UNIVERSITI TEKNIKAL MALAYSIA MELAKA

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)

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. i

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. ii

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. iii

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. iv

TABLE OF CONTENT Abstrak Abstract Dedication Acknowledgement Table of contents List of Tables List of Figures List Abbreviations, Symbols and Nomenclatures i ii iii iv v viii ix 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 v

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 vi

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 vii

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 viii

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 ix

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 x

4.17 Relationship between fan speed and air flow rate graph 61 xi

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 xii

µm - micrometre - Less Than - More Than xiii

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. 1

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. 2

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. 3

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 4

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) 5

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. 6

(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 7

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). 8