on centre along the radial length of the blade 10 which may be 4.8 m (16 feet) or more. Despite the drilling of such holes 26, it should be understood that this operation does not compromise the strength of the blade 10. Figure 4 illustrates a second embodiment of the invention wherein the edge protection member 20 comprises a stainless steel spring strip 32 fastened by rivets 34 at spaced locations along the axial length of the blade 10. The stainless steel spring strip 32 is configured with a hard facing of a known material 36 on its outer surface. Titanium nitride or any other known hardened layer material can be used as the layer 36. Other similar variations are also possible. In practice the edge protection member 20 can be installed at a rate of approximately 30 to 45 minutes per blade. This compares with four hours or more of installation time normally required to install the previously used boot construction. The strips 22 or 32 of the edge protective member 20 can also be constructed to have a maximum thickness at the point of maximum erosion and to have a tighter curvature than the blade 10 so that when installed, the member 20 closely hugs the outer surface of the blade 10. An adhesive may be applied between the edge protection member 20 and the blade 10 further to affix the edge protection member 20 to the blade 10 if desired. With a suitable spacing between the holes 26 in the protection member 20 and the blade 10, the arrangement of the invention can advantageously be applied to blades having a radial length of 4.8 m (16 feet) or more, as well as to blades having a length less than 4.8 m (16 feet).

Claims: An edge protection arrangement (20) for a fan blade (10) having a leading edge with an area of maximum erosion and a selected curvature, the arrangement (20) being characterised by : a. a continuous strip of spring steel (22, 32) bent to a tighter curvature than the curvature of the fan blade (10) leading edge and fixed over the area of maximum erosion (12) on the fan blade leading edge; and b. anti-erosion means (24, 36) on at least one surface of the spring steel strip (22, 32) to prevent erosion of the leading edge. An arrangement according to claim 1, wherein the anti-erosion means comprise an elastomer (24) extruded over the strip. An arrangement according to claim 1 or claim 2, including a plurality of spaced holes (26) in the strip (22, 32) and a plurality of connectors (30, 34) extending through the holes to fix the strip to the fan blade. An arrangement according to claim 1 or claim 3 when appendant to claim 1, wherein the anti-erosion means comprise a hardened outer surface of the strip facing outward away from the blade. An arrangement according to claim 4, including a plurality of holes (26) through the strip and a rivet (30, 34) or screw in each of the holes (26) to fix the strip (24, 32) to the leading edge of the blade (10). A method of protecting the leading edge of a fan blade (10) having an area of maximum erosion (12) and a selected curvature, is characterised by the steps of: a. bending a continuous strip of spring steel (22, 32) to have a greater curvature than the curvature of the leading edge of the fan blade (10); b. applying anti-erosion means (24, 36) over at least one surface of the strip to prevent erosion of said at least one surface; c. pressing the strip (22, 32) onto the blade (10) by at least partly biasing the strip (22, 32) so that when released it tightly grips an outer surface of the blade (10); and d. permanently fixing the strip (22, 32) to the leading edge of the blade. A method according to claim 8, wherein the anti-erosion means comprises an elastomer (24) extruded over the strip (22) before it is fixed to the blade (10). A method according to claim 9, wherein the elastomer is rubber. A method according to claim 10, including providing a plurality of spaced holes (26) along the strip (22, 32) and fixing the strip (22, 32) to the hollow blade using rivets (30, 34) or screws. A method according to claim 10, wherein the anti-erosion means comprise a hard outer layer (36) applied to the strip (32) on the surface of the strip which is away from the blade (10).

Inventors: MONROE ROBERT C, MONROE, ROBERT C.
Applicants: HUDSON PRODUCTS CORP, HUDSON PRODUCTS CORPORATION
Application year: 1993
Main classification: F04D29
IPC codes: F04D29