Wind Tunnel Performance Analysis

(Measuring Power Requirement)

Practical Training Report Submitted by Kailash Kotwani Under guidance of Professor S K Sane and Dr. Hemendra Arya

Center for Aerospace System and Design Engineering Department of Aerospace Engineering Indian Institute of Technology, Bombay August, 2003

Abstract An experiment analyzing performance of wind tunnel and co-relating theoretical analysis is presented. Various losses at different sections in tunnel have been calculated and total pressure drop across the wind tunnel has been estimated using them. Accordingly, total power required or total power invested to run a open circuit wind tunnel is calculated at different flow velocities. An experiment is conducted to measure the electrical power consumed by wind tunnel fans at different velocities. Calculated power required and measured power input will give the efficiency of system. Second task was to determine the input power required at flow velocities beyond the maximum achievable flow velocity in tunnel. That is the present tunnel system provides maximum velocity of 10 m/s and estimation has been conducted to calculate power required at 25 m/s. For the same purpose trend of results of experiment was extrapolated and again efficiencies were obtained at velocities beyond 10 m/s. Nomenclature = Density (kg/m3 ) a = Air density (kg/m3 ) R = Universal gas constant (J/kg.K) T = Temperature (K) p = Pressure drop (Pa) Dp = Dynamic pressure head (Pa) P = Pressure (Pa) w = Density of water (kg/m3 ) V = Flow Velocity (m/s) g = Acceleration due to gravity (m/s2 ) h = Manometeric height (mm of H2 O) Pt = Total pressure (Pa) Q = Volume flow rate (m3 /s) Contents Abstract Nomenclature 1. Introduction 2. Calculating theoretical power required at different flow speeds 2.1 Theory 2.2 Calculation of all Kis 2.3 Calculations and results 3. Experiment to measure power consumed by fans at different flow velocities 3.1 Apparatus 3.2 Theory 3.3 Description 3.4 Precautions 3.5 Observations 3.6 Calculations and Results 4. Extrapolation to determine the power consumption at higher velocities 5. Co-relating theoretical and experimental results 2

6. Conclusions References Appendix A) Wattmeter Multiplier chart B) Matlab Code C) Charts for losses Acknowledgement 1. Introduction In most basic sense, wind tunnels are ground-based experimental facilities designed to produce flows of air (or sometimes other gases), which simulate natural flows occurring outside the laboratory. For most aerospace engineering applications, wind tunnels are designed to simulate flows encountered in the flight of airplanes, missiles or space vehicles. Since last 150 years, man has always constantly endeavored in the direction of improving performance and efficiencies of tunnel system i.e. getting maximum velocity at minimum input power. This exercise proceeds in the same direction. An open wind tunnel was fabricated at IIT Bombay (Image 1) during the 2002summer for the purpose of designing and developing an MAV (Mini Aerial Vehicle). The size of test section is 1m X 1m X 1.25m as shown in Fig. 1 and one can use it for the range of velocities from 0 m/s to 10 m/s. Air inside the tunnel is circulated using six single-phase motor-driven fans and voltage is controlled by 230 V range AutoTransformer. In near future the fans of this wind tunnel will be upgraded to provide velocities in the range of 20 m/s. The sole purpose this exercise is to predict approximately electrical power requirement and efficiency at that speed.

Image 1: Wind tunnel set up2

Figure 1 : Wind Tunnel Details 2 When air flows through a channel of varying cross-section then it undergoes the change in velocity as per the continuity principle. If there is rise in static pressure then the dynamic pressure will drop down and vice versa. Therefore, it appears that the total pressure, which is the sum of static pressure and dynamic pressure, remains constant. However, in practice these velocity changes are not loss free. Some energy will be lost (or rather turned into heat which is not significant when the fluid is incompressible). The loss in each element of the system (bend, duct length, branches, and obstructions) is dependent on average velocity through it. Here it was assumed that flow is uniform and velocity is constant throughout the crossection. All these losses are measured in terms of pressure drop ultimately which provides power required. On other hand an experiment is conducted to measure the power supplied to fans at different flow velocities. Assuming the fact, power is proportional to cube of flow velocities the results obtained are extrapolated to obtain power consumption at higher velocities. Then theoretical and experimental results at measured range and at extrapolated range are co-related to analyze the general trend of power consumption and efficienc y of system.

Number over text as superscript denotes the number of reference given at the end of report.

2. Theoretically Calculating Power required at different flow speeds Final output power produced by fans in an open circuit wind tunnel is invested in overcoming various losses and ultimately flow possessing kinetic energy (Rate of energy is power) is thrown into the ambient atmosphere. This total output power is power required to run the wind tunnel. Here in this section this power will be calculated theoretically at different speeds. 2.1 Theory If p is total pressure drop in (Pa) and Q is Volume flow rate (m3 /s) then power required in (W) is given as Preq = p*Q (1) The total pressure drop between point 1 and point 2 due to losses is given asPt Pt = 0.5 K V1 + drop du e to frict ion in duct lengths 1 2
2

In other way, p = p1 + p2 (2) Where the value of constant K is sum of all Kis calculated for each different type of loss. The different losses are 1. Losses at entry to the system from atmosphere. 2. Losses at changes of duct area or shape. 3. Losses at bend and changes of direction. 4. Losses at division of flow into branches. 5. Losses caused by obstructions, grills and louvers. 6. Losses at discharge from system to atmosphere 2.2 Calculation of all Ki s 1) Loss at inlet Radius of inlet (curved part) r =0.125m, Equivalent diameter d=1.1m r/d = 0.1136 (r is the radius at inlet and d is the mean diameter) From image 2, Appendix C, K1 = 0.06 for r/d =0.125 2) Loss at obstructions, Aerofoil dimension is 0.5*0.01 Area blocked due to obstruction = 0.5 * 0.01 = 0.005 m2 Total wind tunnel cross section area = 1m2 Blocked area / total area = 0.005 From image 3, appendix C, for streamlined strut K2 = 0.01 Blocked area due to tube= length of tube*diameter of tube. = 0.5*0.01 = 0.005 From image 3, appendix C, for round tube K3 = 0.01 5

3) Pressure drop in duct diffuser, A2 = 1.6*2.4 =3.84 m2 , A1 = 1m2 A2 / A1 = 3.84 (A1, A2 are the inlet and outlet areas of the duct) Calculating average height (a) and width (b) for tunnel a = 1.3 m, b = 1.7 Calculating De from eqn 4, De = 1.6 m L = Length of diffuser = 3.75 L/ De =2.343 K4 = 0.45 (From Image 4, appendix C) 4) Loss at outlet, For losses at outlet, Ko = 1 (From Image 5, appendix C) But at outlet, velocity is different from that of the test section. For incompressible flow continuity eqn is given as A1 .V1 = A2 .V2 (3) Where A1 , V1 and A2 , V2 are area of crossection and velocity at test-section and outlet respectively. V2 = (A1 /A2 ).V1 = 0.2604.V1 Pressure lose at outlet = .Ko ..(V2 )2 = . (0.0678).. (V1 )2 Resultant K for losses at outlet = K5 = 0.0678 5) Loss due to the duct friction, This loss depends on equivalent diameter and the flow velocity. Equivalent diameter is given as1

De = 1.265

a 0.6 b 0 .6 ( a + b) 0 .2

(4)

Where a and b are dimensions of rectangular duct. Equivalent diameter for straight channel = 1.1 m And Equivalent diameter for diffuser section = 1.51 m. Using these values, the loss is calculated for different velocities with the he lp of graph in image 6, appendix C. While calculating the duct friction loss, additional factor of 1.25 was assumed to take into account bolts within the ducts. Loss is calculated as shown in calculations. Area of crossection of test section = 1 m2 Flow velocity = Volume flow rate

2.3 Calculations and results: 1) Total pressure drop calculation due to all Ki The value of resultant K is obtained by summing all values of Kis. K = K i = K 1 + K 2 + K 3 + K 4 + K 5 = 0.065 + 0.01 + 0.01 + 0.45 + 0.0678 = 0.6028
i =1 i= 5

(4) Then, P1 = pressure drop = K * 0.5 *a * (V1 )2 (4A) Where, a = 1.225 kg/m3 . This pressure loss is calculated at different test-section velocities (Table 1) and then the graph is plotted. 2) Calculating pressure drop due to duct friction loss Total duct friction loss = friction loss in test section + friction loss in diffuser Duct Skin friction losses are calculated in the following way: For the straight channel, a = 1, b = 1, De = 1.1m. (from eqn 3) For a given flow, say Q= 10m3 / sec, and De = 1.1m, F1 = Pressure drop = 0.9 Pa/m (Image 6, Appendix C) So for the 3.25 m length of the straight channel (inlet + test), Pressure drop = 0.9*3.25= 2.925 Pa. For the diffuser section average a= 1.7 m, b= 1.3m, Correspondingly, De = 1.6 m (from eqn 3) For Q= 10 m3 /s & De = 1.6 m, F2 = Press drop = 0.14 Pa/m (Image 6, appendix C) For the 3.75 m length of the diffuser, pressure drop = 0.14*3.75= 0.49 Pa. While calculating the duct friction loss, a factor of 1.25 was assumed to take into account bolts within the ducts Complete formula for duct friction loss can be written as P2 = (3.25F1 + 3.75 F2 ) * 1.25 (4B) Using eqn 2, 3, 4, 4A and 4B to calculate total pressure drop (given in table 1) at different flow velocities and plotting them (graph 1)

Table 1: Calculation of Total Pressure drop at different flow velocities Flow Pressure loss due Pressure loss due to duct Total pressure Velocity to K factors (Pa) friction (Pa) drop (Pa) (m/s) P1 P2 =(3.25 F1 + 3.75 F2 )*1.25 P= P1 + P2 2 4 6 8 10 15 20 25 30 1.48 5.91 13.29 23.63 36.92 83.07 147.67 230.76 332.29 0.41 0.58 1.32 2.44 4.31 9.53 16.56 28.13 37.38 1.88686 6.48744 14.61174 26.06976 41.2315 92.603375 164.246 258.889375 369.6735

400 350

y = 0.4115x + 0.0066x

Total pressure drop (Pa)

300 250 200 150 100 50 0 0 5 10

Flow Velocity (m/s)

15

20

25

30

35

Graph 1: Total pressure Drop at different Flow Velocity

3. Experiment to measure power consumed by fans at different flow velocities 3.1 Apparatus 1) 3 Wattmeters (Single element electrodynamic portable wattmeter) 2) Micro- manometer (Max p 199.9 mm H2 O) 3) Pitot static tube (mounted in tunnel) 3.2 Theory To measure the density of air, the ideal gas equation is given as P = RT Where P and T are measured laboratory pressure and Temperature. The relationship between dynamic pressure head and velocity is given as p = *aV2 Where Micro- manometer measures pressure in mm of H2 O p = wgh Solving 2 and 3 to obtain, 2 w gh V = a

(5)

(6) (7)

(8)

3.3 Description Open channel wind tunnel is mounted with six fans for producing flow of desired velocity. Six fans run on single-phase supply. Each two fans receive supply from single line. Hence there are total three supply lines. Each connected to one wattmeter for measurement using three wattmeter method. Chart for selecting voltage and current range is given in Table 5, appendix A. A pitot static tube mounted at the center of crossection and at the distance of 78 cm from entry is connected to Micro- manometer for measuring dynamic pressure head. After considering voltage and current ratings of fans, the following range was selected on wattmeter Voltage range: 220 V Current range: 5 Amp Multiplier = 8 (from table in Appendix A) 3.4 Precautions 1) Ensure that pitot static tube is normal to the plane of crossection of wind tunnel 2) Close all the slits and holes of wind tunnel using insulating tape before starting the experiment 3) After increasing dimmer stat voltage, fan speed increases very slowly so give sufficient time to stabilize micro- manometer readings. 3.5 Observations Date: 30th July 2003 Experiment begins at: 3:07 pm Temp at start and end: 29/29 deg C Pressure at start and end: 1003/1003 mbar Humidity at start and end: 77/77 %

Ends at: 4:05 pm

Obs no. 1 2 3 4 5 6 7 8 9 10 11 12 13

Table 2: Measurement of dynamic pressure and power consumption Dimmer stat Dynamic Pressure Wattmeter 1 Wattmeter 2 Wattmeter 3 Voltage (V) (mm of H2 O) (W1) (W2) (W3) 65 0.14 11 8.5 8.5 80 0.27 19 15.5 16 95 0.58 26 24 25 110 1.05 35 33 33 125 1.77 45.5 43 43 140 2.75 54 53 50.5 155 3.74 58.5 59 53 170 4.42 61.5 61 55 185 4.85 62.5 62 56 200 5.10 64.5 64 58.5 215 5.35 66.5 66 61 230 5.60 69 68 63 245 5.70 73 71 67

During the experiment Micro- manometer was fluctuating over a larger range so it was decided to repeat the experiment to reduce the measurement error induced due to Micromanometer. Date: 30th July, 2003 Experiment starts at: 4:21 pm Ends at: 5:05 pm Temp at start/ End: 29/29 deg C Pressure at start/ End: 1003/1003 mbar Humidity at start/End: 76/78 % Table 3: Measurement of dynamic pressure and power consumption Dimmer stat Dynamic Pressure Wattmeter 1 Wattmeter 2 Wattmeter 3 Voltage (V) (mm of H2 O) W1 W2 W3 65 0.1 10 8 10.5 80 0.3 17 15 15 95 0.6 26 24 25 110 1.0 35 32 32 125 1.7 45 42 42 140 2.5 52 52 47 155 3.8 56 57 50 170 4.6 59 59 53 185 4.9 60 61 54 200 5.2 63 62 57 215 5.4 65 64 59 230 5.7 67 67 62 245 5.7 71 70 65

Obs no. 1 2 3 4 5 6 7 8 9 10 11 12 13

3.6 Calculations and Results P = 1.003*103 Pa; T = 273 + 29 = 302 K R = 287 J/Kg K 10

 = P/RT = 1.1572 Kg/m3 Flow velocity is calculated using eqn no. 8 2 w gh V = a Multiplier for wattmeters for selected range of voltage and current is 8, Power consumption = 8*(W1+W2+W3) Using these equations, wind tunnel power consumption has been calculated at different flow velocities in Table 4. Results for both data sets have been plotted in Graph 2. A curve fitting line has been obtained for both the data sets altogether in Graph 3. Table 4: Calculating flow velocity and power consumption by the fans of tunnel Dimmer stat Dynamic Velocity of Power consumption (Watt) Voltage (V) Pressure (mm flow (m/s) of H2 O) 8*(W1+W2+W3) 65 80 95 110 125 140 155 170 185 200 215 230 245 65 80 95 110 125 140 155 170 185 200 215 230 245 0.14 0.27 0.58 1.05 1.77 2.75 3.74 4.42 4.85 5.10 5.35 5.60 5.70 0.10 0.30 0.60 1.00 1.70 2.50 3.80 4.60 4.90 5.20 5.40 5.70 5.70 1.54 2.14 3.13 4.22 5.48 6.82 7.96 8.65 9.06 9.29 9.52 9.74 9.83 1.30 2.25 3.19 4.12 5.37 6.51 8.02 8.83 9.11 9.38 9.56 9.83 9.83 224 404 600 808 1052 1260 1364 1420 1444 1496 1548 1600 1688 228 376 600 792 1032 1208 1304 1368 1400 1456 1504 1568 1648 11

1800 Power consumption (Watt) 1600 1400 1200 1000 800 600 400 200 0 0 5 10 Flow Velocity (m/s) 15

Set 1 Data Set 2 Data

Graph 2: Tunnel power consumption at different flow velocities Passing a curve fitting line through these data points and we will obtain the following curve.
1800 1600 1400 Power Consumption (Watt) 1200 1000 800 600 400 200 0 0 2 4 6 Flow Velocity (m/s) 8 10 12

Graph 3: Approximate curve-fitting line of power consumption vs flow Velocity for both data sets. 12

4. Extrapolation to determine the power consumption at higher velocities Analyzing Graph 3 carefully, one can say that curve is linear for low flow velocities on other hand for higher flow velocities power consumption start increasing exponentially. In general, we know that power is proportional to the cube of velocity. P V3 So ideally if there would have been no losses in the motors of fans and across its blades we should have obtained cubic relationship between power and flow velocity. Our objective is to determine approximately correct relationship between power consumption and flow velocity so that we should be able to extrapolate it to find power consumption at 25 m/s. While conducting experiment one fact was realized for low velocities below 4 m/s (that is in the voltage range of 65 to 100), output of Micro manometer was fluctuating over the larger ranges hence reliability of these readings is low. Secondly, the fans inside the tunnel are designed for voltage rating of 220 V. It is not correct to run these fans on such low voltage ranges. These are the factors, which have brought error in our analysis, and we can see the curve for lower range of velocities is almost linear. So for purpose of extrapolation we will not consider first three measurements (65 V to 110 V). After analyzing readings above 220 V we can say that there is not substantial increase in flow velocity whereas there is sufficient increase in power consumption. Though we cannot conclude the exact reason behind it but some of the possible reasons may be-1) Stalling of fan blades due to high RPM and forward velocities. 2) Above power rating limit of fans, no appreciable increase in flow velocity resulting in poor performance. 3) Selected maximum voltage range on wattmeter is 220, so it may be providing erroneous results beyond voltage limit of 220 V. Hence we will not consider two set of observations noted above 220 V. Finally analyzing remaining selective reading and plotting them on graph.
1800 Power Consumption (Watt) 1600 1400 1200 1000 800 600 400 200 0 0 2 4 6 8 Flow velocity (m/s) 10 12

Set 1 Data

Set 2 Data

Graph 4: Power consumption for selected flow velocities 13

A Matlab code (appendix B) was written for analysis purpose considering only the readings plotted in Graph 4. This code used polyfit and polyval functions and generated following set of data and equation. Y=1.0e+003 *(0.0054*X3 - 0.1222*X2 +1.0097*X - 1.6801) (9)

(This equation is valid for flow velocities greater than or equal to 5 m/s) Where Y= Power consumption (Watt), X = Flow Velocity (m/s) Using eqn 9, calculating power consumption at higher velocities in table 5 and comparing them with measured values to check the validity of eqn 9. Calculated power (using eqn 9) is plotted against velocity in Graph 5. Table 5: Determining power consumption at higher velocities and comparison with measured values Flow Velocity Calculated Power Measured Power % Error (m/s) Using eqn 9 (Watt) (Watt) 5 987 960 2.81 7.5 1290 1320 -2.27 10 1579 1632.5 -3.27 12.5 2358 NA NA 15 4132 NA NA 17.5 7405 NA NA 20 12680 NA NA 22.5 20464 NA NA 25 31259 NA NA

35000 Power Consumption (Watt) 30000 25000 20000 15000 10000 5000 0 0 10 20 Flow Velocity (m/s) 30

Graph 5: Relationship between Estimated power consumption and flow velocity

14

5. Co-relating theoritical and experimental results Power consumption calculated using eqn 9 gave a very small error with experimentally measured values under velocity 10 m/s which proves the validity of estimated eqn 9. Table 6, gives power consumption using eqn 9 (extrapolation), Output power calculated theoretically through losses and efficiency of the system at different velocities and efficiency of the system then efficiency is plotted in Graph 6. Table 6: Estimating efficiency of system from theoretical and extrapolated results Calculated Efficiency of Flow Velocity Power theoretical Power system (%) (m/s) consumption (Watt) (Watt) 5 7.5 10 12.5 15 17.5 20 22.5 25 987 1290 1579 2358 4132 7405 12680 20464 31259
51.60 173.97 412.16 804.74 1390.30 2207.40 3294.64 4690.58 6433.81 5.23 13.49 26.10 34.13 33.65 29.81 25.98 22.92 20.58

40 35 30 Efficiency % 25 20 15 10 5 0 0 10 20 30 Flow velocity (m/s)

Graph 6: Efficiency Vs flow velocity

15

6.Conclusions 1) The present set of fans inside the tunnel provides maximum velocity up to 10 m/s. If we upgrade tunnel using same set of fans to get higher velocities they will give maximum efficiency in 12.5 m/s velocity range beyond that efficiency will go down gradually. So it would be best to use same kind of fans only up to 12.5 m/s. 2) Though efficiency of present system goes down in the range of 25 m/s but this analysis give rough estimate of amount of input power which will be required to achieve velocities around 25 m/s and this knowledge will help in decision process of upgrading the present tunnel system. 3) Suppose we target to achieve a wind tunnel system which will be able to provide maximum velocity of 25 m/s with an efficiency of around 50% so one can predict the minimum power required from above analysis and that will be close to 13 k Watt. With an added factor of safety of 2 k Watt one can say with confidence that at 15 k Watt this system will provide velocity in the range of 25 m/s and two huge motors of 7.5 k Watt may suit our requirements. References 1) B. B. DALY, Woods Practical Guide to Fan Engineering, Woods of Colchester Limited publisher,1979 2) http://www.casde.iitb.ac.in/IMSL/index.html Appendix A) Wattmeter Multiplier chart Voltage range (V) 55 55 110 110 220 220 Current range (A) 2.5 5 2.5 5 2.5 5 Multiplier 1 2 2 4 4 8

Appendix B) Matlab Code X1 = [4.217144407 5.475331979 6.82480379 7.959020518 8.65236751 9.063473984 9.294133605 9.519205758]; Y1 = [808 1052 1260 1364 1420 1444 1496 1548]; X2 = [4.115511534 5.365970539 6.507195092 8.02260891 8.826788876 9.110073129 9.384810226 9.56358458]; Y2 = [792 1032 1208 1304 1368 1400 1456 1504]; Q=[5 7.5 10 12.5 15 17.5 20 22.5 25]; X3=[X1 X2]; Y3=[Y1 Y2]; P3 = polyfit(X3,Y3,3); Z3=polyval(P3,Q); plot(Q,Z3) xlabel('flow velocity (m/s)'); ylabel('Power consumption (Watt)'); 16

Appendix C) Charts for losses

Image 2: losses at inlet1

Image 3: Losses at obstructions 1

17

Image 4: Losses in duct diffuser1

Image 5: Losses at the outlet1

18

Image 6: Losses due to duct friction1 19

Acknowledgement
I take this opportunity to express our sincerest gratitude to Prof. S.K. Sane , for showing us the way and being there by our side at all the crucial moments throughout project work. I would like to thank Dr. Hemendra Arya and Dr. K Sudhakar for their kind cooperation and guidance in this project. I am thankful of Propulsion Laboratory Incharge, Mr Deshpande for his help in project. We are thankful of Mr. Tagare, Mr. Nimkar, Mr. Gade, Mr. Mungekar and Mr. Badekar who helped us with deep gratitude in this project.

-Kailash

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