BULACAN STATE UNIVERSITY

COLLEGE OF ENGINEERING
MECHANICAL ENGINEERING DEPARTMENT

TEST OF CENTRIFUGAL FAN AND ROTARY BLOWER

TEST OF AN AIR COMPRESSOR

SUBMITTED BY GROUP 5

SANTOS, ELAINE
JOSE, CHRISTOPHER
FLORES, CHRISTIAN A.

BSME-4C
INTRODUCTION

Air compressors are used as versatile tool throughout the industries for a variety of
purposes. They are used for various applications in manufacturing plants such as driving
pneumatic tools, and other air operated controlling equipment’s Air compressors are one of the
major sources of energy consumption in industries. In the present scenario, the importance of
energy conservation is increasing day by day. For a manufacturing plant, improving energy
efficiency or replacement of less energy efficient equipment with energy efficient ones can earn
significant savings. In the manufacturing plant, it was found that compressors which are
running were installed in the earlier stages. Due to aging, the efficiency of compressor
decreased, and it resulted in huge expense. As a solution, the performance assessment of the
compressors was done. Compressor with an energy efficiency less than 35% is replaced with
energy efficient Compressor. Modification in the compressor air system was done to improve
efficiency

Air Compressor Specification

The industrial air compressors are classified into two major categories namely (1)
Positive Displacement and (2) Dynamic compressors. The types of air compressor used under
these categories are Reciprocating, screw and centrifugal air compressors. The positive
displacement compressors are further classified as oil injected and oil less and the highest
quality of air is delivered by oil less air compressors. Irrespective of the type of air compressors,
the specification is based on its FAD (Free Air Delivery) and pressure measured in cfm (Cubic
feet per minute) and bar or Kg/cm2 respectively.

The rating of air compressor is specified by its FAD and Pressure. A typical technical
specification for a screw compressor is listed below:

•Air delivery
•Working pressure
•Receiver air tank capacity
•Automatic pressure switch
•Pressure relief valve
•Drain valve
•Suction filter
•Non-return valve
•Maximum noise level (70 dB at normal load condition).

Why onsite capacity assessment? The onsite capacity assessment test helps save energy
and also knows the actual health of an old compressor. A fairly new installations may not yield
any appreciable result in energy saving but an old compressor can certainly a sources of energy
waste. Due to ageing of the compressors and inherent inefficiencies in internal components,
the free air delivered may be less than the design value, despite good maintenance practices.
Sometimes, other factors such as poor maintenance, fouled heat exchanger and effects of
altitude also tend to reduce free air delivery. In order to meet the air demand, the inefficient
compressor may have to run for more time, thus consuming more power than actually
required. The power wastage depends on the percentage deviation of FAD capacity. For
example, a worn-out compressor valve can reduce the compressor capacity by as much as 20%.
A periodic assessment of the FAD capacity of each compressor particularly old ones has to be
carried out to check its actual capacity. If the deviations are more than 10%, corrective
measures should be taken to rectify the same. The ideal method of compressor capacity
assessment is through a nozzle test wherein a calibrated nozzle is used as a load, to vent out
the generated compressed air. Flow is assessed, based on the air temperature, stabilization
pressure, and orifice constant etc. But the nozzle test cannot be carried out in field and
therefore a simpler method adopted for the test.

Methodology of Capacity Test

This test needs less skill and simple arithmetic calculation and any skilled person can
conduct the test under the supervision of a qualified engineer. Instruments needed for the test
are:

(1) stopwatch

(2) Clip on power meter which measures KW.

Use of conventional multi-meter to measure line current to calculate the power should
be avoided because the value of power factor cannot be assumed, and this may lead to wrong
conclusion. Therefore, only clip on power meter should be used to measure the actual power
drawn by the air compressor panel meter installed can be used. The steps involved in
conducting the test are-

•Isolate the air receiver from the air network by closing the delivery valve after the receiver

•Measure the approximate volume of piping network and filters like oil filter, intercooler and
after cooler etc., between compressor and receiver in m3

•Hold the clip-on power meter in any one of the phase in the switch panel

•Empty the air receiver and set the pressure gauge at 0 bar (gauge)

•Drain water from the receiver and do not forget to close the drain valve

•Start the compressor and start the stop watch once the compressor comes to loading mode

•Note down the time in seconds taken to fill the receiver to the normal operating pressure, i.e.
compressor reaches unloading mode

•Tabulate the values as shown in Table 3

ENTERPRETATION

The compressor capacity is estimated using the equation.1 shown below: Free air delivered
using the following formulae: Actual Free Air Delivered (Q) = [(P2-P1)/P0]*[V/T] (1)P2
= Final pressure after filling [kg/cm2 (a)]P1 = Initial pressure [kg/cm2 (a)] after bleedingP0 =
Atmospheric Pressure [kg/cm2 (a)]V = Storage volume in m3 which includes receiver, after
cooler, and delivery piping T = Time take to build up pressure to P2 in minutes. The above
equation is relevant where compressed air temperature is same as the ambient air
temperature, i.e., perfect isothermal compression. In case the actual compressed air
temperature at discharge, say t2OC is higher than ambient air temperature say t1OC (as is usual
case), the FAD is to be corrected by a factor (273 + t1) / (273 + t2). The specific energy
consumption is estimated using the equation. (2) shown below: Specific Energy Consumption
(SEC) = KW/Q 2)(at normal operating pressure) This test not only helps to estimate the specific
power consumption but also helps to estimate the energy saving if the operating pressure is
reduced to lower level. For example, the compressor consumes 12.6 KW at 5 bar whereas it
takes only 11.7 KW at 4 bar leading to a reduction of 7% in power consumption. Further, the no
load power consumption can be used for estimating the total power consumption in full cycle.
For example, the full cycle power consumption in this case would be 18 KW. To estimate the
SEC power consumed during a full cycle shall be used. In the present case, the capacity of the
compressor is estimated at 6.944 m3/mt or 245.39 fm and thus the generation efficiency is
93.37%. The SFC considering the power consumption per cycle for 100 cfm (standard) is 7.34
KW

CONCLUSION

This case example shows the economic benefit of conducting the capacity assessment test.
Since the employees and industry as a whole are working in a target-oriented business
environment they seldom find time to conduct such test. Therefore, they can engage external
agencies or can train their own employees to conduct such capacity test on each compressor at
least once in a fortnight to avoid heavy energy and money loss.

RECOMMENDATION

-MODIFICATION OF AIR COMPRESSOR SYSTEM

In the manufacturing plant, compressors are working at corrosive and high temperature
conditions. The intake air may contain dust which in turn decrease the efficiency of the
compressor. Low maintenance and continuous service are extremely important in this area. So,
upgrading the design of the compressor unit can increase the reliability, safety and overall
efficiency of the screw compressor. The effect of intake air on compressor performance should
not be underestimated. Intake air that is contaminated or hot can decrease compressor
performance and result in excess energy and maintenance costs. If moisture, dust, or other
contaminants are present in the intake air, such contaminants can build up on the internal
components of the compressor, such as valves, impellers, rotors, and vanes. Such build-up can
cause premature wear and reduce compressor capacity. When inlet air is cooler, it is also
denser. As a result, mass flow and pressure capability increase with decreasing intake air
temperatures. Conversely, as the temperature of intake air increases, the air density decreases,
and mass flow and pressure capability decrease. The resulting reduction in capacity is often
addressed by operating additional compressors, thus increasing energy consumption. To
prevent adverse effects from intake air quality, it is important to ensure that the location of the
entry to the inlet pipe is as free as possible from ambient contaminants, such as rain, dirt, and
discharge from a cooling tower. If the air is drawn from a remote location, the inlet pipe size
should be increased in accordance with the manufacturer’s recommendation to prevent
pressure drop and reduction of mass flow. All intake air should be adequately filtered. A
pressure gauge indicating pressure drop in inches of water is essential to maintain optimum
compressor performance.
CENTRIFUGAL BLOWER
Centrifugal blowers, typically made of
fabricated steel, stainless steel or cast
aluminum, use high speed impellers or
blades to impart velocity to air or other
gases. They are usually driven by electric
motors, often through a belt and sheave
arrangement, but some centrifugal blowers
are directly coupled to drive motors.
manometer is provided to find out the
difference of the pressure of Pitot tube and
static tube. A pitot tube is used to measure
the flow speed. Energy meter is provided to
find out the input H.P. to blower so that to
find out the overall efficiency of blower. For
changing the discharge and head, a valve is
provided at the outlet.
MATERIALS AND EQUIPMENT USED

CONDUCTED EXPERIMENT Centrifugal blower test rig with the

An experiment to study the effect of the
different opening of valves in measuring the
overall efficiency of the centrifugal blower
GENERAL DESCRIPTION OF SETUP
To find out the inlet and outlet velocity, the
Pitot tube is provided. A differential
following specification: DC Motor; 1 H.P.,
2800 RPM
RPM Indicator: Non-contact magnetic type
Velocity Measurement; Pitot static tube
Motor Efficiency = 80%
Outlet Diameter: 69 mm (0.069 m)
Inlet Diameter: 150 mm (0.150m)

EXPERIMENTAL PROCEDURE
1. To operate the blower test rig, close the delivery valve and start the blower.
2. Take the readings of static tube, Pitot tube and differential pressure by operating the suitable
valves provided on the differential manometer.
3. Take the reading of Pitot tube at all the positions and find out the mean reading. Read also
the RPM of the motor with the help of RPM Indicator provided on the panel.
4. Record the energy meter (rev/time) to find out the H.P input.
5. Now open the outlet valve at desired position and repeat the procedure of the readings.
6. From the observed readings, efficiency can be found by applying the given formulae.
7. Repeat this procedure at different openings of valves provided at the outlet.
PRESENTATION AND FINDINGS
FORMULAE
𝑟 3600 1000
Input H.P. Shaft = ( ) ( )( ) (nm) 𝜌𝑤
𝑡 𝐸𝑀𝐶 736 V = cV [√2𝑔𝑅 ( − 1)]
𝜌𝑎𝑄𝐻𝑔 𝜌𝑎
Output H.P = 𝜌𝑤
75 H = (h1 + h2) ( ( − 1)
Q = (V) (A) 𝜌𝑎
𝑜𝑢𝑡𝑝𝑢𝑡
Efficiency = ( ) (100)
𝑖𝑛𝑝𝑢𝑡
Nomenclature:
r = revolutions of meter
t = time taken for r
EMC = energy meter constant, 1600 pulse/kwhr
nm = motor efficiency
V = velocity of air
A = area of pipe
Q = discharge
H = head
h1 = Static head
h2 = Dynamic head
R = manometer reading
CV = coefficient of discharge of Pitot tube, 0.98
ρa = density of air, 1.19 kg/m3
ρw = density of water, 1000 kg/m3
g = acceleration due to gravity, 9.81 m/s

RPM Opening t (s) Q h1 (cm) h2 (cm) R (cm) Input Output Overall

(m3/s) (HP) (HP) Efficiency
2590 Full 32 --- 17.3 --- --- 0.31 --- ---
Close
¼ Open 29 0.013 14.6 15.75 1.24 0.42 0.052 12.38
½ Open 25 0.04 9.6 15.1 3.04 0.48 0.13 27.08
¾ Open 24 0.08 8.0 13.64 6.22 0.51 0.25 49.01
Full 23 0.135 3.5 11.74 8.32 0.53 0.274 51.7
Open

CONCLUSION
Based on the sample readings, we therefore conclude that the larger the opening of the valves,
the greater the discharge value of air. The greater the discharge value of air, the higher the
overall efficiency is.

RECOMMENDATION
We recommend to study the effect of the different impellers and also find the overall efficiency
of each.

CENTRIFUGAL FAN

A centrifugal fan is a mechanical device for moving air or other gases. The terms “blower” and
“squirrel cage fan”, (because it looks like a hamster wheel), are frequently used as synonyms.
These fans increase the speed and volume of an air stream with the rotating impellers.

Centrifugal fans use the kinetic energy of the impellers to increase the volume of the air stream,
which in turn moves them against the resistance caused by ducts, dampers and other
components. Centrifugal fans displace air radially, changing the direction (typically by 90°) of
the airflow. They are sturdy, quiet, reliable, and capable of operating over a wide range of
conditions.

The centrifugal fan is one of the most widely used fans. Centrifugal fans are by far the most
prevalent type of fan used in the HVAC industry today. They are often cheaper than axial fans
and simpler in construction. They are used in transporting gas or materials and in ventilation
system for buildings. They are also well-suited for industrial processes and air pollution control
systems.

Performance of Fans

1. Static Head - is the height of the surface of the fluid above the gauge point.
2. Velocity Head - is the head required to produce the flow of fluid.
3. Total Head is the sum of the static head and velocity head
4. Capacity of Fan - is the volume flow rate measured at fan outlet
5. Power Output of a fan or air power is based on fan volume and the fan total pressure.
6. Power Input of Fan or Brake Power - is the power delivered to the fan shaft.
7. Static Efficiency of Fan - is the mechanical efficiency multiplied by the ratio of the static
pressure to the total pressure.

Fan Laws
There are 3 basic fan law which encompass all fan functional principles

1. Fan Speed Variations

2. Fan Size Variations
3. Gas Density Variation

Test of a Centrifugal Fan

1. Scope And Field Of Application

The present operative has the scope to define the operating modalities and acceptance criteria
for the performance test of fan.

2. Reference
• ASME PTC 11-2008;
• ANSI-AMCA STANDARD 210;

3. Definitions
Performance test at inlet
Measure of pressure points on duct installed on inlet of fan;

4. Responsibility
The Quality Control operator (QC) must:
• Perform the mechanical functional test;
• Issue the test certificate;

The Technical manager (TM) must:

• When requested, co-operate with QC during test;
• Define the operating conditions for fans running test.
The Quality Assurance manager (QAM) must verify the right test execution.

5. Operative Conditions
Test Limits
The test technical limits for fans running test are:
• With absorbed electric power ≤ 200 kW and starting current ≤ 190 A, with fan inlet
closed, it is possible to test the fan at the operating speed;
• The test will be carried out with job motor;
• Voltage 0 - 400 V three phase;
• Frequency 50 Hz for direct on line starting, from 5 to 100 Hz for variable speed starting
(inverter).
Inlet Test

The test is performed according to ASME PTC 11 -2008 according to Volume Flow Rate –
Pressure approach and the scope is to verify the contractual performance point of
characteristic curve of fan.
The test is performed using n° 3, or more, different diaphragms chosen so to mach the
equivalent diameter of resistant circuit.
The test media will be air. The conversion from test condition data to design ones will be
performed according to AMCA 210.
Fan Performance Test - Checked Data:
• Inlet Flow Rate;
• Inlet Temperature (Test Condition are Probably Different From Contractual One);
• Static Pressure;
• Absorbed Power;
• Fan Rotation Speed;
• Air Density.

Fan Performance Test - Measure To Be Done:

• Power (Watt);
• Barometric pressure (mm Hg);
• Dry and wet bulb temperature close to testing area (°C);
• Temperature td3 (°C);
• Static pressure in the section 3 Ps3r (PL3) (mm H2O);
• Dynamic pressure in the section 3 Pv3r (PL3) (mm H2O);
• Rotation speed (rpm).
6. Acceptance Criteria
The test will be considered accepted if the static and total fan efficiencies are conforming to
contractual range values inside the ASME PTC 11 tolerances.
Fan Performance Test - Contractual Value:
• Inlet Pressure: X 1 barg
• Outlet Pressure: X 2 barg
• Flow: Y m3/h
• Speed: Z rpm

7. Measuring Equipment
The described test shall be performed, where requested, using calibrated equipment .
The instrumentation to be used consists in :
• Wattmeter
• Barometer
• Dry and wet bulb thermometer
• Digital differential manometer with digital thermometer
• Tachimeter

QUESTIONS

1. The ratio of work-done per cycle to the stroke volume of the compressor is known as.
A. Compressor capacity
B. Compression ratio
C. Compressor efficiency
D. Mean effective pressure
Ans. d
2. The capacity of a compression is 10 m3/minute.10 m 3/minute refers to:
A. Standard air
B. Free air
C. Compressed air
D. Compressed air at delivery pressure
Ans.b

3.The multi stage compression as compared to single stage compression:

A. Improves volumetric efficiency for the given pressure ratio
B. Reduces work done per kg of air
C. Reduces cost of compressor
D. Gives more uniform torque
E. All of the above
Ans. e

4. Compression efficiency is compared against:

 A. Ideal compression
B. adiabatic compression
C. both isothermal and adiabatic compression
D. Isentropic compression
E. Isothermal compression
Ans. e

5.The volume of air delivered by the compressor is called:

A. Free air delivery
B. Compressor capacity
C. Swept volume
D. None of the above
Ans. b

6.The most efficient method of compressing air is to compress it…

A. Isothermal
B. Adiabatically
C. Isentropically
D. Isochronically
Ans. a

7.Ratio of indicated HP and break HP is known as.........

A. Mechanical efficiency
B. Volumetric efficiency
C. Isothermal efficiency
C. Adiabatic efficiency
Ans. a

8. Maximum work is done in compressing air when the compression is......

A. Improves volumetric efficiency for the given pressure ratio
B. Isothermal
C. Adiabatic
D. Polytropic
Ans. c

9. The value of air sucked by the compressor during its suction stroke is called:
A. Free air delivery
B. Compressor capacity
C. Swept volume
D. none of the above
Ans. c

10. Volumetric efficiency is.......

 A. The ratio of stroke volume to clearance volume
B. The ratio of the air actually delivered to the amount of piston displacement
C. Reciprocal of compression ratio
D. Index of compressor performance
Ans. b

11. The pressure of air at the beginning of the compression stroke is _________ atmospheric
pressure
A. Equal to
B. Less than
C. More than
D. None of the above
Ans. b

12. Ratio of compression is the ratio of

A. Gauge discharge pressure to the gauge intake pressure
B. Absolute discharge pressure to the absolute intake pressure
C. Stroke Volume and clearance volume
D. None of the above
Ans. b

13. Cylinder clearance in a compression should be

A. As large as possible
B. As small as possible
C. about 50% of sweet volume
C. About 100% of swept volume
Ans. b

14. Separators are generally installed in compressors

A. After the intercooler
B. Before the intercooler
C. Before the receiver
D. After the intercooler
Ans. a

15. An air receiver is to be placed outside should it to be placed in

A. Sun
B. Shade
C. Rain
D. Anywhere
Ans. b

16. The capacity of compression will be highest when it's intake temperature is
A. Lowest
 B. Highest
C. Anything atmospheric
Ans. a

17. What is the purpose of the blower?

A. Decrease air flow
B. Increase air flow
C. Create vacuum
D. Maintain air flow
Ans. b

18. The impeller in the volute pump is surrounded by

A. Discharge pipe
B. Throat
C. Suction pipe
D. Volute chamber
ans. d

19. A diffuser pump is also called as _______ pump.

A. Reciprocating pump
B. Volute pump
C. Turbine pump
D. Rotary pump
ans. c
20. Depending on the number of impellers, the centrifugal pump is divided into ____ types.
A. Two
B. Three
C. Four
D. Six
ans. a

21. Radial flow pump is a pump classified on the basis of

A. Direction of flow
B. Number of impellers
C. Number of entrances to the impeller
D. Based on shaft
ans. a

22. Which of the following type of pump is based on the number of entrances to the impeller?
A. Single stage pump
B. Single suction pump
C. Mixed flow pump
D. Horizontal pump
ans. b
23. When the specific speed of the pump is <2600, the type of pump is
A. Reciprocating pump
B. Centrifugal pump
C. Mixed flow pump
D. Axial flow pump
ans. b

24. Centrifugal pump is a_________

A. Turbomachinery
B. Flow regulating device
C. Drafting device
D. Intercooling device
ans. a

25. The main function of centrifugal pumps are to ________

A. Transfer speed
B. Transfer pressure
C. Transfer temperature
D. Transfer energy
ans. d

26. Centrifugal pumps transfer energy from _______

A. Rotor to fluid
B. Fluid to rotor
C. Draft to rotor
D. Rotor to draft
Ans. a

27. Which among the following control the flow rate?

A. Valve
B. Pump
C. Head
D. Tank pipe
ans. a

28. Centrifugal pumps transport fluids by converting _________

A. Kinetic energy to hydrodynamic energy
B. Hydrodynamic energy to kinetic energy
C. Mechanical energy to kinetic energy
D. Mechanical energy to Hydrodynamic energy
ans. a

29. The rotational kinetic energy comes from ______

A. Engine motor
B. Pump
C. Tank
D. Draft tube
ans. a

30. The fluid coming into the centrifugal pump is accelerated by ________
A. Throttle
B. Impeller
C. Nozzle
D. Governor
ans. b