UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGNING AIR FILTRATION TEST RIG (PROTOTYPE) IN
EVALUATE EFFICIENCY OF HVAC FILTER
This report submitted in accordance with requirement of the Universiti Teknikal
Malaysia Melaka (UTeM) for the Bachelor Degree of Mechanical Engineering
Technology (Refrigeration and Air Conditioning System) with Honours
by
AHMAD SHAFIQ BIN ABDUL GANI
B071310319
910804-12-5689
FACULTY OF ENGINEERING TECHNOLOGY
2016
DECLRATTION
I hereby, declared this report entitled “Designing air filtration test rig (prototype) in
evaluate efficiency of HVAC filter” is the results of my own research except as cited
in references
Signature : …………………………………………
Author’s name : AHMAD SHAFIQ BIN ABDUL GANI
Date : …………………………………………
APPROVAL
This report is submitted to the Faculty of Engineering Technology of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Mechanical
Engineering Technology (Refrigeration and air conditioning system) with Honours.
The member of the supervisory is as follow
…………………..
(Amir Abdullah bin Muhamad Damanhuri)
i
ABSTRAK
Kawalan pencemaran telah menjadi isu semasa dalam menyediakan kualiti udara
yang bersih. Penapis udara bertindak sebagai pertahanan utama terhadap pencemaran
melindungi komponen pemanasan, pengudaraan dan penghawa dingin (HVAC) dari
kotoran dan seterusnya membekalkan udara bersih kepada pengguna. Kecekapan
penapis udara ditakrifkan bagaimana penapis itu membersihkan udara dengan
menapis habuk-habuk (PM). Kejatuhan tekanan adalah prestasi utama yang menjadi
penunjuk kepada penapis HVAC. Oleh itu, ia boleh mengukur penggunaan tenaga
dengan meramalkan rintangan aliran udara penapis. Rintangan aliran udara yang
rendah adalah salah satu kaedah yang paling mudah untuk mengurangkan kos tenaga
dimana system motor HVAC tidak perlu bekerja keras untuk mengalirkan aliran
udara. Dalam erti kata lain, ujian penapis adalah salah satu kaedah yang terbaik
untuk mengukur prestasi penapis udara. Objektif kajian ini adalah untuk mereka
bentuk prototaip pelantar ujian penapis udara HVAC di mana ia boleh mengukur
prestasi penapis udara berdasarkan parameter utama. Kajian ini terbahagi kepada
beberapa peringkat iaitu persediaan dan penyiasatan pengiraan parameter kecekapan
penapis, proses rekaan dan proses pembuatan pelantar ujian. Rekabentuk pelantar
ujian penapis udara adalah bentuk ‘U’ dengan ukuran 20 inci x 20 inci dan untuk
bahagian penapis adalah 24 inci x 24 inci. Spesifikasi ujian pelantar adalah reka
bentuk untuk memenuhi standard ASHARE52.2 dan EN779 yang pelbagai kadar
aliran udara adalah dalam lingkungan 600 m³/h sehingga 6000 m³/h. Pada akhir
projek, prototaip ini seperti yang di jangka di mana ia boleh digunakan seperti
pelantar ujian penapis udara yang sebenar untuk membuat ujian individu
terutamanya bagi kontraktor bangunan.
ii
ABSTRACT
Contaminant control have become current issue in providing safe air quality. Air
filter perform as the primary defense against pollutants to protect heating
ventilation air conditioning (HVAC) components from dust thus supply clean air
to the occupants. The efficiency of air filter defines how well the filter clean the
air by removing the particulate matter (PM). Pressure drop are the primary
performance indicator for HVAC filter, hence could measure energy consumption
by predicting air flow resistance of the filter. Low air flow resistance is one of the
easiest method to reduce energy cost, as HVAC system motor does not have to
work hard to deliver air flow. In other words, filter testing is one of the best
method to measure performance of air filter. The objective of this study is to
design the HVAC air filter test rig in evaluate efficiency of air filter based on set
key parameter. This study divide into several stage that are preparation and
investigation of filter efficiency parameter, calculation, designing process and
development of the test rig. Design of filter test rig is U shape with dimension 20
inch x 20 inch and for filter section is 24 inch x 24 inch. The test rig specification
are design to meet ASHARE52.2 and EN779 standard which range of air flow rate
is 600 m³/h to 6000 m³/h. For the end of this project, this prototype as expected
can be used as an actual air filter test rig to make individual test especially for the
contractor.
iii
DEDICATION
I dedicate this project to Allah Almighty my creator, my strong pillar, my source of
inspiration, wisdom, knowledge and understanding. He has been the source of my
strength throughout this program and on His wings only have I soared. I also
dedicate this work to my family who has encouraged me all the way and whose
encouragement has made sure that I give it all it takes to finish that which I have
started. This project also is especially dedicated to my supervisor, for his willingness
to guide me to the success of this project for my degree.
iv
ACKNOWLEDGEMENT
First of all, I would like to express my gratitude to my supervisor Mr. Amir Abdullah
bin Muhamad Damanhuri for his mindful supervision and guidance that have guided
me in accomplishing this project. His wide knowledge in this studied area has
contributed in making this project succeed. For my Co-supervisor Mrs. Siti Nor Ain
Binti Mokhtar, no words that I can say other than thank you because a lot of
experienced that I have during through this project. Besides that, I am grateful for
having my housemates and beloved friend as my companion along the way while
working on this project. They have given me the greatest support right from the
beginning and it has given me the courage to move on when not capable to through
more further while developing this project. Finally, thanks a lot to my family who
have been supporting and giving me endless encouragement. Without the spirit and
support that I received throughout this path, possibility these projects will not be
successfully completed.
v
TABLE OF CONTENT
Abstrak i
Abstract ii
Dedication iii
Acknowledgement iv
Table of contents v
List of Tables viii
List of Figures ix
List Abbreviations, Symbols and Nomenclatures xii
CHAPTER 1: INTRODUCTION
1.1 Project Background 1
1.2 Problem Statement 2
1.3 Objective 3
1.4 Scope 3
CHAPTER 2: LITERATURE REVIEW
2.0 Introduction 4
2.1 Air filter 5
2.1.1 Type of Air filter 6
2.1.2 Air Filter Classification 7
2.2 Indoor Air Quality 9
2.2.1 The important of air filtration to Indoor Air Quality and human
Health 9
2.3 Filter Test Rig 10
2.4 Fans 11
2.4.1 Fans Selection 12
2.5 Acrylic 12
vi
2.5.1 Acrylic characteristic 13
2.6 Global Standard for air filter testing 13
2.6.1 Filter Test Rig Standard 14
2.6.1.2 ISO/TS-21220:2009 14
2.6.2 ASHRAE Standard 16
2.6.3 Europe standard 19
2.6.4 Comparison between ASHRAE and Europe Standard 20
2.6.4.1 Test procedure 20
2.6.4.2 Filter classification 22
2.6.4.3 Final pressure drop 23
CHAPTER 3: METHODOLOGY
3.0 Introduction 24
3.1 Preparation and investigation 24
3.2 Calculation 24
3.3 Designing filter test rig 28
3.3.1 Product specification (Material and Equipment) 28
3.3.2 Concept scoring 38
3.3.3 Detailed design 38
3.3.4 Design development using SolidWorks 39
3.4 Data Taken Procedure 45
CHAPTER 4: RESULT & DISCUSSION
4.0 Introduction 47
4.1 Design result 47
4.2 Fabrication (prototype development) 48
4.2.1 Scribing and marking 49
4.2.2 Cutting 49
4.2.3 Drilling 50
4.2.4 Finishing 51
4.2.5 Create and installation damper 51
vii
4.2.6 Making a table trolley 52
4.2.7 Installation wire to fan 53
4.2.8 Joining and installation 54
4.2.9 Closing gap 55
4.2.10 Filter installation 55
4.2.11 Development result 56
4.3 Data validation and energy demand calculation 57
4.3.1 Energy demand calculation 62
4.4 Comparison between HVAC Filter test rig, ASHRAE 52.2 and EN 779
Standard 63
CHAPTER 5: CONCLUSION AND RECOMMENDATION
5.0 Introduction 65
5.1 Summary of the project 65
5.2 Achievement of project activities 66
5.3 Future Development 66
REFERENCE 68
APPENDICES 71
viii
LIST OF TABLES
2.1 MERV categories 17
2.2 The type of contaminant that will growth in their size their
applications 18
2.3 The classification of air filters according to EN 779:2012 19
2.4 The Comparison of ASHRAE52.1, ASHRAE 52.2 and
EN 779:2002 20
2.5 The result and the limit of the each standard 22
3.1 Dimensions and parts drawing before assembly using Solidworks 40
4.1 Average data for air velocity and air flow rate when fan at 800 CFM 58
4.2 Average data of amount of dust and pressure when fan at 800 CFM 59
4.3 Average data of temperature and humidity when fan at 800 CFM 60
4.4 Air flow rate data with different speed 61
4.5 Comparison between HVAC Filter Test Rig, ASHRAE52.2 and EN779 63
ix
LIST OF FIGURES
2.1 AHU compartment 5
2.2 Type of Air filter 7
2.3 The typical minimum efficiency curve 8
2.4 Filter test rig based on EN 779 and ASHRAE 52.2 standard 11
2.5 The schematic diagram of test rig based on EN 779 standard 15
2.6 The dimensions of the test rig based on EN 779 standard 15
3.1 Acrylic sheet 29
3.2 Air filter 29
3.3 Aluminium sheet 30
3.4 Axial fan 30
3.5 Jig saw 31
3.6 Acrylic glue 31
3.7 Sandpaper was used 32
3.8 File 32
3.9 Table at the lab 33
3.10 Hand drill 33
3.11 Screw and screw driver 34
3.12 square hollow iron bar 34
3.13 Regulator 35
3.14 3 pin plug 35
3.15 Pitot tube 36
x
3.16 Anemometer 36
3.17 Tachometer 37
3.18 LEV monitoring device 37
3.19 Concept scoring of this project 38
3.20 Schematic diagram of filter test rig design 39
3.21 Filter test rig drawing design in 2D after assembly 44
3.22 Each side view of 2D drawing 44
3.23 Flow chart process 46
4.1 HVAC filter test rig prototype full 3D drawing 48
4.2 Marking process 49
4.3 Cutting acrylic using jigsaw 50
4.4 Making a hole using hand drill 50
4.5 Finishing process 51
4.6 Acrylic done attached with holder 52
4.7 Making a table trolley process 52
4.8 Wire installation process 53
4.9 Assembly process 54
4.10 Closing gap 55
4.11 Air filter after installation 56
4.12 HVAC filter test rig prototype 57
4.13 Point of data taken 57
4.14 Relationship between velocity and air flow rate graph 58
4.15 Relationship between amount of dust and pressure graph 59
4.16 Relationship between temperature and humidity graph 60
xi
4.17 Relationship between fan speed and air flow rate graph 61
xii
LIST OF ABBREVIATIONS, SYMBOLS AND
NOMENCLATURE
A - Ampere
ASHRAE - American Society of Heating, Refrigerating and
Air-Conditioning
AHU - Air Handling Unit
CAD - Computer Assisted Design
CCWS - Central Chiller Water System
CEN - European Committee for Standardization
CFM - Cubic Feet Per Minute
DEHS - Debian External Health Status
EN - European Standard
EUROVENT - Europe’s Industry Association for Indoor Climate
HEPA - High Efficiency Particulate Arrestance
HVAC - Heating, Ventilation and Air-Conditioning
IAQ - Indoor Air Quality
ISO - International Standard Organization
In.w.g - Inch Water Gauge
MERV - Minimum Efficiency Reporting Value
mm - milimetre
m³/h - Meter cube per hour
m/s - Meter per second
PM - Particulate Matter
Pa - Pascal
SARS - Severe Acute Respiratory Syndrome
TES - Thermal Energy Storage
F - Degree Fahrenheit
xiii
µm - micrometre
˂ - Less Than
˃ - More Than
1
CHAPTER 1
INTRODUCTION
1.1 Project Background
Air-Conditioning is a system where it supply cool air, fresh air and provide
thermal comfort required to the conditioned space (Viswambharan, Patidar, &
Saxena, 2014). There are four main components of air-conditioning system which are
compressor, condenser, evaporator and expansion valve. For large air-conditioning
system usually use air handling unit (AHU) as a device to contribute the cool air to
the conditioned space. To provide thermal comfort in required spaced AHU system
also have their main components such as cooling and heating equipment, humidifier,
air filter and fan. Each components has their importance function for the system. For
example is air filter. The function of air filter is to avoid contaminant and provide
clean to the occupants or the conditioned space (Lyngby et al., 2015). Besides that,
the air filter is also important in air conditioning systems where it can improve the
quality of indoor air in the condition space. Besides that, air filter also can prevent
occupants from suffering health diseases affected from breathing air currently
polluted.
Pollution control has become an issue of great concern. Therefore, the air
filter is a very important agent for the distribution of clean air. Air filter perform as
the primary defences against pollutants to protect heating ventilation air conditioning
(HVAC) components from dust thus supply clean air to the occupants (Berbari,
Shakkour, & Hashem, 2007). To supply clean air, the air filter must be kept in
pristine condition and free from microorganisms that can cause illness to the
residents of the surrounding area. Each filter will have its own life expectancy and
user must to know how long air filter can be used.
2
Many air filter test rig which has been produced nowadays according to the
standards appropriate to the size of the air filter and the pressure drop required. The
lower the pressure drop the less energy required for running the system. The standard
used is ASHRAE (American Society of Heating, Refrigerating and Air-Conditioning
Engineers) standard and Europe standard. For ASHRAE, Standard 52.2 is a standard
that makes reference while Europe Standard is used EN779 as the reference. The
both standard take ISO as their guidelines to develop a filter test rig and each
parameters are taken from that ISO. Besides that, this standard also constantly
updated for several years. The content of this standard will be a signpost to complete
this air filtration test. Therefore, the existence of this standard is extremely important
to the industry as well as universities in researching the substances or equipment that
want to be tested, simulation or as the project research.
1.2 Problem Statement
Nowadays, we always have a problem with life expectancy of the HVAC air
filter, ways to enhance the efficiency and performance of typical control contaminant
filter classes (Bennett, 2012). The user must be difficult to predict the usability of an
air filter used. Therefore, the importance of the organization designing the air
filtration test rig to evaluate the effectiveness of an air filter especially HVAC filter
to predict the duration of its use. We often forget that each air filter should be
checked with the periodic time. Therefore, long dirt suspended on the air filter should
be cleaned to produce good air quality. With a filter of this rig, it can monitor the life
expectancy of the air filter. Besides that, the building owner or contractor can
estimate lifecycles air filter where it can still be use either to replace at the same time
it still can be used. It will lead to saving the cost. Before making a test rig some
things need to be addressed such as the size of the ducting, the size of the air filter
and the air flow required in the test rig system. The design will be a small scale
prototype, means that is for test individual filter. From there we can save the space to
place it. Besides that, it also can saving the energy demand.
3
1.3 Objective
In this study, there are a number of targets to be given full attention in order
to achieve the objectives. Therefore, the following below are objectives of this
project.
1. To design HVAC filter test rig prototype that can measured performance of
air filter refer to ASHRAE52.2 and EN779 standard.
2. To fabricate and develop HVAC filter test rig prototype to meet design scale
of single air filter used in common market which is 24 inch x 24 inch.
1.4 Scope
This research will focus on designing and develop prototype of the air
filtration test rig in evaluate efficiency of HVAC filters. Several scope have been
selected to this project and only equipment that will be aim which the type of air
filter only washable furnace filter (primary and secondary filter). The design required
for two air filters which are pre pleated and pocket bag filter. The size of that air
filter only 24 inch x 24 inch where the standard size for commonly used in AHU. For
the parameters that will measured in this project which are the particle size where it
just 0.3 μm until 10.0 μm and the actual air flow rate for the fan is 800 CFM. Besides
that, for standard static pressure 0.2 to 0.4 inch per water gauge per 100 feet where it
for the usually standard industry using.
4
CHAPTER 2
LITERATURE REVIEW
2.0 Introduction
This chapter will focus on the theory and terms mainly related to this
research, which is about how to designing air filtration test rig, evaluate its efficiency
and its relationship with indoor air quality. The sources of theory are from previous
research, related articles and from the global standard. This chapter aim to give a
better understanding about this research and to give strong evidence, support and
reasons why this research should be done. Lately, there is numerous studies have
been related to the level of indoor air quality (IAQ) and its effect on human health,
therefore this study focusing on the air filter test rig design and evaluate its
efficiency. Thus, this research will aim to the HVAC filter at the air handling unit
(AHU).
Air cooling is a system where it cools the refrigerant and cooling medium of
water and sent away to be cooled. There are a lot of cooling system used at present,
especially in industries that busy which are a central chiller water system (CCWS),
Thermal energy storage (TES) and hybrid evaporative cooling system. Central chiller
system cooling process water in the chilled water plant to be sent to the conditioned
space. Thermal energy storage is a process in which the cooling water to be frozen
during the off peak and would send the cold water at peak time on the conditioned
space. Hybrid evaporative cooling system, it is same as the CCWS where it cooled
refrigerant and water but differ in medium that cools the condenser. CCWS system
cools the condenser using cooling tower which hybrid system cools the condenser
use water from the reservoir tank and the air supply from the fan. All the three
5
system using AHU as a device to supply air to the conditioned space. Because of that
AHU become a most important part in HVAC system.
AHU is device used to condition and circulate air as part of a heating,
ventilating, and air-conditioning (HVAC) system. Usually it exists with a large metal
box and inside it containing a heating or cooling elements, blower, sound attenuators,
dampers and air filter racks or chambers. Ductwork ventilation system are connected
with the air handlers to distributes the conditioned air through the building and it
returns back to the AHU (Edward G. Pita, 2013) as shown in figure 2.1. There are
two types of AHU which are draw through type and blow through type. Draw
through type is when the fan located downstream of the cooling coil and blow
through type is when fan located upstream located upstream of the coils.
Figure 2.1: AHU compartment
(Source: http://www.technovation.org/images/gif/AHU1000_app.GIF)
6
2.1 Air filter
Air filter is the component that must have in HVAC system to provide a good
indoor air quality because of that air filter cannot be separated with indoor air
quality. When talking about the air filter indirectly indoor air quality also being
considered because the air filter is an important role in providing good indoor air
quality (T J. Robinson & A. E. Ouellet, 1992). The higher the efficiency of an air
filter that improved indoor air quality provided. The good indoor air quality given the
good performance of equipment. Problems that always occur in HVAC systems
especially odour pollution and air quality that is the air filter one of the causes
(Bluyssen et al., 2003).
2.1.1 Type of Air filter
There are many types of air filters are always used in HVAC system. For the
pre- filter commonly uses a pleated filters, filter pad, metal panels, media rolls, fan
coils filters and primary bag filters. Each type has a difference of size. The air filters
are difference design such as washable furnace filter, rigid filter and HEPA filter.
The air filter plays significant role in HVAC system.. Every place with
ventilation system will needs an air filter. For example, occupants need the air filters
because of many environments that have been affected by airborne particle that
cannot be seen by the naked eye. Because of that each places have their interest type
of air that want to use.(William C. Hinds, 1999). The following places have their
own interests to require good air quality is why we need to choose the type of air
filter. The examples filter for every needs is comfort, power systems, oral solid
dosage, clean process, air pollution control and industrial (Camfil Product Catalogue,
2015). Figure 2.2 shows the type of air filter commonly used in industry nowadays.
7
(i) Metal panels filter (ii) Pre-pleated filter (iii) Primary bag filter
Figure 2.2: Type of Air filter (Camfil Product Catalogue, 2015).
2.1.2 Air Filter Classification
HVAC filters made of semi porous, the fibrous material which prevents the
passage of particles. Manufacture of particle filters will depend on the size of the
filter, the filter material, depth and any related to pore size and fibre. The
characteristics of a filter with a MERV (minimum efficiency reporting value) size it
depends where it is between MERV size of 1 to 20 (Hitchcock et al., 2006).
To review the performance of the air filter, several test procedure must be
carried out to prove the theory is the same as the experiment or test
performed.(Vaughn & Ramachandran, 2002) The test also being carried out
according to standard guidelines. American Society of Heating, Refrigerating, and
Air-Conditioning Engineers (ASHRAE) introduce filters with MERV with standard
testing method ASHRAE 52.2. From this testing, it is measured in 12 particle size
ranging from 0.30 to 10.0 micrometres. Some procedure will be followed in this test
to determine the MERV which is from MERV 1 to MERV 12. If higher the rating of
the MERV is higher the efficient of the filter and capture more particles with small of
size particles. In addition to efficiency, filter attributes also include a reasonable
holding capacity and adequate airflow for ventilation. Another factor must to be
consider media filter become more efficient as they load, whereas electronic cleaning
devices that need to be washed or wiped rapidly lose efficiency as the plates that
generate the electrostatic charge become coated with particles. There are no
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certification for the testing in the United States for the testing standards (Sublett et
al., 2010). Figure 2.3 shows the typical minimum efficiency curves ASHRAE 52.2.
Figure 2.3: The curve on the table above shows to the following applications
(Camfil Farr, 2013):
95% or MERV 14 - typically applied as the final filter in hospital
HVAC systems.
85% or MERV 13- typically applied in above average commercial
applications.
65% or MERV 11- applied in standard commercial buildings, such as
office space.
25% or MERV 6 and 7- pleated panel filters, applied in office
environments, and pre filters.
<20% or MERV 1 through 5- typical polyester or fiberglass
throwaway panels and metal washable filters (Camfil Farr, 2013).
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