Methods of Testing Heavy Duty Dampers for Rating

Transcription

1 Methods of Testing Heavy Duty Dampers for Rating AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL INC. The International Authority on Air System Components

2 AMCA Publications Authority AMCA International Standard 510 was approved by the membership of the Air Movement and Control Association International Inc. on July 26, It was approved as an American National Standard by the American National Standards Institute (ANSI) and became effective on October 9, As of 2015, this document no longer undergoes routine maintenance and has been withdrawn due to a lack of use. Since the document is no longer regularly reviewed by engineers as part of AMCA's document review cycle, it is to be used as a historic reference. It is not a current American National Standard. Copyright 2009 by Air Movement and Control Association International Inc. All rights reserved. Reproduction or translation of any part of this work beyond that permitted by Sections 107 and 108 of the United States Copyright Act without the permission of the copyright owner is unlawful. Requests for permission or further information should be addressed to the Executive Director, Air Movement and Control Association International, Inc. at 30 West University Drive, Arlington Heights, IL U.S.A. Objections Air Movement and Control Association International, Inc. will consider and decide all written complaints regarding its standards, certification programs, or interpretations thereof. For information on procedures for submitting and handling complaints, write to: Air Movement and Control Association International 30 West University Drive Arlington Heights, IL U.S.A. AMCA International, Incorporated c/o Federation of Environmental Trade Associations 2 Waltham Court, Milley Lane, Hare Hatch Reading, Berkshire, United Kingdom RG10 9TH Disclaimer AMCA uses its best efforts to produce standards for the benefit of the industry and the public in light of available information and accepted industry practices. However, AMCA does not guarantee, certify or assure the safety or performance of any products, components or systems tested, designed, installed or operated in accordance with AMCA standards or that any tests conducted under its standards will be nonhazardous or free from risk.

3 Review Committee John Hughey, Chair Per Olesen Shane Glidewell Johnny Johnson Dave Forney Jack Neiser Pete Connor Scott Hall John Powell Joseph Brooks Tim Orris Clarage Air Clean Damper Co. Barron Industries Barron Industries Effox, Inc. Effox, Inc. Ron-Noc Industries, Inc. Wahlco Metroflex Wahlco Metroflex AMCA International, Inc. AMCA International, Inc.

4 Related AMCA Documents Related Publications AMCA Publication 502 AMCA Publication 503 Damper Application Manual for Heating/ Ventilating, and Air Conditioning Fire, Ceiling (Radiation), Smoke and Fire/Smoke Damper Application Manual Related Standards ANSI/AMCA Standard 210 ANSI/AMCA Standard 500-D Laboratory Methods of Testing Fans for Certified Aerodynamic Performance Labortory Methods of Testing Dampers for Rating

5 Contents 1. Purpose and Scope Normative References Definitions / Units of Measure / Symbols Definitions Units of measure Instruments / Methods of Measurements Observations / Conduct of Tests Leakage test Cycle test Obstruction test Deflection test Seal gap test Seal air consumption test Stall test Drive redundancy test Calculations Annex A Flow Measurement (Normative) Annex B Test Report Form (Informative)

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7 Methods of Testing Heavy Duty Dampers for Rating 1. Purpose and Scope The purpose of this standard is to establish testing methods to be used in measuring the performance of dampers used in the utility and heavy industry. The scope of the products covered in this standard shall include dampers, which are used to control flow of a gas (be it a specific gas, a mixture of gas and air, or air alone) or to isolate one section of a duct system from another section of the system. The scope narrows to those dampers generally described as custom design, heavy duty, or severe service, because such dampers are normally used in applications where elevated temperature, erosion and/or corrosion conditions exist. 2. Normative References ANSI/AMCA Laboratory Methods of Testing Fans for Aerodynamic Performance Rating, Air Movement and Control Association International, Inc., 30 W. University Drive, Arlington Heights, IL U.S.A., Definitions / Units of Measure / Symbols 3.1 Definitions Heavy duty damper A device used to control, isolate or divert a gas in a process, industrial or power generation application in accordance with customer requirements Performance variables Shop conditions Ambient temperature and atmospheric pressure in the manufacturing test facility at the time of the damper test System conditions The design temperature and pressure conditions under which the damper will operate, as specified by the purchaser Pressure drop Pressure drop is a measure of the resistance to airflow across a device. It is expressed as the difference in static pressure across an air control device for a specific rate of airflow Closure pressure Pressure drop across a closed damper Leakage Leakage is the amount of gas passing though a device when it is in the closed position at a specific pressure differential and density. It is expressed as the volumetric rate or percentage of specified flow Gland leakage A gland is a device, such as the outer sleeve of a stuffing box, designed to prevent a fluid from leaking past a moving machine part. In this context, gland leakage refers to leakage thru any moving part sealing device intended to prevent or limit the amount of gas from leaking from inside the damper to the atmosphere or vice versa Miscellaneous Shall and should The word shall is to be understood as mandatory, the word should as advisory. 3.2 Units of Measure System of units SI units (The International System of Units, Le Systéme International d'unités) [1] are the primary units employed in this standard, with I-P units (Inch-Pound) given as the secondary reference. SI units are based on the fundamental values of the International Bureau of Weights and Measures [1], and I-P values are based on the values of the National Institute of Standards and Technology, which are in turn based on the values of the International Bureau Basic units The unit of length is the meter(m), or the millimeter (mm); I- P units are the foot (ft) or the inch (in). The unit of mass is the kilogram (kg); the I-P unit is the pound mass (lbm). The unit of time is either the minute (min), or the second (s). The unit of temperature is either the degree Celsius ( C), or the degree Kelvin ( K). I-P units are either the degree Fahrenheit ( F), or the degree Rankine ( R). The unit of force is the newton (N); the I-P unit is the pound force(lbf) Flow rate and velocity Flow rate The unit of volumetric flow rate is the cubic meter per second (m 3 /s); the I-P unit is the cubic foot per minute (cfm) Velocity The unit of velocity is the meter per second (m/s); the I-P unit is the foot per minute (fpm). ANSI/AMCA

8 3.2.4 Pressure The unit of pressure is the pascal (Pa) or the millimeter of mercury (mm Hg); the I-P unit is either the inch water gauge (in. wg), or the inch mercury (in. Hg). Values in mm Hg or in in. Hg shall be used only for barometric pressure measurements Torque The unit of torque is the newton-meter (N-m); the I-P unit is the foot-pound (ft-lbf) Gas properties The unit of density is the kilogram per cubic meter (kg/m 3 ); the I-P unit is the pound mass per cubic foot (lbm/ft 3 ). The unit of viscosity is the Pascal-second, (Pa-s); the I-P unit is the pound mass per foot-second (lbm/ft-s). The SI unit of gas constant is the joule per kilogram-kelvin (J/kg-K); the I- P unit is the foot-pound force per pound mass-degree Rankine, (ft-lbf/lbm- R) Dimensionless groups Various dimensionless quantities appear in the text. Any consistent system of units may be employed to evaluate these quantities unless a numerical factor is included, in which case units must be as specified. 4. Instruments / Methods of Measurements The requirements of ANSI/AMCA 210, Section 5, shall apply where required. 5. Observations / Conduct of Tests 5.1 Leakage test Purpose The purpose of this test is to determine the amount of leakage past the closed damper at a specified operating pressure Test setup A test apparatus is to be used that allows pressure to be applied against the closed damper. The amount of gas that flows past the damper can be determined using a calibrated orifice plate or pitot tube (see Annex A). The customer is to specify if testing is to be done at system conditions otherwise the testing will be done at shop conditions and adjusting for actual conditions by the ratio of specified and tested gas density. Dampers shall be oriented in the installed position for testing when specified Test equipment Calibrated orifice plate or pitot tube A manometer of the liquid column type using inclined or vertical legs or other instruments which provide a maximum uncertainty of 1% of the maximum observed test reading during the test or 1 Pa (0.005 in. wg) whichever is larger A thermometer capable of temperature accuracies within 5 C (9 F) and with a temperature range that covers the specified operating temperature during the test Method of determining the applied force or torque required during the test to compare to predicted actuator requirements. This may consist of a pressure gauge, catalog actuator output data, a spring scale and torque arm, or other device Measurements to be taken during the test Temperature of air used to pressurize damper Pressure applied to damper Flow measurements as required for instrument Applied torque or force required to maintain the measured leakage Test methods Leakage testing shop condition With the duct pressurized to the specified condition, and maintained for a period of ten minutes, record temperature, pressure at the damper, applied torque (or force), and flow measurement Leakage testing system condition Partially open damper blade(s) allowing enough flow for heating. Heat damper until temperature reaches the test temperature and maintain for ten minutes. Close the damper blade(s) fully, and adjust upstream pressure to test pressure, record temperature, pressure at the damper, applied torque (or force), and flow measurement data Test evaluation The calculations require having the test data adjusted for temperature, altitude or other operating conditions different from any test conditions. Pass/fail criteria: If the damper exceeds the manufacturers quoted leakage rate or if the applied torque required to achieve acceptable leakage rates exceeds specifications, 2 ANSI/AMCA

9 Duct Pressure Measurement PLANE 1 Flow Measurement (Pitot or Orifice) Flow Control T1 Heating Element Pressurizing Fan Leakage to Atmosphere Test Damper Fully Closed in Position of Installation Figure 5.1 Leakage Test Setup ANSI/AMCA

10 the damper fails this test. Observations shall be recorded on the Test Report Form (see Annex B) Gland leakage The leakage tests measure the total leakage of the damper. When measurement of the gland leakage is required by the customer, a blanking plate shall be placed over the downstream side of the damper and the test procedure repeated. 5.2 Cycle test Purpose The purpose of this test is to demonstrate the successful operation of a damper through its entire range of movement Test setup The damper is to be placed in the positioning which it is to be installed, unless otherwise agreed to by the customers. If the damper is to be tested at conditions other than ambient conditions, the purchaser must specify the temperature and/or pressure that is to be applied to the damper during the cycle test Test equipment: A timer An amp meter A thermometer A manometer or pressure gauge A pressure gauge for measuring the fluid pressure applied to the damper actuator Measurements to be taken during the test: Time of operation from energizing of actuator to completion of stroke in seconds Maximum power required during stroke, in amps or fluid pressure applied to damper actuator Temperature of gas used to pressurize damper Test method If the damper is to be tested at other than ambient conditions, the specified temperature and pressure shall be applied to the damper and time allowed for equilibrium to be reached. Minimum settling time at specified temperature shall be no less than 10 minutes. The damper shall be cycled from full open to full close three times. The following observations shall be recorded on the Test Report Form (see Annex B): Time required for damper to move from actuator energization to end of stroke in each direction Maximum amperage or fluid pressure during stroke in each direction Temperature, and pressure Test evaluation No calculations are required for this test. Pass/fail criteria: If the damper manifests any of the following symptoms during the cycle test, it will be considered to have failed the test: Failure to operate Requiring any assistance to facilitate movement Any evidence of permanent distortion or damage after the test is complete Overload of motor 5.3 Obstruction test Purpose The purpose of this test is to demonstrate operation of the damper in simulated field conditions with the damper partially obstructed Test setup The damper shall be placed in the position in which it is to be installed. The purchaser shall specify the type, amount, and condition of material that is to be placed in the path of damper operation (Example: twelve inches of dry cement dust) Test equipment No test equipment is required for this test Measurements to be taken during the test No measurements are required for this test Test method The damper shall be cycled through the obstruction as specified. 4 ANSI/AMCA

11 The damper can be placed horizontally,vertically, or in the position in which it is to be installed. When specified, damper will be tested at operational temperature and pressure Damper Drive AMP Meter Duct Pressure Duct Pressure Control Flow Control T1 Heating Element Pressurizing Fan Figure 5.2 Damper Cycle Test Setup ANSI/AMCA

12 Figure 5.3 Obstruction Test Setup 6 ANSI/AMCA

13 5.3.6 Test evaluation No calculations are required for this test. Pass/fail criteria: Any permanent distortion or damage, stopping without completing the stroke, or requiring any assistance to continue operating will indicate that the damper has failed the test. Observations shall be recorded on Test Report Form (see Annex B). 5.4 Deflection test Purpose The purpose of this test is to determine blade deflection Test setup The damper shall be tested in the installed position and temperature, and pressurized on the side of the blade(s) corresponding with the customer s system once the damper is fully closed. A bar or other support will be placed across the downstream damper flanges at the point of maximum blade deflection. If this point is not readily apparent, a series of measurements across the blade will be made to determine this. If the damper consists of multiple blades having varying cross sections, measurements of each blade type will be made Test equipment A dial indicator is required Measurements to be taken during the test The blade deflection shall be measured Test method With the damper pressurized to the specified conditions, the dial indicator will read directly. If a seal air system is required, the seal air blower should be operating. The damper shall be maintained at a near constant temperature throughout the test Test evaluation No calculations are required for this test. Pass/fail criteria: Deflection at the blade(s) point of maximum deflection will be measured and recorded on the Test Report Form (see Annex B). Data will be compared to the specification to demonstrate conformance. The test temperature and pressure shall also be recorded. 5.5 Seal gap test Purpose The purpose of this test is to determine the total amount of gap present between sealing surfaces of a damper. This test is intended to compare the conformance of the manufactured part to specifications. It is not normally performed under conditions of pressure and temperature unless otherwise specified Test setup The damper should be placed in the position in which it is to be installed with the specified closing force applied Test equipment Standard sets of feeler gauges are required Measurements to be taken during the test Gap dimensions shall be measured Test method The damper shall be placed in the fully closed position. Measurements shall be taken at the gap between the blade(s) and the mating seal at 12" intervals, but no fewer than three measurements per side. The gap will be measured by the largest feeler gauge that can be inserted between the two mating surfaces without forcing them apart. The gap measurements shall be recorded for each location Test evaluation Calculations to be made: Average gap = sum of all gap measurements/number of measurement points Total gap area = average gap sealed perimeter Pass/fail criteria: If the average gap or the total gap area is more than specified, the damper has failed the test. Observations shall be recorded on the Test Report Form (see Annex B). 5.6 Seal air consumption test Purpose The purpose of this test is to determine the seal air fan consumption Test setup The damper should be tested in the installed orientation and pressurized on the side of the blade(s) corresponding with the customer s system Test equipment The seal airflow will be measured using either a pitot traverse or a calibrated orifice. ANSI/AMCA

14 Figure 5.4 Seal Air Consumption Test Setup 8 ANSI/AMCA

15 A static pressure tap shall be installed in the damper seal air chamber to record the chamber pressure Measurements to be taken during the test: Chamber pressure Seal air fan flow Test method With the damper pressurized to the specified conditions, the seal air valve shall be opened and the seal air fan started. Measure and record damper seal airflow, duct static pressure, seal air chamber pressure and temperature on the Test Report Form (see Annex B) Test evaluation No calculations are required for this test. Pass/fail criteria: If the measured seal air fan flow exceeds the specified flow, the damper has failed. If the chamber pressure is below the specified value, the damper has failed. 5.7 Stall test Purpose The purpose of this test is to demonstrate the structural integrity of the damper under the maximum actuator output Test setup The damper should be placed horizontally, vertically or in the position in which it is to be installed. A solid blockage capable of stopping the operation of the damper shall be inserted into the path of damper movement. The blockage shall be installed in such a way as to prevent movement on either opening or closing. The purchaser may specify that the location of the blockage be selected to produce the maximum amount of loading eccentricity. For electrically actuated dampers, the circuit protection should reasonably approximate the type of protection that will be used in final installation. The purchaser and manufacturer shall agree upon type and size of circuit protection that will be used during the test. For dampers that are actuated pneumatically or hydraulically, the pressure of the motive fluid shall be regulated as specified Test equipment No test equipment is required for this test Measurements to be taken during the test No measurements are required to be taken during this test Test method The damper will be either opened or closed until it contacts the blockage and stalls. The obstruction shall be removed and the damper shall be subjected to a Damper Cycle Test as described in Section Test evaluation No calculations are required for this test. Pass/fail criteria: Any visible sign of damage or permanent distortion or failure to pass the Damper Cycle Test will be an indication that the damper has failed the test. Observations shall be recorded on the Test Report Form (see Annex B). 5.8 Drive redundancy test Purpose The purpose of this test is to demonstrate the successful operation of a guillotine damper with only one half of a dualconnected drive system operating. Due to the complexities of maintaining operating conditions of temperature and flow, this test is normally performed under shop conditions unless otherwise specified Test setup The damper shall be placed in the position in which it is to be installed. One side of the drive system will be disconnected from the blade assembly. Any parts that might jam or interfere with damper operation are permitted to be removed prior to damper operation. It is allowable for the damper manufacturer to completely remove one side of the drive system prior to positioning the damper Test equipment No test equipment is required for this test Measurements to be taken during the test No measurements are required for this test Test method The damper shall be operated through one complete cycle (from full open to closed and back to full open or from full closed to open and back to full closed) Test evaluation No calculations are required for this test. Pass/fail criteria: The damper will be considered to have failed the test if it stops at any point during the cycle or requires any form of assistance to continue its movement. Observations shall be recorded on the Test Report Form (see Annex B). 6. Calculations If the tests are conducted at other than operating conditions, they shall be corrected to operating conditions. ANSI/AMCA

16 Annex A Flow Measurement (Normative) Flow measurement and test setups shall conform to ANSI/AMCA 210, Figures 1, 2A, 2B, 3, 4A, 7 and ANSI/AMCA

17 Annex B Test Report Form (Informative) Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION AND CONTROL INTERNATIONAL MEMBER 5.1 Leakage Test Purpose: The purpose of this test is to determine the amount of leakage past the closed Damper at a specified operating pressure. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper Installed Orientation: Tested Orientation: Operating Conditions: Test Conditions: Adjusted Conditions: Gas Temperature: Gas Temperature: Gas Temperature: Gas Pressure: Gas Pressure: Gas Pressure: Gas Density: Gas Density: Gas Density: Allowable Leakage: Measured Leakage: Adjusted Leakage: Damper has Passed/Failed Test: Comments: Approved By: Date: ANSI/AMCA

18 Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION MEMBER AND CONTROL INTERNATIONAL 5.2 Damper Cycle Test Purpose: The purpose of this test is to demonstrate the successful operation of a damper through its entire range of movement. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper: Installed Orientation: Tested Orientation: First Cycle Operating Conditions: Test Conditions Open Cycle Test Conditions Closed Cycle Gas Temperature: Gas Temperature: Gas Temperature: Gas Pressure: Gas Pressure: Gas Pressure: Allowable Time: Measured Time: Measured Time: Allowable Amps/Pressure: Measured Amps/Pressure: Measured Amps/Pressure Second Cycle: Gas Temperature: Gas Temperature: Gas Temperature: Gas Pressure: Gas Pressure: Gas Pressure: Allowable Time: Measured Time: Measured Time: Allowable Amps/Pressure: Measured Amps/Pressure: Measured Amps/Pressure: Third Cycle: Gas Temperature: Gas Temperature: Gas Temperature: Gas Pressure: Gas Pressure: Gas Pressure: Allowable Time: Measured Time: Measured Time: Allowable Amps/Pressure: Measured Amps/Pressure: Measured Amps/Pressure Damper has Passed/Failed Test: Comments: Approved By: Date: 12 ANSI/AMCA

19 Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION MEMBER AND CONTROL INTERNATIONAL 5.3 Obstruction Test Purpose: The purpose of this test is to demonstrate operation of the damper in simulated field conditions with the damper partially obstructed. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper: Installed Orientation: Description of Obstruction: Tested Orientation: Pass/Fail Criteria: Any permanent distortion or damage, stopping without completing the stroke, or requiring any assistance to continue operating will indicate the damper has failed the test. Observations: Approved by: Date: ANSI/AMCA

20 Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION MEMBER AND CONTROL INTERNATIONAL 5.4 Deflection Test Purpose: The purpose of this test is to determine blade deflection. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper: Installed Orientation: Tested Orientation: Pass/Fail Criteria: If the deflection of the center of the blade exceeds the specified amount, the damper has failed the test. Specified Conditions Measured Conditions Temperature: Temperature: Pressure: Pressure: Maximum Deflection: Maximum Deflection: Based on comparison of specified to measured blade deflection, the damper has Passed/Failed this test: Comments: Approved By: Date: 14 ANSI/AMCA

21 Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION AND CONTROL INTERNATIONAL MEMBER 5.5 Seal Gap Test Purpose: The purpose of this test is to determine the total amount of gap present between sealing surfaces of a damper. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper: Specified Total Gap Area: Specified Average Gap: Pass/Fail Criteria: If the average or total gap is greater than the specified gap, or if the total gap area is more than specified, then the damper has failed the test. Side 1 Gap Measurement Side 2 Gap Measurement Side 3 Gap Measurement Side 4 Gap Measurement Average Gap = Sum of Gaps/No. Gaps = Total Gap Area = Average Gap/Sealed Perimeter = Based on comparison of specified to measured blade deflection, the damper has Passed/Failed this test: Comments: Approved by: Date: ANSI/AMCA

22 Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION MEMBER AND CONTROL INTERNATIONAL 5.6 Seal Air Consumption Test Purpose: The purpose of this test is to determine the seal air consumption. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper: Installed Orientation: Tested Orientation: Pass/Fail Criteria: If the measured seal airflow exceeds the specified flow, the damper has failed the test. Specified Conditions Measured Conditions Seal air pressure: Seal air pressure: Duct static pressure: Duct static pressure: Specified flow: Specified flow: Based on comparison of specified to measured seal airflow the damper has Passed/Failed this test: Comments: Approved By: Date: 16 ANSI/AMCA

23 Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION AND CONTROL INTERNATIONAL MEMBER 5.7 Stall Test Purpose: The purpose of this test is to demonstrate the structural integrity of the damper under the maximum actuator output. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper: Installed Orientation: Description and Location of Obstruction: Tested Orientation: Observations: Pass/Fail Criteria: Any visible sign of damage or permanent distortion, or failure to pass the damper cycle test will cause the damper to fail the test. Based on observations and passing the Approved: Damper Cycle Test 5.2 (see attached Test Report) the damper has Passed/Failed Date: this Test: ANSI/AMCA

24 Insert your Logo here AMCA 510 Heavy Damper Method of Test AIR MOVEMENT ASSOCIATION AND CONTROL INTERNATIONAL MEMBER 5.8 Drive Redundancy Test Purpose: The purpose of this test is to demonstrate the successful operation of a guillotine damper with only one half of a dual-connected drive system operating. Date: Test Personnel: Witnesses: Reference No: Customer/User Information: Description of Damper: Installed Orientation: Description of drive type and how disconnected: Tested Orientation: Observations: Pass/Fail Criteria: The damper will be considered to have failed the test if it stops at any point during the cycle or requires any form of assistance to continue movement. Based on observations and successfully Approved: completing a complete cycle, the damper Passed/Failed this test: Date: 18 ANSI/AMCA

25 AIR MOVEMENT AND CONTROL ASSOCIATION INTERNATIONAL INC. 30 West University Drive Arlington Heights, IL U.S.A. Tel: (847) Fax: (847) info@amca.org Web: The Air Movement and Control Association International Inc. is a not-for-profit international association of the world s manufacturers of related air system equipment, primarily but limited to fans, louvers, dampers, air curtains, airflow measurement stations, acoustic attenuators and other air system components for the industrial, commercial and residential markets.