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Juan Loera, P.E. Carollo Engineers
Math and Maintenance for Pumps and Blowers
Overview of Blower Technologies and Comparison of High-Speed Turbo Blowers
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Today’s Buzzword in Wastewater Treatment High Speed Turbo Blowers
Changed the industry Significant area of innovation in blower design
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Agenda Role of blowers in wastewater treatment
facilities Review of Different Blower Technologies
Positive displacement Multi-stage Single-stage centrifugal High-speed turbo blowers
Compare various high-speed turbo blowers
Things to consider on your next project Questions and Comments
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Role of Aeration Blowers in Wastewater Treatment
Facilities
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Process Air Production Represents Over one Half of Total Energy Used at a Typical WWTP
Energy usage at a typical WWTP
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Benefits of High Efficiency Blowers
Energy consumption commonly accounts for 75 percent of the total life-cycle cost of a blower
Optimized blower and process air controls will also help reduce blower operating costs
75%
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Review of Different Blower Technologies
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Different Blower Technologies
Multi-Stage Centrifugal High-Speed Centrifugal
Single-Stage Positive Displacement
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The Right Blower?
One type fits all is not the right answer! Need to find the right fit for each project
Blower that provides the most efficient system
Best value to Owner
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Typical Blower Efficiencies
Blower Type Nominal Blower Efficiency (percent)
Nominal Turndown (percent of rated flow)
Positive Displacement 45-65 50
Multi-Stage Centrifugal (inlet throttled) 50-70 60
Multi-Stage Centrifugal (variable speed) 60-70 50
Single-Stage Centrifugal, Integrally
Geared (with inlet guide vanes and
variable diffuser vanes)
70-80 45
Single-Stage High Speed Turbo ** 70-82 50
**Testing methods are not consistent among different manufacturers
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Blower Curves Comparison B
low
er D
isch
arge
Pre
ssur
e (p
si)
Blower Flow (scfm)
Positive Displacement
Single-Stage Centrifugal*
High-Speed Turbo**
Multi-Stage Centrifugal
System Curve
* Single-stage centrifugal blower with dual-point control
** High-speed turbo blower with speed control only
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Centrifugal Blower Operating Range
Res
ourc
e R
atio
Blower at various capacities
Surge Line
Operational Range
Choke Point
Flow Rate
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Positive Displacement Blowers
Impeller: Two or three lobes Controls
Constant or variable speed (typically belt-driven)
Simple instrumentation Requires large silencers (intake and discharge) Lowest capital cost Smaller installations
Positive Displacement
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Multi-Stage Centrifugal Impeller
Series of enclosed impellers Cast or fabricated Various steel alloys
Controls Inlet throttling Discharge throttling (less efficient) Speed control with VFD
Bearings Anti-friction roller type Grease or oil lubrication
Instrumentation Simple Monitor bearing temperature and vibration
Electric motor (2-pole most often) IC engines (not often)
Multi-Stage Centrifugal
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Single-Stage Centrifugal
Single-Stage
Single impeller Open face (most common) Enclosed (Roots) Milled or investment casting Aluminum and SST most common
Controls Constant speed Inlet guide vanes Discharge variable diffuser vanes Turndown to ~ 45%
Bearings Journal type bearings Anti-friction roller-type on smaller units
Instrumentation Complex Vibration, temperature, pressure, power
Electric motor (2-pole or 4-pole) IC engines
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High-Speed Turbo Blowers
High-Speed Turbo Blower
Significant area of innovation in blower design
Introduced to North American market around 2007
Industry “game changer” Offers energy savings with
lower maintenance costs
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High-Speed Turbo Blowers
High-Speed Turbo Blower
Single impeller (dual impeller by some manufacturers) Open-face impeller Three-dimensional milling or cast Various material choices (aluminum
alloys, stainless steel, etc.) Controls
Variable speed (single-point control) Discharge variable diffuser vanes (Turblex
dual-point control) Turndown to ~ 50%
Advance bearing design Allow for higher speeds Two configurations
Air bearing (most common) Magnetic bearing
Bearings require no lubrication system
~
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High-Speed Turbo Blowers
High-Speed Turbo Blower
Instrumentation and electrical components New to municipal wastewater market High speed VFD (may require
harmonic filters) High-speed permanent magnet motor
Blower enclosure Single-source responsibility by
blower manufacturer for all components
Easy installation Cooling requirements vary by
manufacturer Provides sound attenuation
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High-Speed Turbo Blowers Turbo Blower Technology – at a Glance
Advantages Disadvantages
High efficiency over wide range of flows
Relatively new technology in North America
Packaged unit provides small footprint Limited sizing options
Good turndown capacity Multiple units needed for large installations
Quiet operation Unknown long-term reliability Few moving parts, low maintenance requirements
Periodic replacements of special electrical components
No complex oil cooling system required
VFD requires special filters to eliminate disturbances to plant’s power system
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Comparison of Various High-Speed Turbo Blowers
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High-Speed Turbo Blowers Many manufacturers entering US
wastewater market
Neuros
Hoffman
Siemens (Turblex)
HSI ABS (HST)
Aerzen (K-Turbo
Atlas Copco
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Two Types of Installations
Inlet air from blower room
Piped/ducted inlet air
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Differences Among the Various High-Speed Turbo Blowers
Bearing Configuration Impeller Fabrication
and Materials Cooling System Blower Controls
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Two Bearing Configurations
Blower Manufacturer Air Bearing Magnetic Bearing
Neuros
Turblex
Aerzen
HSi ABS Dresser Roots Atlas Copco Piller TSC Hoffman Howden
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Impeller Design
Blower Manufacturer Milled Impeller Cast Impeller
Neuros
Turblex
Aerzen
HSi ABS Dresser Roots Atlas Copco Piller TSC Hoffman Howden
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Cooling System
Blower Manufacturer
Use Process Air (Self-Contained
within Enclosure)
Separate Cooling System
(External Heat Rejection)
Neuros
Turblex
Aerzen
HSi ABS Dresser Roots Atlas Copco Piller TSC Howden Hoffman
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Blower Controls
Blower Manufacturer
Single-Point Control
(Variable Speed)
Dual-Point Control (Variable Speed +
Other)
Neuros
Turblex
Aerzen
HSi ABS Dresser Roots Atlas Copco Piller TSC Howden Hoffman
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Things to Consider on Your Next Project
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Clealry Define Efficiency
A determination of wire-to-air efficiency takes into consideration all blower energy losses affecting the Owner’s “bottom line.”
* Testing methods are not consistent among different manufacturers
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Specify a Pressure Rise to Surge Point
Res
ourc
e R
atio
Flow Rate
System Curve
Operational Range
Speed Lines
Specified Design Point
Pressure Rise To Surge
Surge Line
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Specify Site Specific Operating Conditions Temperature
High Temp used to size blower (volute/impeller)
Site atmospheric pressure Guaranteed power consumption at actual
operating conditions Base specified points on estimated operating
time under those conditions
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Questions & Comments
Contact Information:
Juan Loera, P.E. [email protected]
(714) 593-5100