Appendix C - Standard Operating Procedures (SOP)

978 Pages·2011·14.41 MB·English

Appendix C
SOPs
LABORATORY TESTING OF VENTILATION FAN PERFORMANCE
Standard Operating Procedure (SOP) A1
PAAQL SOP A1
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LABORATORY TESTING OF VENTILATION FAN PERFORMANCE
Standard Operating Procedure (SOP) A1

Prepared by
Steve E. Ford (Univ. of Illinois Urbana-Champaign) and Bill W. Bogan

Reviewed by
Yuanhui Zhang (Univ. of Illinois at Urbana-Champaign), Steve J. Hoff (Iowa State Univ.),
and Albert J. Heber

Effective Date: November 6, 2006

PURDUE AGRICULTURAL AIR QUALITY LABORATORY (PAAQL)
Agricultural and Biological Engineering, Purdue University
West Lafayette, IN 47907
PAAQL SOP A1
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Table of Contents

Page
1. Scope and Applicability..............................................................................................3
2. Summary of Method...................................................................................................3
3. Definitions....................................................................................................................3
4. Health and Safety........................................................................................................4
5. Cautions.......................................................................................................................4
6. Interferences................................................................................................................4
7. Personnel Qualifications............................................................................................4
8. Equipment and Supplies............................................................................................4
9. Procedures...................................................................................................................5
10. Data and Records Management................................................................................6
11. Quality Control and Quality Assurance...................................................................6
12. References....................................................................................................................7
Appendix A. Fan test datasheet........................................................................................9
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1. Scope and Applicability

1.1. This SOP describes performance testing of ventilation fans that are used on
mechanically-ventilated barns and livestock buildings, including manure sheds.
1.2. Fan testing determines performance in terms of airflow rate, pressure, speed of rotation,
power and ventilation efficiency.
1.3. The methodology described in this SOP is suitable for the testing of wall-mounted,
constant- or variable-speed ventilation fans, including manure storage pit fans. It does
not apply to the testing of air circulating fans.
1.4. Testing is performed in accordance with two industry standards:
1.4.1. American Society of Agricultural and Biological Engineers (ASABE) Standard S565
(“Agricultural Ventilation Constant Speed Fan Test Standard”)
1.4.2. Air Movement and Control Association (AMCA) Standard 210-99 (“Laboratory
Methods of Testing Fans for Rating”) – Equivalent to American Society of Heating,
Refrigeration and Air-conditioning Engineers (ASHRAE) Standard 51-1999
1.5. Testing of the fans is conducted using a stationary laboratory fan test facility located in
the Bioenvironmental and Structural Systems (BESS) Laboratory, Agricultural
Engineering Sciences Building, University of Illinois at Urbana-Champaign.

2. Summary of Method

An airflow test chamber was designed and constructed according to AMCA 210-
99/ASHRAE 51-1999 standard format (Fig. 15 of AMCA 210-99, included as Fig. 1 at the
end of this SOP). The airflow test chamber measures airflow in the range of 100 - 28,000
ft3/min (accuracy ±2%). The fan being tested is mounted in the chamber, and the volume of
air handled is measured at up to six distinct static pressures by varying the air supplied by the
chamber’s variable supply system. This is done by measuring the pressure differential across
the nozzle in the center of the chamber, which is proportional to the volume of air moved by
the fan. Electrical measurements (voltage and current) are made with a Valhalla Scientific
2100 power analyzer (for single-phase testing) or a Valhalla Scientific 2300 power analyzer
(for three-phase testing). The rotational speed of the fan impeller is measured with either a
digital stroboscope (Nidec-Shimpo Model DT-301) or a fiber-optic photoelectric sensor
(Banner Model SM312FMHS). Wet and dry bulb temperature and barometric pressure are
measured so that air density may be calculated. Fan ventilation efficiency ratio (VER) is
calculated in units of ft3/min-W.

3. Definitions

3.1. BESS Bioenvironmental and Structural Systems
3.2. Manure pit fan A ventilation fan used to remove harmful gases
from a manure pit, and which is designed to resist
corrosion caused by these gases.
3.3. PAAQL Purdue Agricultural Air Quality Laboratory
3.4. Variable-speed fan A fan whose speed can be modulated, usually based
on temperature.
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3.5. Ventilation efficiency ratio (VER) Airflow volume per unit of power consumed by the
operation of the fan. Units used for VER in this
SOP are ft3/W.
3.6. Ventilation fan An un-ducted, axial-flow fan system used for air
exchange (as opposed to air circulation) purposes.
Generally consists of an impeller, housing, motor,
shutter or damper, and guard.

4. Health and Safety

4.1. Fans should not be plugged in until the test and warm-up period is started.
4.2. Wear safety glasses while the fan is operating.

5. Cautions

5.1. Since the air chamber is under negative pressure, any leaks between the flow nozzles
and the fan will cause a negative bias in fan airflow results. Make sure that there are no
leaks in the chamber, or in the mounting seal. Ensure all joints around the fan assembly
and the chamber are sufficiently tight. Test for leaks in the chamber by sealing up the
fan opening (no fan installed) and pressurizing the chamber while introducing smoke
into the chamber. Leaks are readily identified by visualizing the smoke.
5.2. Fans should be mounted for testing in the same configuration as they are installed or
deployed in the field. All protective screens or guards, hoods or other wind-deflecting
attachments, or discharge cones should be in-place during testing. Failure to do so may
produce data which are not truly applicable to the field performance of the fan.

6. Interferences

6.1. In order to avoid inaccurate airflow data due to blockage, the exhaust area of the fan
being tested should be kept clear (to a distance of at least three times the fan diameter).

7. Personnel Qualifications

7.1. Personnel should be trained in the operation of all instruments listed in Sections 8.1
through 8.6.1. The training will be provided by PAAQL and UIUC BESS Laboratory
personnel.
7.2. Personnel must read and understand all applicable instrument manuals and this SOP
before operating any of the equipment. These documents will be kept at the UIUC
BESS.

8. Equipment and Supplies

8.1. Airflow test chamber as specified in AMCA 210/99 (See Fig. 1)
8.2. Variable voltage transformer capable of delivering 230 V with a precision of ±0.5 V
8.3. Manometer (Model 40HE35WM, Meriam Process Technologies, Cleveland, OH)
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8.4. Micro-manometer (Model 1430, Dwyer Instruments, Michigan City, IN)
8.5. Mechanically aspirated psychrometer (Model Series 37210, Oakton Instruments, Vernon
Hills, IL)
8.6. Barometer (Model 469, Princo Instruments, Southampton, PA)
8.7. Power analyzer (Model 2100 or 2300, Valhalla Scientific, San Diego, CA)
8.8. Fan impeller rotational speed monitor (two options)
8.8.1. Digital stroboscope (Model DT-301, Nidec-Shimpo America Corp, Itasca, IL)
8.8.2. Fiber-optic photoelectric sensor (Model SM312FMHS, Banner Engineering,
Minneapolis, MN)

9. Procedures

9.1. Fan Performance Test
9.1.1. Instrument checks (To be performed prior to each series of tests)
9.1.1.1. Manometer
9.1.1.1.1. Check fluid level according to instrument manual.
9.1.1.1.2. With high and low pressure manifolds shunted, zero the instrument by
adjusting the level until the micromanometer reads zero.
9.1.1.2. Psychrometer
9.1.1.2.1. Turn instrument on and observe the wet bulb temperature reading.
9.1.1.2.2. Replace batteries if it takes more than 2 min for the wet bulb temperature to
stabilize.
9.1.1.3. Barometer
9.1.1.3.1. Check the white zero pointer in the cistern and adjust to zero according to the
instrument manual.
9.1.2. Test procedure
9.1.2.1. Mount the fan in the test chamber, with the fan inlet facing the main chamber, as
shown in Fig. 1. All joints between the fan assembly and the chamber itself must
be sufficiently tight that air leakage does not occur during the test. Leaks can be
detected with a tufted wand while the chamber is pressurized with the chamber air
supply.
9.1.2.2. Check and zero the manometers before the fan is turned on.
9.1.2.3. Turn the fan motor on and ensure that the input voltage is 230 V. Allow the fan
motor to operate 20 min before proceeding with test.
9.1.2.4. Measure and record wet-bulb and dry-bulb air temperature of the lab with the
psychrometer.
9.1.2.5. Measure and record the barometric pressure.
9.1.2.6. Turn on the chamber air supply fan.
9.1.2.7. Set the fan static pressure at free air (0" static pressure), which is to equalize the
pressure in the chamber immediately upstream of the test fan with the pressure in
the lab area surrounding the chamber. This is conducted by adjusting the
operating static pressure point of the test fan by adjusting the supply fan blade
pitch and by-pass door. Large changes in static pressure should be performed by
blade pitch adjustment. Adjust the by-pass door for small changes.
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9.1.2.8. The pressure drop (ΔP) across the measurement nozzles should remain above 0.5
inches of water gauge (iwg). The number of nozzles open must be lowered if the
measurement falls below 0.5 iwg. If only one nozzle is open and the pressure
differential drops below 0.5 iwg, select a smaller nozzle size.
9.1.2.9. Record the number of flow nozzles open, nozzle diameter (in.), pressure drop
across the flow measurement nozzles (in. of water), fan speed (rpm), voltage (V),
current (A), and power (W). A sample data sheet is included in Appendix A of
this SOP.
9.1.2.9.1. Take readings when the system is at equilibrium. Equilibrium can be
recognized by observing the stable pressure and other variable readings, or by
taking trail measurements of the various variables until constant values are
obtained. Equilibrium is usually reached within one to five minutes when the
system is warmed-up. Note any test conditions (static pressures) under which
equilibrium cannot be reached.
9.1.2.10. Increase the fan static pressure by 0.05 iwg, and repeat steps 9.1.2.7 through
9.1.2.9. The fan should be tested for at least 5 points, from 0.0 iwg up to 0.25 iwg
static pressure, or airflow cut-off, whichever comes first. The former of these
would result in a total of six static pressure points being tested (0, 0.05 iwg, 0.10
iwg, 0.15 iwg, 0.20 iwg, and 0.25 iwg).

10. Data and Records Management

10.1. Appendix A of this SOP contains a sample data sheet to be used for recording the data
collected in these tests.
10.2. Maintain all laboratory records in a worksheet of the electronic field notes spreadsheet
designated for this method. Supplement this electronic record by a bound record book
designated for the method, which should contain copies of the electronic record.
10.3. Manage all data according to SOP B5.
10.4. Document all data and information on field data sheets, and within site logbooks with
permanent ink, or in electronic field notes.

11. Quality Control and Quality Assurance

11.1. Equipment manuals & certification
11.1.1. Master copies of instruction manuals and calibration certificates (when applicable) for
all instruments described herein are kept in a specific file drawer, and made available
to the users during training and measurement.
11.1.2. The fan test data will be kept at the UIUC BESS and delivered to PAAQL. The
PAAQL will distribute the data to the trailer at the respective farm.
11.2. Equipment performance checks and calibration
11.2.1. Manometer
11.2.1.1. Calibrate with the micro-manometer annually according to manufacturer’s
procedures. Perform the following steps on the micro-manometer before using:
11.2.1.1.1. Check fluid level.
11.2.1.1.2. Remove needle tip. Clean and reinstall.
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11.2.1.1.3. Check battery and replace (AA) if necessary.
11.2.2. Psychrometer
11.2.2.1. Calibrate thermometers annually. Calibrate four points between 32ºF and 100ºF in
a water bath with either a NIST-traceable thermometer or a block calibrator
(Model DB-35L, Techne Incorporated, Burlington, NJ).
11.2.3. Power analyzer
11.2.3.1. Cross check performance of the Valhalla Scientific 2100 or 2300 power analyzer
with a power transducer (Model EW5–20B, Ohio Semitronics, Hilliard, OH).
Voltage and current should be calibrated against a multimeter (Model 75 or
Model 77, Fluke Corp., Everett, WA). Both of these checks should be done
annually.

12. References

12.1. AMCA Standard 210-99. 1999. Laboratory Methods of Testing Fans for Rating. Air
Movement and Control Association, Inc., Arlington Heights, IL.
12.2. ASABE Standard S565. 2005. Agricultural Ventilation Constant Speed Fan Test
Standard. American Society of Agricultural and Biological Engineers, St. Joseph, MI.
12.3. Barometer Manual. Operations Manual for Model 469 Barometer. Princo Instruments,
Southampton, PA.
12.4. Manometer Manual. Operations Manual for Model 40HE35WM Manometer. Meriam
Process Technologies, Cleveland, OH.
12.5. Micro-Manometer Manual. Operations Manual for Model Model 1430 Micro-
Manometer. Dwyer Instruments, Michigan City, IN
12.6. Power Analyzer Manual. Operations Manual for Model 2100 or 2300. Valhalla
Scientific, San Diego, CA.
12.7. Psychrometer Manual. Operations Manual for Model Series 37210 Mechanically
Aspirated Psychrometer. Oakton Instruments, Vernon Hills, IL
12.8. Stroboscope Manual. Operations Manual for Model DT-301 Digital Stroboscope. Nidec-
Shimpo America Corp, Itasca, IL
12.9. SOP B5. 2006. Data Management for Barns. Standard Operating Procedure B5. Purdue
Ag Air Quality Lab.
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Figure 1. Configuration of the fan testing chamber, as adapted from AMCA210-99 Figure
15. M = Main chamber dimension (ft); PL. = Plane; P = Static pressure; t = Dry-bulb
s d
temperature; ΔP = Pressure differential; Settling means = mesh screen to create uniform
flow.

Notes:
1. Dotted lines on fan inlet indicate an inlet bell (bell-mouth inlet that is fabricated of steel
or alloy with flange) and one equivalent duct diameter which may be used for inlet duct
simulation. The duct friction shall not be considered.
2. Dotted lines on fan outlet indicate a uniform duct 2 to 3 equivalent diameters long, and of
an area within ± 0.5% of the fan outlet area and a shape to fit the fan outlet. This may be
used to simulate an outlet duct. The outlet duct friction shall not be considered.
3. Variable supply system may be an auxiliary fan or throttling device.
4. The distance from the exit face of the largest nozzle to the downstream settling means
shall be a minimum of 2.5 throat diameters of the largest nozzle.