Math and Maintenance for Pumps and Blowers

Overview of Blower Technologies and

Comparison of High-Speed Turbo Blowers

Juan Loera, P.E.

Carollo Engineers
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

75%

Energy consumption commonly Optimized blower and process air

accounts for 75 percent of the controls will also help reduce
total life-cycle cost of a blower blower operating costs

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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
Nominal Blower Nominal Turndown
Blower Type
Efficiency (percent) (percent of rated flow)

Positive Displacement 45-65 50

Multi-Stage Centrifugal
50-70 60
(inlet throttled)
Multi-Stage Centrifugal
60-70 50
(variable speed)
Single-Stage
Centrifugal, Integrally
Geared (with inlet 70-80 45
guide vanes and
variable diffuser vanes)
Single-Stage High
70-82 50
Speed Turbo **

**Testing methods are not consistent among different manufacturers

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 Blower Curves Comparison
Blower Discharge Pressure (psi)

System Curve

High-Speed Multi-Stage
Turbo** Centrifugal
Positive Single-Stage
Displacement Centrifugal*

Blower Flow (scfm)

* Single-stage centrifugal blower with dual-point control
** High-speed turbo blower with speed control only
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Centrifugal Blower Operating
Range
Surge Line
Blower at various
capacities
Resource Ratio

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 Multi-Stage Centrifugal
 Instrumentation
 Simple
 Monitor bearing temperature and vibration
 Electric motor (2-pole most often)
 IC engines (not often)
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Single-Stage Centrifugal
 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 Single-Stage

 Instrumentation
 Complex
 Vibration, temperature, pressure, power

 Electric motor (2-pole or 4-pole)


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IC engines
High-Speed Turbo Blowers

 Significant area of innovation

in blower design
 Introduced to North American
market around 2007
 Industry “game changer”
 Offers energy savings with
lower maintenance costs
High-Speed
Turbo Blower

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High-Speed Turbo Blowers
 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 High-Speed
 Two configurations
Turbo Blower
 Air bearing (most common)
 Magnetic bearing
 Bearings require no lubrication system

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High-Speed Turbo Blowers
 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 High-Speed
 Cooling requirements vary by Turbo Blower
manufacturer
 Provides sound attenuation

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 High-Speed Turbo Blowers
Turbo Blower Technology – at a Glance

Advantages Disadvantages

High efficiency over wide Relatively new technology in

range of flows North America
Packaged unit provides
Limited sizing options
small footprint
Multiple units needed for large
Good turndown capacity
installations
Quiet operation Unknown long-term reliability
Few moving parts, low Periodic replacements of
maintenance requirements special electrical components
VFD requires special filters to
No complex oil cooling
eliminate disturbances to
system required
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 Siemens (Turblex) Aerzen (K-Turbo

Hoffman HSI ABS (HST) Atlas Copco

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Two Types of Installations

Piped/ducted inlet air

Inlet air from blower room

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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
Air Bearing Magnetic Bearing
Manufacturer

Neuros
Turblex
Aerzen
HSi
ABS
Dresser Roots
Atlas Copco
Piller TSC
Hoffman
Howden

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 Impeller Design

Blower
Milled Impeller Cast Impeller
Manufacturer

Neuros
Turblex
Aerzen
HSi
ABS
Dresser Roots
Atlas Copco
Piller TSC
Hoffman
Howden

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 Cooling System
Separate Cooling
Use Process Air
Blower System
(Self-Contained
Manufacturer (External Heat
within Enclosure)
Rejection)

Neuros
Turblex
Aerzen
HSi
ABS
Dresser Roots
Atlas Copco
Piller TSC
Howden
Hoffman

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 Blower Controls
Single-Point Dual-Point Control
Blower
Control (Variable Speed +
Manufacturer
(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
Surge Line

Speed Lines
Pressure Rise
To Surge
Resource Ratio

Specified
System Curve Design Point
Operational
Range

Flow Rate

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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

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