Performance Op Tim Ization

7/29/2019 Performance Op Tim Ization

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PerformanceOptimization:Fan, Pump, & Blower Systems

R E F E R E N C E G U I D E

Fourth Edition


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First Edition, 1992Second Edition, December 1998Third Edition, December 2000

Revised by:

Dan Dederer, P.Eng.,Enertech Solutions Inc.

Neither Ontario Power Generation, nor any person acting on its behalf,assumes any liabilities with respect to the use of, or for damages resultingfrom the use of, any information, equipment, product, method, or processdisclosed in this guide.

The sun represents sustained life

while the lightning bolt depicts energy.The integration

represents the perfect partnership of energy utilization and the

environment that encourages wise use and respect for all naturalresources.The roof represents the in-house aspect of energy

efficiency throughout Ontario Power Generation

Marcel Gauthier

Georgian Bay Region - Retail

Printed in Canada.Copyright 1992, 1998, 2000 Ontario Power Generation

Energy Savings are Good Business


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PerformanceOptimization:Fan, Pump & Blower Systems

R E F E R E N C E G U I D E

Third Edition


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i

TA B L E O F C O N T E N T S

INTRODUCTION ..............................................................................1

1.0 P ERFORMANCE OPTIMIZATION FUNDAMENTALS ...........................3

Fan,Pump,and Blower Systems ...................................................3System Defined......................................................................3

System Point of Operation.....................................................4System Flow and Pressure Relationship.................................4

Fan/Pump Performance Curve .............................................9

Energy-Saving Techniques.............................................................9General .................................................................................9

Reducing Motor Input Power ..............................................11

2.0 P ERFORMANCE OPTIMIZATIONTECHNIQUES AND MEASURES ..................................................15

Primary Measures For Energy Reduction ...................................15Speed Modulation ...............................................................15

Equipment Upgrade ............................................................16

High Efficiency Motors ........................................................16

Reduction of Impeller Diameter...........................................16

Variable Inlet Vanes ............................................................16

Booster Pony Applications .................................................16

Ancillary Measures for Energy Reduction ..................................17System Effect Factors ...........................................................17

Elimination of Cavitation ...................................................17

High Performance Lubricants.............................................17

Coatings..............................................................................17

Internal Running Clearances .............................................17

System Maintenance ...........................................................18


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Process Control ...................................................................18

3.0 ASSESSMENT METHODS .........................................................19

General .......................................................................................19

Prescreening Information...........................................................19Step 1: Review Process &

Instrumentation Diagram (P&ID).......................................21

Step 2 : Review Prescreening Information...........................22Step 3 : Prescreening Conclusions .......................................30

Load Data Gathering...................................................................30Design Data........................................................................31

Observations and Estimates by Operating Staff ...................31

Plant Operating Records .....................................................31

Temporary Metering............................................................32

Field Performance Testing ..................................................32

Development of Load Duty Cycle ..............................................34

Technical Options Review..........................................................35General...............................................................................35

System Loss Evaluation........................................................36

Equipment Internal Evaluation ..........................................37

Application Considerations.................................................38

Energy Assessment .....................................................................39

Economic Analysis ......................................................................40Total Savings.......................................................................40

Cost Estimates......................................................................40

Simple Payback and IRR .....................................................41

Feasibility Report........................................................................42

ii



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4.0 P ERFORMANCE EVALUATION OF CANDIDATES............................43

General .......................................................................................43

Applicable Safety Standards........................................................43

Applicable Performance Test Standards......................................44Pump Performance Test Standards.....................................44

Fan and Blower Performance Test Standards.....................44

Measurement Parameters and Test Instruments .........................45Measurement Parameters ...................................................45

Test Instruments..................................................................45

Calibration of Test Instruments...........................................45

General Test Procedures .............................................................46Location of Test Points ........................................................46

Control of Turbo Machine and System................................47

Performance Test Records...................................................48Rotational Speed Measurement ...........................................48

Motor Input Power Measurement ........................................49

Pump Test Procedures ................................................................51

Liquid Density.....................................................................51

Liquid Flow Rate Measurement ...........................................51

Pump Head Measurement...................................................53

Pump Test Calculation................................................................55Liquid Properties Calculation..............................................56

Liquid Flow Rate Calculation..............................................56

Pump Head Calculation .....................................................57

Pump Power Calculation ....................................................58

Fan and Blower Test Procedures.................................................59Gas Properties .....................................................................59

Gas Flow Rate Measurement ...............................................61

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Fan and Blower Pressure Measurement..............................63

Fan and Blower Test Calculation.................................................65Gas Density Calculation (same as specific gravity).............65

Gas Flow Rate Calculation..................................................66

Fan and Blower Pressure Calculation ................................68

Fan Power Calculation .......................................................70

5.0 SAFETY...............................................................................71General .......................................................................................71

Plant Regulations........................................................................71

Safety Items Specific to Fan, Pump,and Blower Systems ...........72

APPENDICES ................................................................................75

iv



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CHAPTER1.0

1.1 Fixed Resistance System........................................................5

1.2 Fixed Resistance System with Constant Static Pressure........6

1.3 Variable Resistance System with Constant Pressure..............7

1.4 Variable Resistance System with Constant Flow....................8

1.5 Variable Resistance System withVarying Flow and Pressure ....................................................9

1.6 Performance Curve for 100 HP Motor.................................12

1.7 Effect of Speed Reduction ...................................................13

CHAPTER3.0

3.1 Process and Instrumentation Diagram ................................22

3.2 Data-Gathering Decision Tree..............................................33

3.3 Load Duty Cycle Chart ........................................................34

3.4 Typical Pump Load Duty Cycle............................................35

v

LI S T O F F I G U R E S


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CHAPTER4.0

4.1 Location of Test Points.........................................................46

4.2 Selection of Flow-Measuring Plane......................................47

4.3 Connecting a Wattmeter......................................................49

4.4 Liquid Flow Rate Measurement:Vessel and Timer ...............52

4.5 Liquid Flow Rate Measurement:Orifice Plate ......................524.6 Pressure Tap Geometry........................................................53

4.7 Gauge Reference to Datum .................................................54

4.8 Suction Head by Calculation ...............................................55

4.9 Pitot Static Tube...................................................................62

4.10 Double Reverse Tube.........................................................62

4.11 Inclined Manometer ..........................................................62

4.12 Static Pressure Readings ....................................................64

CHAPTER3.0

3.1 Prescreening Review...........................................................23

vi

LI S T O F F I G U R E S

LI S T O F TA B L E S


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It is estimated that as much as 20% to 50% of the electrical powerused to run industrial fan,pump, and blower systems can be savedby overcoming operating inefficiencies.

Opportunities to improve operating efficiency are overlooked forfour reasons:

low awareness about energy-efficient technologies the financial and operational benefits are not understood

initial costs taking precedence over life-cycle costs

energy-saving projects are considered less important than otherproduction-related expenditures.

This handbook:

characterizes various systems

provides a quick reference on performance optimizationtechniques

provides guidelines on how to pre-screen candidates andperform a feasibility study

Introduction 1

Introduction


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reviews field performance testing procedures

reviews general plant safety practices

2 Fan, Pump, and Blower Systems


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System Point of Operation

The system point of operation is the intersection between thesystem resistance curve and the turbo machine performance

curve. This point determines the flow rate. There are two ways tochange the point of operation:

change the characteristics of the turbo machine performancecurve,varying speed,changing inlet vane settings, etc;

alter the system curve by changing system losses or flow.

Frequently, these two changes occur simultaneously.

For example: An increase in system resistance may beautomatically counteracted by an increase in speed,which keepsflow constant.

System Flow and Pressure Relationship

How flow and pressure are related in a system depends onwhether the system components are fixed resistance (e.g.,

ductwork) or variable resistance (e.g.,dampers, filter, etc.).

Fixed Resistance System

Pressure is proportional to Flow2

For example: A forced draft fan, fitted with variable inlet guidevanes, supplies air to a boiler. The ductwork system has nothrottling dampers.



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Figure 1.1 shows the system, the fan curve, and a fixed

resistance system curve.

Fixed Resistance System with Constant Static Pressure

Pressure a FIow2 + Constant Static Pressure

For example: A pump supplying a water tower must overcomethe constant static pressure (head) corresponding to the

elevation of the tower, plus the fixed resistance in the pipesystem.

Performance Optimization Fundamentals 5

SystemResistance

CurveTurbo

MachinePerformance Curve

Inlet Stack

Boiler

Fan

Flow

Pressure

Figure 1.1

Fixed Resistance System


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Figure 1.2 shows the system, the pump curve, and a fixedresistance system curve with a constant static head.

Variable Resistance System with Constant Pressure

Pressure = Constant

For example: A blower on a multi-port fume collection systemis modulated by an inlet damper to maintain a constant

pressure in a header, regardless of the number of opencollection ports.


SystemResistance

Curve

ConstantStaticHead

InletPump

Flow

Press

ure

WaterTower

Figure 1.2:

Fixed Resistance System with Constant Static Pressure


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Figure 1.3 shows the system, the fan curve,and a constantpressure system resistance curve.

Variable Resistance System with Constant Flow

Flow = Constant

For example: To form insulation batts, a fan is used to drawinsulation fibers onto a moving conveyor. The fibers must

move at constant velocity to disperse uniformly, and the speedof the conveyor is varied to form different thicknesses of batts.The lower pressure drop through thinner batts is offset bypartially closing a damper at the fan inlet.


SystemResistance

Curve

Slide

Gates

Fan

Flow

Press

ure

Header

InletDamper

Collection Ports

Figure 1.3

Variable Resistance System with Constant Pressure


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Figure 1.4 shows the system, the fan curve, and a constant flow

system resistance curve.

Variable Resistance System with Varying Flow and Pressure

This system is usually defined as a series of discrete operatingpoints with no consistent relationship between flow andpressure.

For example:A mine ventilation fan is fitted with manual

control Variable Inlet Vanes (VIV), which are adjusted toprovide the correct air flow to various areas of the mine. Areasof the mine not in use are isolated by doors.


SystemResistance

Curve

FanFlow

Pr

essure

InletDamper

RawInsulation

Conveyor

Figure 1.4

Variable Resistance System with Constant Flow


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Figure 1.5 shows the system, the fan curve,and the operatingpoints defined by varying flow and pressure.

Fan/Pump Performance CurveEach fan or pump is characterized by a set of operating points(flow, pressure) called itsperformance curve. The manufacturersupplies this curve, from which the application engineer selectsthe best fan or pump to meet the system needs. Since systemsoften have a range of operating points, selecting the optimumfan/pump is critical.

ENERGY-SAVING TECHNIQUES

General

The objective of all turbo machinery performance optimizationtechniques is to provide the correct flow and pressure to meet theprocess requirements,using less electrical power.


Points of Operation

Fan

Doors

Mine Shafts

VIGV

Flow

Pressure

DesignPoint

ClosedMine

SupplyShaft

Figure 1.5

Variable Resistance System with Varying Flow and Pressure


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The brake horsepower required by the fan, pump, or blower is afunction of the total efficiency of the turbo machine:

BHP = 1 x [AHP] or BHP = 1 x [WHP]hT hT

The input kW required to produce the BHP for the turbo machineis a function of the motor efficiencyhm and the efficiency of anyother components in the drive train,e.g.,V-belts, fluid drive,ASDho,etc.:

kW = 0.746 x 1 x 1 x BHP

hm ho

As shown above,all optimization techniques for fans,pumps, andblowers involve either an improvement in the efficiency of theturbo machine or drive train, and/or an improvement in systemrequirements (i.e., reduced flow and/or pressure).

Reducing Motor Input Power

Motor input power must be reduced to achieve energy savings.This is achieved by reducing the brake horsepower requirementsor varying the speed of the motor.

Maintaining Constant Motor Speed with Reduced Brake-Horsepower Requirements

For a constant speed motor, applying performance optimizationtechniques to the turbo machine will reduce input power tothe motor, since less brake horsepower (load) is applied to themotor shaft. Figure 1.6 shows a performance curve for atypical induction motor.



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Varying the Speed of the Motor and Turbo Machine

This approach includes all applications where the requiredpoints of operation can be achieved by varying the speed of

the motor. For a fixed resistance system, the theoreticalrelationship between speed and brake horsepower is:

BHP a RPM3

As brake-horsepower requirements decrease,motor inputpower reduces accordingly.


B - % Power Factor

C - Current (FLA=100%)

A - % Efficiency

D - kW Input

Shaft Output - BHP

90

80

70

60

0

0 25

94

92

90

88

86

A B

100

75

50

25

0

100

75

50

25

0

C D

50 75 100 125 150

Figure 1.6

Performance Curve for 100 HP Motor


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For example: Reducing system pressure losses by removingthe throttling valve and simultaneously slowing the machine,results in reduced brake horsepower, as shown in Figure 1.7.


Flow Capacity

Pressure

BrakeHorespower

Reduced Horsepower

System Resistance Curve

System Resistance Curve

Original Point of Operation

New Point of Operation

Figure 1.7

Effect of Speed Reduction


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The performance optimization techniques addressed in thishandbook are divided into two categories:

1. Primary Measures for Energy Reduction moderate to high cost quantifiable energy savings

2. Ancillary Measures for Energy Reduction low to moderate cost fine-tuning measures may be done independently or in conjunction with primary

measures

PRIMARY MEASURES FOR ENERGY REDUCTION

Speed ModulationSpeed control of equipment is achieved in one of two ways:

by varying the speed of a motor coupled directly to the load,i.e.,ASDs,multi-speed motors,DC motors;

by coupling a fixed-speed driver to the load via a device thatpermits speed adjustment of the load, i.e., fluid drives, gear

systems and adjustable belt drives.

Techniques and Measures 15

C H A P T E R 2

Performance OptimizationTechniques and Measures


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Equipment Upgrade

Turbo machine upgrades may have applications in these areas:

higher efficiency turbo machinery may now be available; due to industrial process changes, turbo machine re-selection

may improve efficiency at the new points of operation;

worn impeller replacement.

High Efficiency Motors

The turbo machinery may operate more efficiently if the existingmotor is replaced with a high efficiency motor or one selectedcloser to its current operating conditions.

Reduction of Impeller Diameter

Due to over-sizing, the turbo machine may operate against apartially-closed damper or valve. Resizing the impeller reduceshorsepower requirements. BHP is proportional to impeller

diameter.

BHP1 = Diameter1 5

BHP2 Diameter2

Variable Inlet Vanes

These are used to control flow on fans and blowers and aregenerally efficient in the range close to maximum flow conditions.

Booster Pony Applications

A booster fan,blower, or pump is used for systems that experienceinfrequent peaks or upset conditions. This allows main equipmentto operate at maximum efficiency under normal conditions.



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ANCILLARY MEASURES FOR ENERGY REDUCTION

System Effect Factors

Equipment cannot perform at capacity if fans,pumps, and blowershave poor inlet and outlet conditions. Correction of system effectfactors (SEFs) can have a significant effect on performance andenergy savings.

Elimination of Cavitation

Flow, pressure,and efficiency are reduced in pumps operating

under cavitation. Performance can be restored to manufacturersspecifications through modifications. This usually involves inletalterations and may involve elevation of a supply tank.

High Performance Lubricants

The low temperature fluidity and high temperature stability ofhigh performance lubricants can increase energy efficiency byreducing frictional losses.

Coatings

Coating system components such as pump bowls, impellers,casings, and inner linings of pipe works reduces frictional lossesand increases efficiency.

Internal Running Clearances

The internal running clearances between rotating and non-rotatingelements strongly influences the turbo machine's ability to meetrated performance. Proper set-up reduces the amount of leakage(recirculation) from the discharge to the suction side of theimpeller.

Techniques and Measures 17


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System Maintenance

Fan, pump, and blower systems may undergo an actual loss ofefficiency due to dirt build-up on components such as filters, coils,

and impellers. Duct leaks may be a major problem with highpressure blower systems.

Process Control

The process served by fans,pumps, and blowers should utilize theflow in an efficient manner based on actual requirements.To achieve this:

shut turbo machinery off when it is not required

control flow to prevent usage of capacity not required for theprocess

eliminate recirculation modes if possible

close duct and pipe runs when they are not needed



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GENERAL

Some industrial fan,pump, and blower systems operate efficiently,and regular maintenance will ensure continued performance ofthese systems.

The performance of most other turbo machines can be improved.

Determining the feasibility of performance optimization measuresinvolves:

l. Candidate Prescreening2. Load Data Gathering3. Development of a Load Duty Cycle4. Technical Option Review5. Energy Assessment

6. Economic Analysis7. Feasibility Report

PRESCREENING INFORMATION

Engineering and operating data are typically incomplete orunavailable. The information needed to establish candidatepotential and viability is usually obtained through observations anddiscussions with operating personnel.

Assessment Methods 19

C H A P T E R 3

Assessment Methods


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The following items should be noted when prescreeningcandidates:

VISUA L EXA MINAT ION

- visual overview of complete system

- condition of turbo machine and system (i.e., leakage, age)

- nameplate information of both motor and turbo machine

- inlet and outlet connections (i.e., elbows obstructingsmooth flow)

- type of elbows in system (i.e., long radius or short square)

- ductwork/piping changes (i.e., closure of runs)

- conditions of entry points to plenums or vessels (i.e., square-edged instead of bell-mouthed)

- maintenance condition of turbo machine and system

- gaskets protruding into fluid stream- damper and valve locations (i.e., percent closed)

- automatic or manual controls of dampers/valves

DISC USSIONS WIT H OPERATING PER SONNEL

- equipment installation date

- future expansion plans for process- turbo machine suitability for process (i.e.,

adequate capacity)

- equipment maintenance (i.e., last servicing by manufacturer)

- type of fluid handled (i.e., corrosive or erosive)

- system or process changes



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- availability of process and instrumentation diagrams andperformance curves

- number of operating points

- required performance at each operating point

- estimated annual hours at each operating point

- control mechanism to achieve various operating points

- approximate range of valve or damper settings

- approximate range of speed control

- bypass, idling,or flow wastage when process cycle does not-require turbo machine

- turbo machine operation problems (i.e.,noise,vibration,duct pulsation)

Step 1: Review Process & Instrumentation Diagram (P&ID)

To enhance system knowledge, review a process andinstrumentation diagram (P&ID) of the system. Sketch by hand ifdrawings are unavailable. Figure 3.1 shows a P&ID for a typicalcentrifugal-induced draft (ID) and forced-draft (FD) fan application.

P&IDs graphically represent the system and process by:

- showing the position of the turbo machine to othercomponents

- differentiating between fixed and variable pressure losscomponents

- indicating the parameter controlled in the system (i.e.,pressure, flow, temperature)

- locating the system control point (i.e.,discharge ducting, inletplenum)



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Step 2 : Review Prescreening Information

Evaluate accuracy, importance, and relevance of informationobtained in the field. Use the following prescreening review todetermine if there are inefficient conditions that can be improved.


Cell 1

Cell 2

Cell 3

Cell 4

Gas

Furnace

Crude Oil

Hot Air

Flue Gases

Temperature

regulation

Heat

Exchanger

Oxygen percentage monitor

Multiple pipe

systemsHeated

crude oil

to first stage

separation

M1

I.D.

Fan

M2

F.D.

Fan

3-phase

600VTo Main

3-phase

600VTo Main

Cold Air

Flue gases

to atmosphere

1 and 2

AC motors

(250 hp)

Figure 3.1

Process and Instrumentation Diagram


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Table 3.1

Prescreening Review


Condition

Inefficient TurboMachine

Characteristic

Misapplication oflow efficiency

impeller

Inefficient drive

Age of equipment

Turbo machine

operating at poor

selection point

Comments

Radial blade impellers needed for material-handling

applications

Oversized motor

Motor not high efficiency design

Oversized V-belt drive package

Old adjustable speed-drive technology

Older equipment is generally less efficient

Turbo machine relocated for a different application

Elimination of some pipe/duct runs on multi-run

distribution system

Addition of auxiliary cleaning equipment

Throttled operation for oversized turbo machine

Straight Radial Blades

Approximately 65% / 70%

peak static efficiency

Airfoil Blades

Approximately 84% / 90%

peak static efficiency

Rota

tion

Rota

tion

Operation with original

equipment

Pressure

Actual

Operating Point

Flow

Original

Selection

Point

Operation with new

reselected equipment

Actual

Operating Point

Pressure

Flow


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Table 3.1

Prescreening Review (contd)


Condition

Poor Maintenance

Characteristic

Excessive systemresistance

Worn impeller or

bearings

Flow leakage

Internal turbo

machinedeficiencies

Comments

Dirty screens, nozzles, filters, coils Material build-up on impellers, turning vanes

Vibration/imbalance

Holes in flex connection

Deteriorated gaskets

Loose or distorted flanges

Corrosion or erosion in piping and ductwork

Worn pump seals Running clearance

Flow

Rota

tion

Build-upInlet Box

Improper set-up of fan

impeller allows air to

recirculate internally

Build-up on fan blades

reduces efficiency

Erosion of fan blades

reduces efficiency


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Table 3.1



Condition

System EffectFactors

Characteristic

Poor fan intakedesign

Comments

Elbow directly on inlet causes non-uniform flow profile

Rounded elbow is better than square elbow

Addition of turning vanes will streamline flow

Installation of splitter plate reduces entry turbulence on

fans located near walls

Length

of Duct

D

R

Turning

Vanes

Splitter


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Table 3.1



Condition

System EffectFactors (contd)

Characteristic

Poor fan intakedesign (contd)

Comments

Butterfly damper close to fan inlet creates turbulence and

decreases performance

Orientation of inlet elbows can cause air to pre-swirl in

the direction opposite to wheel rotation

Turning vanes can improve performance for this condition

Butterfly Inlet Damper

Turning

VanesImpeller

Rotation

Corrected Counterrotating SwirlCounterrotating Swirl

Impeller

Rotation


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Table 3.1



Condition


Characteristic

Poor fandischarge design

Obstructions at

fan inlets and

outlets

Comments

Elbow directly on fan discharge causes performance

deficiency

If fan cannot be re-oriented, careful turning-vane design is

required

Poor transition and flex connection installations disrupt

flow and cause turbulence

Elbow on Discharge Fan Re-oriented toUp-blast Position

Discharge Duct Work

Flex Connection

Axial Fan

Inlet Duct Work


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Table 3.1



Condition


Excessive Flow

and Pressure

Losses

Characteristic

Air pockets atpump inlet

Poor pump inlet

design

High pressure

losses across

system

components

Comments

Caused by lack of streamlined design

Increases exponentially with flow velocity

Pressure Loss = Co x (Velocity)2

An air pocket can form where

a symmetrical elbow appears

in a suction line

Eccentric tapered reducer

prevents air pockets (above)

when pipe size is reduced

Suction SuctionAir pocket

Vertical elbow permits

reasonably equal distribution

to impeller. Flow is still better

with straight section before

pump.

Horizontal elbow distorts

and may reverse flow. With

double-suction pump, inlet

on small radius side may be

partly starved.

Poor ductwork offset with

square elbows

Improved ductwork with

turning vanes


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Table 3.1



Condition

Excessive Flowand Pressure

Losses (contd)

Oversized Turbo

Machine

Inefficient Control

of Turbo Machine

Characteristic

High pressurelosses across

system

components

(contd)

Excess flow

Flow wastage

Continuous

operation with

partially closed

dampers or valves

Throttled

operating point

Unnecessary

operation

Comments

System entry conditions from plenums and vessels should

provide smooth entry conditions for fluid

System constrictions may result from construction

methods used to bypass other plant equipment

System valves and dampers may be in a permanent,

partially closed position

Existing process may operate with less flow

Changes to process may reduce flow requirements

Process cycle may have periods with no need for turbo

machine operation

Turbo machine may be running while rest of process is shut down

Multi-port collection or distribution system may have ports

left open unnecessarily

Original performance margins were too great

Turbo machine relocated from different application

System resistance over-estimated

Removal of system component has reduced pressure drop

Original sizing done for infrequent upset condition

Turbo machine throttling used instead of speed control

Outlet fan dampers used instead of variable inlet vane control

No controls are used and turbo machine supplies excess capacity

Recirculation mode used when process does not require

turbo machine operation

Lack of control sequence may have turbo machine

running when not required

Vena Contracta increasesentry losses

Optimal off-set design with

rounded elbows and turning vanes

Addition of bell mouth creates

smooth entry with minimal losses

Vena Contracta


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Step 3 : Prescreening Conclusions

Figure 3.2 presents general conditions that may indicate wheresystems are operating inefficiently. With this information, you can

determine if a candidate(s) merits a more in-depth engineeringfeasibility study to determine viable technical solutions andquantify savings.

Further assessment should be carried out by an experiencedengineering specialist (i.e., consultant engineer, contractor,equipment manufacturer, or customer operating staff).

Appendix A provides guidelines engineering specialists may followwhen they prepare optimization feasibility studies.

LOAD DATA GATHERING

The engineering specialist will prepare feasibility study findingsand recommendations,based on:

evaluation of viable technical options that can be employed

accurate determination of energy savings

economic analysis

To effectively carry out this study:

locate all point(s) of operation (i.e., flow, pressure, and power);

determine the turbo machine load duty cycle;

evaluate data accuracy and reliability;

evaluate characteristic of data: seasonal, batch,product oroutput fluctuations.

Common sources of information are given in the followingsubsections. Figure 3.2 provides general guidelines on how togather data for development of the load duty cycle.



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Temporary Metering

performed when operating data is unavailable (or deemedunreliable)

typical power metering would be for a two-week period,with15-minute interval samples

interpretation of results should take into account seasonal orproduction variations

if possible, metering on other parameters should be donesimultaneously, i.e., temperature,rotational speed, damper

settings, pressure,pressure differential across variableresistance components,etc.

Field Performance Testing

testing must be done to verify point(s) of operation and systembehavior.

Chapter 4 of this handbook gives more guidelines on fieldperformance testing.



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AreOperating Records

Complete?

No

Yes

Is theLoad Pattern

Seasonal?

Field MeasurementRequired

No

Yes

Can theDuty Cycle be

Developed by OtherMeans?

No

Yes

Gather GeneralInformation

Extended DataAccumulation Period

Generate Load Duty Cycle

Short DataAccumulation Period

AreOperating Records

Available?

- Horsepower of Motor- Hours of Operation- Suppliers' Performance Curve

InitiateData Gathering

No

Yes

Figure 3.2

Data Gathering Decision Tree


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DEVELOPMENT OF LOAD DUTY CYCLE

The load duty cycle is a frequency distribution of the time that aturbo machine operates at each point of operation. Two

components are needed for development:

turbo machine load Plot the points of operation on theturbo machine performance curve to identify system flow andpressure relationship.

duty cycle This is the number of hours the turbo machineoperates at each point of operation.

Tabulate all data in a load/duty/cycle chart. An example is shownin Figure 3.3.

Figure 3.3

Load Duty Cycle Chart


Point Time atof Flow Pressure Brake Speed Input Operating kWh/yr

Operation Hp (RPM) kW to Motor Point(hr/yr)

1

2

3

4

5

6

TOTALkWh/yr


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It may be useful to construct a histogram of load versus time toshow graphically the load duty cycle of the system. Select thehorizontal axis for an appropriate system parameter. See

Figure 3.4.

TECHNICAL OPTIONS REVIEW

General

Assess the practicality of implementing the various performanceoptimization techniques. The following items are needed for thisprocess:

manufacturer's performance curve; load duty-cycle charts, as completed for existing system,and for

system employing performance optimization techniques (seepage 34);

system P&ID (see page 21);

system loss evaluation (see page 36);

report on equipment internal inspection (see page 37).


Percent Flow

Perc

entTotalOperatingTime

20

10

0

0 10 20 30 40 50 60 70 80 90 100

B

Figure 3.4

Typical Pump Load Duty Cycle


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To determine the best performance optimization technique,

1. Review the process requirements. Determine if the processcan operate just as well with reduced flow or pressure.

2. Review system test results to identify peak pressure losses.Evaluate if these losses can be reduced by modifying thesystem.

3. Compare turbo machine field performance test results withmanufacturer's predicted performance. Check equipmentinternal inspection report to account for discrepancy between

actual and predicted performance. Assess the need forequipment repair/maintenance.

4. Assess the viability of each performance optimizationtechnique.

Since each installation has unique characteristics, good engineeringjudgement and experience is required to carry out a thoroughevaluation of each technical option.

System Loss Evaluation

To carry out a comprehensive performance evaluation, thefeasibility study must address:

original design parameters used for equipment rating

actual system requirements

duct/pipe geometry and associated system losses

Examples of duct/pipe arrangements that cause high system losses:

short radius elbows used in duct/pipe instead of long radiuselbows or turning vanes;

poor duct/pipe inlet conditions from vessels and plenums;



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steel bracing left inside ductwork

inappropriate damper linkage adjustments

Call a manufacturer's service representative or experienced turbomachinery engineer for an accurate evaluation of the internalcondition of the turbo machine.

Application Considerations

To check the suitability of each performance optimizationtechnique, consider the entire system including:

type of fluid stream

environmental consideration (i.e., indoor, outdoor, hazardousarea)

system limitations

physical constraints

Following are typical application considerations for turbo machineperformance optimization techniques:

Adjustable Speed Drives

- spectrum analysis on impeller may be required

- low-speed motor-cooling limitations

- reduced motor torque may not overcome high breakaway

torque at start-up- may require motor oversizing

- fans may be forced into unstable operating ranges

- pumps can experience extremely high temperature build-up,if pressure reduction is less than static head



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Equipment Upgrade

- high efficiency impellers are generally not suitable for harshenvironments

Impeller Trimming

- provides permanent de-rating

- not suitable if full capacity occasionally needed

Variable Inlet Valves

- have non-linear control range when low flows required,maycause pulsations in pressure

ENERGY ASSESSMENT

Compare the electrical consumption of each of the selectedperformance optimization measures with the consumption of theexisting system. All desired points of operation will requireconsideration.

Electrical savings can occur in demand (kW) and energy (kWh).Demand savings depend on whether turbo machinery loadcoincides with the plant's monthly peak.

Annual energy savings are based on:

hours the process or turbo machine operates at each point ofoperation

average loading at times of monthly demand peaks demand and energy rates for the particular plant



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ECONOMIC ANALYSIS

Total Savings

Total savings of performance optimization may result from indirectbenefits as well as electrical savings.

Some examples are:

improved power factor

raw material savings

improved product quality

reduced labour costs

Classify non-energy savings into groups of hard and soft dollarsavings, based on how easily they can be quantified.

Cost Estimates

Assess the economics of the performance optimization technique

by establishing cost estimates:

Capital Equipment

- quotations from manufacturers

- suppliers catalogues

Engineering and Design

- estimate as a percentage of direct costs- quotations from consultants or contractors

Installation

- applying an hourly rate to estimated labour requirements

- quotations from contractors



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- equipment rentals

- miscellaneous materials

Simple Payback and IRR

Compare the total cost of implementing a performanceoptimization technique against the total benefit. Two methodsusually used are: Simple payback and internal rate of return (IRR).

Simple payback is used to determine the time required for thesavings to repay the initial capital outlay.

Time (years) = Project costAverage annual cash savings

Internal rate of return takes into account the time value of money.It is an adjusted rate that discounts savings (inflows) and theexpense of the project (outflows) to zero. Determine a project'sacceptability on these grounds,by comparing the performanceoptimization project's IRR against the company's prescribed rate of

return.

If the IRR passes this test, the project will likely be undertaken.The IRR is calculated by finding the discount rate, R, that solves thefollowing equation:

(Cinflow) = (Coutflow)n

(1+R)n (1+R)n

where:Cinflow = cash inflowsCoutflow = cash outflowsR = rate of return that will solve the expressionn = signifies that the discounted inflows and

outflows must be added from time zerothrough time n.


n

t=0


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GENERAL

This section provides an overview of information required toconduct field performance tests of fan, pump, and blower systems.The equations, and calculation procedures required to correct themeasured data back to the manufacturer's performance curves, arealso outlined.

APPLICABLE SAFETY STANDARDS

The fans,pumps, and blowers discussed in this handbook arerotating equipment driven by electric motors. When dealing withthis equipment, extreme caution must be exercised to avoidelectric shock or injury from rotating or moving mechanicalcomponents.

All applicable safety standards in effect at the equipment site mustbe observed. Also follow safety standards and practices outlined inChapter 5 of this handbook and:

AMCA Publication #410

Recommended Safety Practices for Air Moving Devices

Performance Evaluation of Candidates 43

C H A P T E R 4

Performance Evaluationof Candidates


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APPLICABLE PERFORMANCE TEST STANDARDS

The data included in the test manuals referenced below for fans,pumps, and blowers will be adequate to conduct the performance

tests in most cases. If unusual liquids or gases are being handled,or if a significant amount of duct work or piping is locatedbetween the pressure measuring points and the equipment, furtherinformation may be required. Additional information regarding thedensities and viscosities of various liquids or gases and the frictionlosses of pipes,ducts, fittings, and transitions may be required. Thisinformation is readily available in various engineering handbooks

and textbooks. Pump Performance Test Standards

Performance testing standards for pumps have been prepared andpublished by the Hydraulic Institute,Cleveland, Ohio,USA. Thetesting standard is part of a complete set of pump standardspublished as:

Hydraulic Institute Standards

Fan and Blower Performance Test Standards

The Air Movement and Control Association,Inc. (AMCA),ArlingtonHeight, Illinois,USA,has several publications for testing fans andblowers. The publication most applicable to the type of testperformed under this program is:

AMCA Publication 203

Field Performance Measurements of Fan Systems

This publication is one of four manuals that also cover the designof air systems, fan and system interaction, including fan laws andsystem effect factors (SEF), and troubleshooting of air-movingsystems.



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MEASUREMENT PARAMETERS AND TEST INSTRUMENTS

Measurement Parameters

The parameters that must be determined for accurate evaluation offan, pump or blower performance are:

liquid or gas properties, i.e.,density and, for liquids,viscosity;

flow rate;

inlet and outlet pressure head;

rotational speed of equipment;

input power.

Test Instruments

The instruments required to measure each parameter are listed inthe appropriate test procedure sections.

Calibration of Test Instruments

Instruments used in field performance tests are often subjected torough handling and hostile environments.Consequently, it isessential to ensure that the instruments are in good condition andare capable of providing accurate and repeatable measurements.As a minimum, the following procedure should be adopted:

physical inspection and functionality test of instrument before,

during,and after each field test; scheduled calibration of instruments to a recognized national

standard;

calibration of instruments after repair, or if any doubt arisesregarding accuracy.

Note: An extra set of instruments can be useful to check accuracy

or replace malfunctioning instruments.



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GENERAL TEST PROCEDURES

Location of Test Points

To obtain reliable measurements of the inlet and dischargepressures of the equipment, the location of pressure test pointsin the pipes or ducts should normally be at least five to tenequivalent diameters downstream of the nearest elbow,transition, or other flow disturbance (Figure 4.1).

Figure 4.1

Location of Test Points

An appropriate pressure loss calculation for the duct or pipeand any fittings between the equipment flange and themeasuring point must be made and added to the measuredpressure.

The flow-measuring plane should also be five to ten equivalentdiameters downstream from the nearest flow disturbance oroutlet flange as illustrated in Figure 4.2.


, , , , , , , ,

, , , , , , , ,

, , , , , , , ,

, , , , , , , ,

y y y y y y y y

y y y y y y y y

y y y y y y y y

y y y y y y y y

do

di

L > 5 x do

L > 5 x di


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Inspect the duct/pipe to check that no branches or leaks occurbetween the measuring plane and the equipment to ensurethat the flow measured has passed through the equipment.

Figure 4.2

Selection of Flow Measuring Plane

Control of Turbo Machine and System

The purpose of this test is to determine the performance of themachine during operation. If the system or process varies, themachine performance may modulate during the time the test isbeing conducted. This must be avoided.

The duty points at which a performance test is required mustbe selected by referencing the process and instrumentationdiagram and the duty cycle developed during the prescreeningand data-gathering process.


BadMeasuring

Plane

PreferredMeasuringPlane

, ,

, ,

y y

y y

, , , , , , , , , y y y y y y y y y


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A control lockout must be implemented in consultation withplant operating personnel to hold the machine at a constantpoint of operation during the test.

The determination of a single performance point may takefrom several minutes to several hours, depending on thegeometry of the system and the amount of test data to becollected.

Multiple readings of data such as power, speed,controlvalve/damper position, and temperature and pressure of fluidshould be taken to ensure these parameters are held constant

for long tests.

Performance Test Records

A field test data sheet should be prepared before the test toprovide a consistent and complete format for recording test data.

A custom form should be prepared for each machine to betested. Refer to theHydraulic Institute andAMCA 203handbooks for examples of typical data sheets.

Sketches of the test point locations, system duct, or pipingorientation and dimensions,and a copy of the P&ID are anecessary part of the performance test records.

Rotational Speed Measurement

Instruments most commonly used include an electronic contact ornon-contact tachometer, stroboscopic tachometer, or revolutioncounter with a chronometer. Following are some considerationsfor speed measurements:

Select good physical access to the shaft or some rotatingcomponent of the machine.



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Select instruments that will provide accurate readings for the speedrange of interest. A demonstrable accuracy of 0.5% or better isacceptable.

At least two readings,one near the beginning of the test andone near the end, should be taken.

If the test duration is longer than 15 minutes,additionalreadings should be taken, approximately every 15 minutes.

If multiple readings show the speed to be constant, the timebetween readings can be extended.

Note: Rotational speed should not change during the course of thetest.

Motor Input Power Measurement

The primary reason for conducting the tests is to estimate howmuch the motor input power can be reduced, using theoptimization techniques available. Therefore, it is essential that a

comprehensive analysis of the motor input power be conducted.

Figure 4.3

Connecting a Wattmeter


Wattmeter

Motor

StarterMotor

CT-1 PT-1

CT-2

CT-3

PT-2

1

2

3

0

0

0


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Many of the machines to be tested under this program will bethree-phase, 320,460 or 575 volt. Portable power analyzers arereadily available measure the input power in this range, taking

into account voltage,amperage,and power factor. They canprovide a direct readout of kW. Refer to Figure 4.3.

Specialized measuring equipment,utilizing potential andcurrent transformers, would normally be required for systemsabove 600 volts. A qualified electrical engineer may have todesign an adequate power measuring system.

A qualified electrician should connect these analyzers to the

motor input power leads.

For systems fitted with ASDs, measure the power going into theASD, rather than the power going into the motor. To determinethe actual power being consumed by the equipment,efficiencycorrection factors for part load operation should be included inthe calculations.

The test data sheet should allow for the recording of volts, amps,power factor, and kilowatts, as a minimum.

At least two readings,one near the beginning of the test andone near the end, should be taken.

If the test duration is longer than 15 minutes,additionalreadings should be taken, approximately every 15 minutes.

If multiple readings show the power to be constant, the timebetween readings can be extended.

Note: The power consumed throughout the duration of the testshould be constant.



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Pump Head Measurement

A broad range of instruments are available to suit any application.

Characteristics of the liquid, i.e., temperature, corrosiveness,etc., and the expected range of the measured head must beconsidered to avoid damage to the instrument by overloading,or by exposure to hot or corrosive fluids.

Figure 4.6

Pressure Tap Geometry

The range and precision of the instrument should be selectedso that the accuracy of the reading is better than 2%.

Pressure taps with the proper geometry should be used toensure accurate pressure readings. Refer to Figure 4.6 forexample.

Locate pressure taps in the suction and discharge lines in anarea where steady flow conditions exist.


Brass Plug

Nipple

Connects

HereNipple

Connects

HereApprox. Rad.

d

4

Approx. Rad.d

4

d to1"

8

1"

4d

Pipe Coupling

Weld

Minimum

2d


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The geometry of the pipe between the gauge and the pumpflange must be known,so that friction loss can be calculatedand used to arrive at pump total head at the flanges.

If the pump is drawing from or discharging to a pit or tank thatis open to atmosphere, it may be more convenient to calculatethe head at the corresponding pump flange from the differencein elevation and the appropriate losses. Refer to Figure 4.8.

Pressure readings should be observed periodically throughoutthe test to ensure no significant fluctuation occurs.

Figure 4.8

Suction Head by Calculation

PUMP TEST CALCULATION

Measured pump performance will normally be compared with thepump performance curve issued by the manufacturer. Correctionsfor specific gravity, viscosity, and speed may be necessary if thefluid characteristics and/or pump speed tested differ from that

shown on the performance curve.


Static

Head


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The pump input power should then be further corrected to therated speed and specific gravity shown on the performancecurve

BHPc = BHP x Nc 3 x SgcN Sg

where:BHPc = pump input power at rated speedBHP = pump input power at test speedNc = rated speedN = test speed

Sgc = rated specific gravitySg = test specific gravity

FAN AND BLOWER TEST PROCEDURES

Gas Properties

The gas density must be determined to accurately calculate other

performance parameters.Gas density is a function of absolutepressure, temperature,and molecular weight.

Absolute pressure is determined by adding the barometricpressure at the site and the static pressure at the measuringplane.

Barometric pressure can be determined with a portableaneroid barometer.

Static pressure at the measuring plane must be measured asdiscussed on page 64.

Gas temperature is determined with an instrument-qualitythermometer.

If the fan is handling ambient air, molecular weight can beassumed to be that of air with appropriate corrections made for

relative humidity. Relative humidity is determined by



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measuring wet bulb and dry bulb temperatures with a slingpsychrometer.

To determine the density of a gas other than air may require

the use of complex equipment by a qualified expert to obtainthe chemical composition of the gas. If the gas is a complexmixture of various constituents, as found in many industrialprocesses, the company chemist or an independent laboratoryshould be consulted to collect a gas sample for analysis in thelab. Particular care should be used if the gas is toxic,corrosive,or explosive.

Note: It is important to ascertain from the P&ID that the gas doesnot undergo any change in moisture content or molecular weight(i.e.,water sprays, cooling coils, burners,etc.) between the fan orblower and the plane at which wet and dry bulb temperatures orgas constituents and barometric pressure are measured. If nochanges occur, the gas wiIl approximate the perfect gas laws andthe ratio of absolute temperatures and absolute pressures can be

used to determine the density at all planes of interest. For thisreason, it is important to record the temperature and staticpressure at all planes of interest.



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Gas Flow Rate Measurement

Air or gas flow rate is determined by performing a velocitypressure traverse in the duct using one of the following:

pitot tube and inclined manometer, electronic micromanometeror magnehelic gauge

vane anemometer

thermistor anemometer used as a probe and readout

The airflow measurement methods recognized by Air Movement

and Control Association (AMCA) require the use of a pitot statictube or a double reverse tube, and an inclined manometer,preferably with a variable slope ratio to provide sufficient accuracyat a range of air velocities. Figures 4.9 4.11 (p. 62) show variousdevices used to measure air or gas velocity pressure.

The velocity pressure traverse must be conducted in an area ofthe duct where the flow is stable and uniform. Refer to

AMCA 203 for guidelines to select and qualify a suitabletraverse plane location. Generally, the requirement is that morethan 75% of the velocity pressure readings should exceed 1/10of the maximum reading.

The number and distribution of traverse points required in aduct is a function of the duct geometry. Refer toAMCA 203 forguidelines on how to select traverse points. The number of

points required byAMCA 203 should be taken as a minimum.A traverse using fewer points is unacceptable.

Consider the following:

a pitot traverse normally requires two people, since it is usuallyimpossible to hold the pitot tube steady and record the velocitypressure reading at the same time.



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Air Flow

Static

PressureTotal

Pressure

Reverse

Tube

Stainless

Steel Tubing

preferred approx.

.375" OD

Air Flow

Impact Tube

10 in. wg1:1

Slope Ratio

0.5 in. wg20:1 Slope Ratio

1 in. wg10:1 Slope Ratio

2 in. wg5:1 Slope Ratio

Figure 4.9

Pitot Static Tube

Figure 4.10

Double Reverse Tube

Figure 4.11

Inclined Manometer


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The access holes drilled in the duct for the pitot tube should beplugged when not in use to prevent leakage or disruption offlow profiles in the duct.

A pitot traverse in a large duct may require special pitot tubes,longer than the standard maximum of 5 feet or access fromboth sides of the duct.

Measurements in high temperature, toxic, or combustible gasstreams also require special consideration. If possible, thetraverse should be conducted in a duct under negative staticpressure so that the gas will not leak out on the tester.

Note: Determining the f low through a fan or blower is generallythe most complex part of the performance measurements. Ifproper equipment and procedures are used,and the selection of atraverse plane is satisfactory, the flow rate can be determined towithin 2% to 10% accuracy. A review of the uncertainty analysis inAMCA 203will highlight the parameters that need to be mosttightly controlled to maintain the best accuracy.

Fan and Blower Pressure Measurement

A broad range of instruments are available.

Characteristics of the gas, i.e., temperature, corrosiveness,etc.,and the expected range of the measured pressure, must beconsidered to avoid damage to the instrument by overloadingor by exposure to hot or corrosive gases.

The range and precision of the instrument should be selectedso that the accuracy of the reading is better than 2%.

Pressures to be determined for fans and blowers include static andvelocity pressures, which,when added, equal total pressure.

Velocity pressure is determined from the calculated flow rate,the area of the duct,and the density of the gas stream.



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Record duct dimensions for all planes of interest.

Static pressure readings in the fan discharge duct and in the faninlet duct and static pressure readings at the velocity pressuretraverse plane will be required.

Static pressure can be measured from the static tap on the pitotstatic tube,as the tube is traversed in the duct. This willprovide several consistent readings. Refer to Figure 4.12.

The pitot tube should be oriented in the same way as forvelocity pressure readings or the pressure read from the statictap may not be accurate.

Static pressure taps can be made in the wall of the duct. RefertoAMCA 203 guidelines. Four pressure taps are required,equally spaced around the periphery of the duct. The readingsfrom the four taps should be averaged to provide the staticpressure at that plane.

Note: Fan suppliers normally specify pressures at the inlet and

discharge flanges of the equipment. Consequently, it is important


Ps3

Pv3

Ps5 Ps4

Fan Static Pressure

Ps = Ps2 - Ps1 - Pv1

where Ps2 = Ps5

where Ps1 = Ps4

where Pv1 = Pv3

Figure 4.12

Static Pressure Readings


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where:V3 = average velocity (ft/min)Pv3 = velocity pressure (in.wg)

d3 = density (lbm /ft3

)Knowing this velocity and the geometry of the ductwork, the flowrate can be calculated as follows:

Q3 = V3A3

where:Q3 = gas flow rate (cfm)

V3 = average velocity (ft/min)A3 = duct area at traverse plane (ft2)

The fan or blower flow rate is defined as being the volume flowrate at fan inlet density. Continuity of mass allows for thecalculations of volume flow rates at other planes in the system. Ifthe densities at the other planes are known, the following equationis used:

QX = Q3 x d3dx

where:Qx = flow rate at plane xQ3 = flow rate at traverse planed3 = density at traverse planedx = density at plane x

To compare the calculated fan or blower flow rate to theperformance curve supplied by the fan or blower manufacturer, itmay be necessary to correct for fan speed, using the followingequations:

Qc = Q x Nc

N



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Performance curves supplied by the fan or blowermanufacturer will show the pressures based on the equipmentinlet and outlet flanges.

To compare the pressures measured during the test to theperformance curve, it is necessary to take into considerationany pressure losses and system effect factor (SEF) between thepressure measuring stations and the fan inlet and outlet flangesto determine the total pressure at the fan inlet and outletflanges.

Also calculate velocity pressure at the outlet flange.

Fan static pressure is given by

FSP = TPo - TP1 - VPo

where:FSP = fan static pressureTPo = total pressure at fan outletTP1 = total pressure at fan inlet

VPo = velocity pressure at fan outlet

Fan static pressure is normally shown on the manufacturer'sperformance curve. This is plotted against flow rate. To correctthe FSP from the test speed and density to that shown on theperformance curve, the following formula is used:

FSPc = FSP x Nc 2 x dc

N dwhere:

FSPc = corrected fan static pressureFSP = test fan static pressureNc = corrected speedN = test speeddc = corrected inlet density

d = test inlet density



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Fan Power Calculation

Input power to the motor must be calculated in the mannerapplicable to the instrument being used.

The performance curve supplied by the fan and blowermanufacturers normally shows the input power to the fan orblower. Therefore, the motor input power measured during thetest must be corrected for part-load efficiency to reflect thepercent of full-load power at which the motor is operating.

If the equipment is V-belt driven, further adjustment of the

measured power is required. It is necessary to estimate theV-belt drive losses as a function of motor horsepower.

To correct the measured power to the fan or blower for thespeed and density shown on the manufacturer's performancecurve, the following formula should be used:

BHPc = BHP x Nc 3 x dcN d

where:BHPc = corrected input horsepowerBHP = test input horsepower

= kWmeasured x Effmotor x Effdrive0.746

Nc = corrected speedN = test speed

dc = corrected inlet densityd = test inlet density



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GENERAL

Rotating machinery is a particularly dangerous element of plantequipment due to the tremendous forces that they exert,bothmechanically and electrically. Always employ safety measureswhen carrying out performance tests and exercises. Extremecaution is to be exercised at all times. For the most part, this

means applying common sense to the situation. However, everyindustrial environment will have specific safety regulations thatmust be followed.

PLANT REGULATIONS

General safety items apply to most industrial settings. Always referto existing regulations in specific industrial plants.

Hard hat, safety glasses,and certified boots must be worn at alltimes.

Visitors must stay in designated areas.

Safety meetingsare to be conducted before workcommences to discuss hazardous aspects of the work.

Safety 71

C H A P T E R 5

Safety


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couplings,and bearings, even when these parts are enclosed bysuitable guards.

During testing, the rotating speeds must never exceed the

manufacturer's rating or catastrophic failure may result.

When testing at various points of operation,care should betaken to ensure that the equipment is not operated in anunstable region of the equipment's performance curve. Severevibration and catastrophic equipment failure may result if:

- a fan is operated in a stall condition

- a pump is operated in a manner that causes cavitation

It must always be recognized that the components of fans,pumps, and blowers are highly stressed. Operation and testingshould be done only by knowledgeable and experiencedpersonnel. If there is any doubt as to safety aspects of thework,refer either to a qualified plant engineer or to themanufacturer of the particular equipment involved.



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A - ENGINEERING SPECIALIST PROPOSAL GUIDELINES

The Performance Optimization Feasibility Study proposal shouldinclude the following outline:

(1) Cover Sheet

Study title

Submitted to (customer name,contact, and location)

Date submitted

Submitted by (engineering specialist and company)

(2) Executive Summary

(3) Application/Process Description

Equipment type and size (fan, pump,or blower system)

Process information (batch, continuous,other)

Fluid or material moved (air, water, gas, sewage,etc.)

(4) Current Situation

Current operating conditions

Appendices 75

C H A P T E R 6

Appendices


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Equipment condition (new, refurbished,etc.)

Estimated service life remaining

Present control scheme Future expansion plan if known

(5) Potential for Energy Savings

Classify options or measures to be examined into thefollowing general categories:

a) ASD (electronic, mechanical, other)

b) Equipment modification (sizing, new designs,etc.)

c) Process modification (process change,ponyequipment,etc.)

d) Other (specify)

Estimated annual savings (on-peak and off-peak kW and

kWh)(6) Customer Benefits

(7) Scope of Work

Objectives of the study

Project initiatives and methodology

Project schedule(8) Study Team

Proposed staff

Sub-contractors

Resums for key personnel

Type of liability insurance, if any



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Estimated service life remaining

Future expansion plan

(6) Feasibility Study Methodologya) Load-Data Gathering

Discuss load-data gathering sources

Test methodology and instrumentations used

Field data summary

Internal inspection of equipment Load-data sensitivity analysis

b) Development of Load-Duty Cycle

System curve

Number of operating hours at each operating point

Develop lead/duty/cycle chart and/or histogramc) Technical Options Review

Equipment performance curve

List at least three alternatives to optimize the system

Assess viability of each technical option

Identify ancillary measures to fine-tune system Analysis of Equipment condition

d) Energy Assessment and Economic Analysis

Develop load/duty/cycle chart for each technical option

Calculate demand and energy savings for each option(on-peak and off-peak)

Appendices 79


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C - GLOSSARY OF TERMS

Adjustable Speed Drive: A mechanical, hydraulic,or electricsystem used to match motor speed to changes in process load

requirements.

Blower: A fan with discharge pressure from 2 psig (55.4 Wg) to36 psig (914.6 Wg).

Design Point: A point of operation generally based on a duty thatis slightly higher than the highest duty ever expected for theapplication.This point represents a specific set of criteria used to

select the fan,pump,or blower.Duty: For a fan, the inlet volume flow at a rated fan pressure; for apump, the inlet volume at a rated head.

Fan: A device that causes flow of gaseous fluid by creating apressure difference on the medium to be transported.

Field Performance Tests: Field determination of turbo machine

flow, pressure and power to identify actual points of operation.Head, Dynamic or Total: In flowing fluid, the sum of the staticand velocity pressures at the point of measurement.

Head, Static: The static pressure of a fluid expressed in terms ofthe height of a column of fluid that it would support.

Horsepower (Hp): The measure of work equivalent to lifting

550 lbs one foot in one second,or 745.7 watts.Load Duty Cycle: The relationship between the operating timeand rest time,or repeatable operation at different loads.

Load: The burden on a motor by the driven machine,sometimessynonymous with 'required power.'

Motor: A device that takes electrical energy and converts it into

mechanical energy to turn a shaft.

Appendices 81


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Net Positive Suction Head (NPSH): The amount of pressure inexcess of the fluid vapor pressure required to prevent theformation of vapor pockets.

Performance Curve: A plot of the fan,pump, or blowerperformance characteristics from zero delivery to free flow.

Point of Operation: Where the system curve intersects thepressure and flow curve on the turbo machine's actualperformance curve.

Pressure, Static: The pressure with respect to a surface at rest in

relation to the surrounding fluid.Pressure, Total: The sum of the static pressure and the velocitypressure at the point of measurement.

Pressure, Velocity: The pressure at a point in a fluid existing byvirtue of its density and its rate of motion.

Process and Instrumentation Diagram (P&ID): A schematic

of a process that graphically represents the relationship of allprocess equipment to interconnecting piping,duct-work,and theassociated control sensors, actuators, and controllers; usuallyaccompanied by a sequence of operation.

Process Control: How turbo machine performance is altered tosatisfy system requirements.

Speed Modulation: A control process whereby the speed of a

rotating machine is varied between preset speeds to maintain acontrol setpoint.

Static Efficiency of a Fan: The total efficiency multiplied by theratio of fan static pressure to fan total pressure.

Static Suction Head: The total system head on the suction sideof a pump with zero flow (can be positive or negative).



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Suction Lift: The head in reference to the system datum that isimposed on the suction of a pump and, for open systems, is theelevation of the pump above the transported fluid exposed to

atmosphere.System: The combination of turbo machine and the connectedhardware through which flow occurs.

System Effect Factor: A factor related to the velocity of thetransported medium that corrects for pressure losses due tosystem inlet and outlet conditions that deviate from standard testconditions.

System Losses: Pressure drop across system hardwarecomponents.

System Resistance: Resistance to flow resulting from thepressure drop and frictional losses of all system hardware.

Throttling: An irreversible adiabatic process that involveslowering the pressure of a fluid without work to control flow rate.

Turbo Machinery: Equipment that uses rotating elements toimpart work on a transported medium, or that uses the energy in aflowing medium to impart work on an external load.

Variable Inlet Vanes (VIVs): An inlet device that changes thedynamic characteristics of the machine as if it were a differentmachine at each of the vane positions.

Appendices 83


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ACKNOWLEDGEMENT

Portions of this publication have been reprinted with thepermission of the Air Movement and Control Association, Inc. and

the Hydraulic Institute. More information on standards for thedesign, testing, and application of fan,pump,and blower systems isavailable from the above-mentioned associations.

Fans/Blowers: Air Movement and Control Association, Inc.30 West University DriveArlington Heights, Illinois, 60004-1893Tel: (708) 394-0150

Fax:(708) 253-0088

Pumps: Hydraulic Institute30200 Detroit RoadCleveland, Ohio,44145Tel: (216) 899-0010Fax:(216) 892-1404

Neither of the said associations assume any liability with respect tothe use or misuse of the information, data,designs,concepts,calculations, or source listing,contained in the handbook.



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Performance Op Tim Ization

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