DESIGN OF PORTABLE WELDING FUME EXTRACTOR MACHINE

UNIVERSITY OF GONDAR

INSTITUTE OF TECHNOLOGY

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

DESIGN OF PORTABLE WELDING FUME EXTRACTOR MACHINE

A Thesis Submitted in Partial Fulfillment of the Requirements for the Degree of

Bachelor of Science in Mechanical Engineering

(Design Engineering Stream)

Thesis by:
 Tadiwes Mesfin ………………. GUR/01070/09
 Surafel Tewelde……………….. GUR/01058/09

Advisor:
Mr. Belete Ambachew

July, 2021

UOG, IOT, Department of Mechanical and Industrial Engineering

 UNIVERSITY OF GONDAR

SCHOOL OF MECHANICAL AND INDUSTRIAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

DESIGN OF PORTABLE WELDING FUME EXTRACTOR

Thesis by:

 Tadiwes Mesfin
 Surafel Tewelde
Institute of Technology

Approved by Board of examiners:

_____________________ ________________ ______________

Chairman Date Signature

______________ ________________ ______________

Advisor Date Signature

______________ _____________ ___ ______________

Internal Examiner Date Signature

______________ ________________ ______________

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 APPROVALS
To the best of our knowledge and as understood by the students in the Research Integrity and
Copyright Disclaimer, this thesis “DESIGN OF PORTABEL WELDING FUME EXTRACTOR
MACHINE” adheres to the provisions of guidelines, policies and legislation's of the Ethiopian Institute of
basic metal and metal work technology during their research work and use of copyrighted material. The
thesis is complete and can be presented to the thesis evaluation committee.

__________________ ________________
Adviser Name Signature date

iii
 DECLARETION
We hereby certify that we are the sole author of this thesis and that no part of this thesis has been
published or submitted for publication.
We certify that, to the best of our knowledge, our thesis does not infringe upon anyone’s copyright nor
violate any proprietary rights and that any ideas, techniques, quotations, or any other material from the
work of other people included in our thesis, published or otherwise, are fully acknowledged in accordance
with the standard referencing practices.
We declare that, this is original work of our thesis, including any final revisions, as approved by our thesis
committee and the Graduate Studies office, and that this thesis has not been submitted for a higher degree
to any other University or Institution.

Name:

 Tadiwes Mesfin
 Surafel Tewelde

Title of the Thesis: Portable Welding Fume Extractor Machine

Department: ________________________________________________________

Signature: __________________________________________________________

Adviser: ___________________________________________________________

Signature: __________________________________________________________

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 ACKNOWLEDEMENT

We are grateful and would like to express our sincere gratitude to our supervisor Mr.Belete
Ambachew and Mr.Kalab lab assistance for those germinal ideas, invaluable guidance, continuous
encouragement and constant support in making this thesis possible. They has always impressed us with
his outstanding professional conduct, Mr.kalab his s0trong conviction for science, and his belief that a
degree program is only a start of a life-long learning experience. We appreciate his consistent support
from the first day we applied to graduate program to these concluding moments. We are truly grateful for
his progressive vision about our design, his tolerance of mistakes, and his commitment to our future career.
We also sincerely thanks for the time spent proofreading and correcting our many mistakes. We sincere
thanks go to all members of the staff of the Mechanical Engineering Department, IOT library staff, who
helped us in many ways and made our stay at IOT pleasant and unforgettable. Many special thanks go to
all our friends for their help, inspirations and supports during this study and design work.

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 ABSTRACT
In this paper, the objective of the study is to determine the effective portable welding fume
extraction system and safe protection during welding process for welding in higher technical institute the
welding is basic labs which learn the joining of two similar metals and also a common industrial process.
During Welding operation, the fumes and metallic gases are emitted from the work piece, which cause the
pollution and hazard to a worker health condition, when gases were inhaled or ingested. This will cause
respiratory effects such as lung function changes, bronchitis and possible of lung cancer. The present
work deals with the designing of portable fume extraction system at 1HP motor and 3D solid-work also
check the performance such as efficiency of the system, functionality of filtration system, and
environmental friendly, during the welding process. The system designed simple and less cost effective,
safety, functionality, ease of availability and affordable maintainability the system was designed using
American Society of Heating, Refrigerating and Air-Conditioning Engineers (ASHRAE) standard among
others. To observe and filter the hazard’s elements like oxides of Sulphur, oxides of nitrogen, oxides
monoxide and other suspended particulate matter which formed during welding process.

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Contents
APPROVALS ...................................................................................................................................... iii
DECLARETION ................................................................................................................................. iv
ACKNOWLEDEMENT ...................................................................................................................... v
ABSTRACT ........................................................................................................................................ vi
LIST OF FIGURES ............................................................................................................................ ix
LIST OF TABLES .............................................................................................................................. xi
ABBREVIATIONS AND SYMBOL ................................................................................................. xii
CHAPTER – ONE ........................................................................................................................... - 1 -
1. INTRODUCTION ........................................................................................................................ - 1 -
1.1 BACKGROUND OF THE PROJECT .................................................................................. - 1 -
1.2 PROBLEM OF STATEMENT ............................................................................................ - 10 -
1.3 OBJECTIVE OF THE PROJECT ...................................................................................... - 11 -
1.3.1 GENERAL OBJECTIVE ................................................................................................. - 11 -
1.3.2 SPECIFIC OBJECTIVE................................................................................................... - 11 -
1.4 METHODOLOGY ............................................................................................................... - 12 -
1.5 SCOPE OF THE PROJECT ................................................................................................ - 13 -
1.6 LIMITATION....................................................................................................................... - 14 -
CHAPTER - TWO ......................................................................................................................... - 15 -
2. LITERATURE REVIEW .......................................................................................................... - 15 -
CHAPTER - THREE ..................................................................................................................... - 19 -
3. DETAIL DESIGN OF COMPONENT .................................................................................... - 19 -
3.2 DESIGN FRAME ................................................................................................................. - 22 -
3.3 SELECTION OF FILTER PAPER ..................................................................................... - 23 -
3.4 DESIGN OF DUCT .............................................................................................................. - 28 -
3.5 DESIGN OF CENTRIFUGAL BLOWER .......................................................................... - 35 -
3.5.1 DIFFERENT TYPE OF BLOWER .................................................................................. - 35 -
3.6 DESIGN OF VOLUTE CASING ......................................................................................... - 41 -
3.6.1 FAN CASE COVER DESIGN ......................................................................................... - 42 -
3.6.2 PIPE HOOD DESIGN ..................................................................................................... - 42 -
3.7 DESIGN OF RIVET PIN ..................................................................................................... - 42 -

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 3.8 DESIGN OF PRESSURE ..................................................................................................... - 44 -
3.9 DESIGN PF TEMPRETURE .............................................................................................. - 45 -
COST ANALYSIS ...................................................................................................................... - 45 -
CHAPTER –FOUR ........................................................................................................................ - 48 -
4. SOFTWARE ANALYSIS .......................................................................................................... - 48 -
CHAPTER –FIVE ......................................................................................................................... - 59 -
5. RESULT AND DISCUSSION ................................................................................................... - 59 -
5.1 RESULT................................................................................................................................ - 59 -
5.2 DISCUSSION ....................................................................................................................... - 61 -
CHAPTER SIX .............................................................................................................................. - 62 -
CONCLUTION AND RECOMMENDATION ............................................................................ - 62 -
6.1 CONCLUSION ..................................................................................................................... - 62 -
6.2 RECOMMENDATION ........................................................................................................ - 63 -
REFERENCE................................................................................................................................. - 64 -
APPENDEX ................................................................................................................................... - 65 -

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 LIST OF FIGURES

Figure 1. Pressurized cylinder ............................................................................................................ - 6 -

Figure 2. Welding machine ................................................................................................................ - 7 -
Figure 3. Submerged Arc Welding (SAW) ......................................................................................... - 8 -
Figure 4. Gas Tungsten Arc Welding (GTAW) .................................................................................. - 8 -
Figure 5. Gas Metal Arc Welding (GMAW) ...................................................................................... - 9 -
Figure 6. Welding fume and problems of our respiratory system ...................................................... - 11 -
Figure 7. General Methodological analysis....................................................................................... - 12 -
Figure 8 .specific methodology ........................................................................................................ - 13 -
Figure 9. Conceptual design ............................................................................................................. - 20 -
Figure 10. Solid work Frame ............................................................................................................ - 23 -
Figure 11. Air filter .......................................................................................................................... - 24 -
Figure 12. Laboratory filter .............................................................................................................. - 25 -
Figure 13. Filter paper uses for paper chromatography ..................................................................... - 26 -
Figure 14. Oil filter .......................................................................................................................... - 28 -
Figure 15 . Solid work air filter ........................................................................................................ - 28 -
Figure 16 .Solid work Duct .............................................................................................................. - 35 -
Figure 17. Types of blower curve ..................................................................................................... - 36 -
Figure 18. Inlet and Outlet Velocity Diagram of the Impeller ........................................................... - 39 -
Figure 19 . Solid work Impeller........................................................................................................ - 41 -
Figure 20. Volute passage cross section. .......................................................................................... - 41 -
Figure 21 . Solid work Rivet ............................................................................................................ - 44 -
Figure 22. Fan case .......................................................................................................................... - 48 -
Figure 23. Impeller .......................................................................................................................... - 49 -
Figure 24. Fan case cover ................................................................................................................. - 50 -
Figure 25. Duct ................................................................................................................................ - 51 -
Figure 26. Air filter .......................................................................................................................... - 52 -
Figure 27. Pipe hood ........................................................................................................................ - 53 -
Figure 28. Frame ............................................................................................................................. - 54 -
Figure 29. Drawer ............................................................................................................................ - 55 -

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Figure 30. Pipe hood 2 ..................................................................................................................... - 56 -
Figure 31. Rivet pin ......................................................................................................................... - 57 -
Figure 32. Assemble drawing ........................................................................................................... - 58 -

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 LIST OF TABLES

Table 1. Long and short term effects of welding fume ........................................................................ - 3 -

Table 2. Conceptual design .............................................................................................................. - 19 -
Table 3. Specification of the project ................................................................................................. - 20 -
Table 4. Summary of material selection and its properties ................................................................ - 21 -
Table 5. Standard air flow characteristics w.r.t duct size .................................................................. - 31 -
Table 6. Application verses velocity table. ....................................................................................... - 32 -
Table 7.Thickness of aluminum and steel for duct. ........................................................................... - 33 -
Table 8. Differences pressure ratio between fans and blowers .......................................................... - 36 -
Table 9. Properties of stainless steel ................................................................................................. - 45 -
Table 10. Calculated results of radial type centrifugal blower ........................................................... - 59 -

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 ABBREVIATIONS AND SYMBOL

(𝐻𝐸𝑃𝐴): High-Efficiency Particulate Air

(𝑂𝑆𝐻𝐴): Occupational Safety and Health Administration
𝐴𝑆𝐻𝑅𝐸: America society of heat refrigeration and air conditioning engineers
𝐵𝑡𝑢: British thermal unit
𝐶𝑓𝑚: Cubic feet per meter
𝐹𝑝𝑚: Feet per meter
𝐼𝐵𝑅: India boiler regulation
𝑀𝐼𝐺: Metal inert gas
𝑇𝐼𝐺: Tungsten inert gas
𝑉𝑝: Velocity of pressure
𝑆𝑝: Static pressure
𝑄𝑐: Main flow rate of the duct

𝑆𝑡: Tear strength

𝑆𝑐: crushes strength

𝑆𝑠: Shear strength

𝐼𝑆: International standard code

𝐴𝑐: Cross sectional area of main duct

𝐷𝑐: Main duct diameter

𝑅𝑡 & 𝑄𝑡: Tongue radius and tongue angle

𝑉: Volume
𝛣2: Vane discharge angle
𝐾”: Over all pressure coefficient
𝑇: Torsion

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𝐾: Bending angel coefficient
𝐶𝑃: Coefficient of pressure
𝑇𝑜: Temperature at impeller eye
𝑉𝑟: Radial pressure
𝑈: Inlet impeller rotational speed
𝛽 &𝛼: Beta and alpha
𝑃𝑎: Absolute pressure
𝑃𝑖: Inlet pressure
𝑃𝑑: Discharge pressure
𝑍: Blade numbers
𝑊: Weight of gas
𝐻𝑜: Head of impeller
𝑃𝑜: Pressure at impeller eye
𝑈2: Thickness factor

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 DESIGN OF PORTABLE WELDING FUME EXTRACTOR MACHINE

CHAPTER – ONE

1. INTRODUCTION
1.1 BACKGROUND OF THE PROJECT
Most everyday construction processes in our society today engaged at least one welding operation.
Welding is the process of permanently joining two or more materials together, usually metals, by heat or
pressure or both. When heated, the material reaches molten state and may be joined together with or
without additional filler materials being added. Thermoplastics, for example can be welded together using
a suitable heat source to form permanent joins. Many different energy sources can be used for welding
including gas flames, electric arcs, electric resistance, lasers, electron beams, friction, molten metal baths
and ultrasound. Welding includes joining methods as diverse as fusion welding, forge welding, friction
welding, braze welding, brazing, soldering and explosion welding. Welding is a potentially hazardous
activity and precautions are required to avoid electrocution, fire and explosion, burns, electric shock,
vision damage, inhalation of poisonous gases and fumes, and exposure to intense ultraviolet radiation [1].

Welding Fume extraction System must be working in a high efficiency to avoid the lung, eye, skin, cancer,
blood circulation, up to death accident (hazards). This is because this system is function to extract the
smoke during welding process especially for MIG and ARC welding. The welder also needs a safety dress
and protection such as glove, head cover, safety goggle, safety boot and etc. These extraction system will
reduce the bad effect during welding process in the job site. In a real world, welding is a popular step
which means many people know how to do the welding process. Some people also make the welding for
their minor money income and fully money income. This is because the salary for the welder is not so
bad. Unfortunately, welding also has an effect. Every year, thousands of welder suffer injuries as a result
of lung cancer and eye accidents most time that occur because proper safety precautions are not followed
at the job site. Health issues mostly occur because carelessness. Any injury can be painful and can
incapacitate a person, or lead permanent disability or death. Fumes are air which originate from toxic
gases such as acetylene (C2H2), ozone (O3), nitrogen oxides (NO), carbon monoxide (CO), etc...
generated when coatings on metal surfaces are heated such as epoxy resins, degreasing agents, paint and
generated when the arc flash and some degrease chemicals or paints reacts. This gas is dangerous to the
welder because its will affect the eyes and other body parts. Fumes can cause symptoms such as nausea,
headaches, dizziness, and metal fume fever. The possibility of more serious health effects exists when

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highly toxic materials are involved. For example, manganese gases are produced during the welding
process or may be produced by the effects of process radiation on the surrounding environment. Radiation
is electromagnetic energy given off by the arc or flame that can injure eyes and burn skin [1].

Generally almost all metallic element that can be weld has their Owen exhaust effect gas during welding
operation

About welding and cutting fume

Welding fumes are a mixture of metal fumes and gasses produced during welding operations. They
generally have different compositions, depending on the metals used for welding and uses welding type,
so they contain several contaminants.

• Mixture of airborne particles and gasses released or produced by the welding process

• Composition varies according to the welding process and typically contains metal oxides and other metal
reaction products, particulate from flux of electrodes and gases produced by UV light like ozone and
shielding gases

• Finer dust mass fraction is alveoli and can accumulate in the lungs and remain in the body • Compounds.
90% of the particles come from the welding consumables Welding fumes enter the human body through
the lungs. They mix with the air we inhale [2].

Metals

Aluminum, Antimony, Arsenic, Beryllium, Cadmium, Chromium, Cobalt, Copper, Iron, Lead,
Manganese, Molybdenum, Nickel, Silver, Tin, Titanium, Vanadium, Zinc.

Gases

• Shielding

Argon, Helium, Nitrogen, Carbon Dioxide.

• Process

Nitric Oxide, Nitrogen Dioxide, Carbon Monoxide, Ozone, Phosgene, Hydrogen Fluoride, Carbon
Dioxide.

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Health risks (hazards) when inhaling welding fumes [2].

Table 1. Long and short term effects of welding fume

Fume/Dust immediate effects long-term effects

Welding fume (general) Hoarseness, sore throat, eye Bronchitis,

irritation , metal fever

Reprotoxic Chromium (in Carcinogenic

welding fume in case of -among
other things stainless steel
welding)

Metal fever Carcinogenic

Nickel (in welding fume in case

of -among other things stainless
steel welding)

Aluminum Irritation of respiratory org,

metal fever

Manganese Pneumonia Damage to central nervous

system

Zinc Metal fever

Copper Metal fever

Magnesium Irritation of respiratory organs,

Lead Changes of blood and kidneys

Reprotoxic

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Factors that affect worker exposure to welding fume
• Type of welding process

• Base metal and filler metals used

• Welding rod composition

• Location (outside, enclosed space)

• Welder work practices

• Air movement

• Use of ventilation controls

Reducing exposure to welding fume

• Welders should understand the hazards of the materials they are working with. OSHA’s Hazard
Communication standard requires employers to provide information and training for workers on
hazardous materials in the workplace.

• Welding surfaces should be cleaned of any coating that could potentially create toxic exposure, such as
solvent residue and paint.

• Workers should position themselves to avoid breathing welding fume and gases. For example, workers
should stay upwind when welding in open or outdoor environments.

Classification of Welding Processes and their exhaustion of gas

Welding is broadly classified into two types:
I. Plastic Welding:
In this case the two pieces of metals to be joined are heated to plastic state and welding is completed by
forcing them. In this case no filler material is added.
II. Fusion Welding:
In this case the two pieces of metal are heated and brought to molten state and filler material is added and
allowed to solidify.
Plastic and fusion welding processes are further classified as follows:

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I. Plastic Welding:
(a) Forge Welding:
It is the oldest method of joining two pieces of metals. In this case heat is created by blacksmith’s fire and
the two pieces of metals to be joined are heated and brought to plastic state. Then they are superimposed
and hammered together to form the joint [3].
(b) Resistance Welding:
In this case a heavy electric current is passed through the pieces of metals to be joined. Then because of
electric resistance, the metals are heated to plastic state and by applying force, welding can be completed.
In this case, no additional filler material is required and the metal pieces are pressed in the two copper
electrodes [4].

(1) Spot Welding:

It is used for welding ferrous and non-ferrous sheets up to a thickness of 8 mm. The sheets to be welded
are held between the fixed and movable electrodes as shown. Then the electrodes are pressed by pressing
the foot lever. When the electrodes are pressed, current flows and the two parts at the pressed points are
brought to plastic state. Then, this plastic metal mixes, solidifies to form the joint.

(2) Projection Welding:

It is the slight modified form of spot welding process. In this case current and pressure are localized at the
welding points by making projections for the upper sheet of metal. The two metal sheets are held in
position between fixed arm and upper movable arm. Then the current is passed and welds at all the points
of projections are obtained due to flattering of projections.
For producing continuous welds between two over lapping sheets this seam welding is used. In this case
the two sheets to be seam welded are held as shown between the electrodes. When the electrode wheels
rotate continuous weld will be produced.

(3) Seam Welding:

Seam welding is the joining of work pieces made of similar or dissimilar materials along a continuous
seam. Seam welding can be broken down into two main techniques, resistance seam welding and friction
seam welding [4].

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(II) Fusion Welding:
(1) Gas Welding:
In gas welding heat energy required to heat the surfaces is obtained by the combustion of mixture of two
gases. Generally oxygen and acetylene are used for gas welding purpose. These gases are mixed in proper
proportions in the welding torch. This welding torch is provided with two regulators to regulate the gases.
The flame produced due to the combustion is used to heat the metal surfaces to plastic state and welding
is completed by adding the filler material [3].

(A) Oxyacetylene Welding:

As the name implies in this case the two gases used are oxygen and acetylene. It is to be noted that oxygen
and acetylene are commercially available in cylinders. If required acetylene can be produced by the
chemical reaction between calcium carbide and water as under-
CaC2 + 2HO → C2 H2 + Ca(OH)2
And the chemical reaction for the combustion of acetylene is,
2C2 H2 + 5O2 → 4CO2 + 2H2 O (Acetylene)
When the combustion takes place, we get the flame at the tip of the torch.

Figure 1. Pressurized cylinder

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(B) Arc Welding:
(I) Metal Arc Welding:
It mainly consists welding rectifier, electrode (or welding rod) holder, welding rod, and work piece.
When the welding rod touches the work piece, an arc is produced and tremendous amount of heat is
liberated. The temperature of the arc is about 3600° C. This heat energy is utilized for melting work piece
and welding rod. So, a small pool of molten metal is formed. This molten metal is agitated by the action
of arc and the metal is perfectly mixed and after cooling it produces a sound joint.

Figure 2. Welding machine

(II) Submerged Arc Welding (SAW):

It is the improved arc welding process, which is used for the production of butt welds of thick steel plates.
In this case the arc produced is submerged (covered) in the flux, hence the name submerged arc welding.
Through the flux hopper, flux is supplied and wire feeder feeds the bare wire continuously.
In this case arc produced is submerged in the flux. Because of heat of arc the wire and parent metals melt
and form a pool of molten metal. Thus molten pool produces a welded joint after cooling.

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 Figure 3. Submerged Arc Welding (SAW)

During SAW welding process the flux coating on the rod disintegrates and then forms a gas that shields
the weld from the atmosphere. The slag that is produced by the flux coating prevents the weld metal
from oxidizing [3].
(III) Gas Tungsten Arc Welding (GTAW):
It is a fast process, produces clean welds and it can weld metals considered to be impossible to weld. TIG-
welding utilizes a non-consumable electrode in a special holder, a separate filler material and an inert gas
i.e., argon gas cylinder, power supply source.
When the tungsten electrode strikes the work piece, an arc will be produced. Around the arc inert gas
shielding is formed as the gas is coming out from the torch. Because of heat of arc, work piece and filler
material melt and form a molten pool. This molten pool after cooling forms a sound welded joint in the
shielding of inert gas [3].

Figure 4. Gas Tungsten Arc Welding (GTAW)

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(IV). Gas Metal Arc Welding (GMAW):
In MIG welding us get clean and good welds also fast filler metal deposition rates. It uses high welding
current which is used to break the globules of molten metal into fine spray.
MIG uses a consumable electrode. It is supplied through an electrode holder into the arc. Then at the same
speed electrode is melted and deposited into the weld. A small motor with adjustable speed will be used
to remove the wire from the reel and fed into the arc.
Generally CO2 or Argon are used as shielding gases. Mainly the process was developed for welding
Aluminum and Titanium. But nowadays it has wide application since it can be used for welding in all the
positions; and less skilled operators are required to operate this set up [5].

Figure 5. Gas Metal Arc Welding (GMAW)

(V) Termite Welding:

In Termite welding process, the parts which are to be welded are placed in the mold as shown then the
superheated Termite steel is poured from the refractory lined crucible as shown. Due to the heat of Termite
steel, the surfaces of metals to be welded are brought to plastic state and if required some mechanical
pressure is applied to complete the weld [4].

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Fabrication ventilation and filter system
Welding Fume Extractors are intended to be used as a safety test for manufacturing to shield
consumers from the industrial hazards posed in different welding applications. Assuming that the vast
majority of reparable particles in the air stream are smaller than 0.4 microns in size filter, a controlled
ventilation system capable of filtering down to that amount is what is needed to ensure the welder's safety
and health. While selecting an appropriate ventilation system, it is necessary to make sure you are aware
of all the factors that may differ the filtration capacity of welding gases. The particular application of
welding is usually the number one variable which helps to decipher what is recommended, but additional
configurations such as HEPA or ASHRAE filters, cleanable media, multi-operators or portability are
dependent on various elements that are best discussed with a trained specialist. Thermal Cutting and
welding processes produces enormous amount of toxic gasses and airborne consists of ozone, Hexavalent
Chromium (CrVI), Nitrogen oxides, Manganese and Carbon Monoxide. The welding technique such as
Scarfing, MIG, TIG, GMAW, GTAW, Oxyacetylene Torch Cutting, SMAW, and Gas Tungsten Arc
Welding are widely used by Construction and automotive Industries.
.
1.2 PROBLEM OF STATEMENT
All forms of welding produce visible smoke that contains harmful metal fume and gas byproducts.
Welding fumes contain a variety of metals, including aluminum, arsenic, beryllium, lead and manganese.
Argon, nitrogen, carbon dioxide, carbon monoxide and hydrogen fluoride gases often are produced during
welding. This causes the increasing level of health such eye and lung cancer accident and injuries among
welding user at the job site. All of that effect can be painful and can incapacitate a person, or lead
permanent disability or death. In addition the welding smoke affect the temperature of the working area
becomes hot. As a result it creates uncomfortable working conditions during the working time. So in our
project we try to prevent this welding smoke by designing portable welding fume extractor to control and
prevent workers health from hazards toxic exhaust gas by suck the welding smoke through the duct with
the help of centrifugal blower and motor.

Welding fumes can cause serious health problems for workers if inhaled

Short-term exposure can result in:

 nausea, (maklshelsh)
 dizziness, (mefzezi)

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  Eye, nose and throat irritation.

Long -exposure to welding fumes can lead to:

 Cancer of the lung,

 Larynx and urinary tract,
 Nervous system damage and
 Kidney damage.

Figure 6. Welding fume and problems of our respiratory system

1.3 OBJECTIVE OF THE PROJECT

1.3.1 GENERAL OBJECTIVE

 The general objective of the project is to design portable welding fume extractors for better health
and comfortable working condition.

1.3.2 SPECIFIC OBJECTIVE

 Literature survey.
 Conceptual design.
 Part design

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  To analysis of cost effectiveness of design
 To draw the part and assembly drawing of welding fume extractor.
 To reduce the emission of toxic gases to the environment and control the pollution rate of
emission

1.4 METHODOLOGY
Methodology is the systematic, theoretical analysis of the methods applied to design project. It comprises
the theoretical analysis of the body of methods and principles associated with a branch of knowledge.

Figure 7. General Methodological analysis

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 Introduction

Observation about fume extractor data

Literature review

Selection of material
element

Design of machine
part

Examine the
results

Conclusion

Figure 8 .specific methodology

REQUIREMENT
Skill; (I) Arc welding skill.
 (II) CAD skill (SolidWorks).
 (IV) Basic electrical knowledge
1.5 SCOPE OF THE PROJECT
The scope of this t is designing of portable and cost effective welding fume extractor. During
working conditions very toxic gases are exhaust in to the surroundings of the working place, such as
Argon, nitrogen, carbon dioxide, carbon monoxide and hydrogen fluoride gases often are produced during
welding. This causes the increasing level of accident and injuries among welding user at the job site. So
this projects helps to avoid the inhalation of the fumes in the practice lab. Also it helps to reduce the
emission of toxic gases to the environment and control the pollution rate of emission.

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The scope of this study is to the design and fabrication of a portable fume extractor machine that can
extract fumes generated during welding processes in anywhere. In the cause of carrying out this study, the
following design considerations were given due attention; the machine should be efficient during use in
the hot shop as well as easily movable (portability), safety and ease of operation. In addition, the cost of
construction was also considered

1.6 LIMITATION
We designed this project by according our fasil campus mechanical workshop. This can be prevent
only system that remove welding Fume from the breathing zone of welder. And also this extractor machine
limited for one hose system due to its power uses and number of hose. If we want two expand work we
need to use more than 3 kilo watt power ac motor and double hose the extraction of welding fumes from
the surrounding air not only ensures clean air at the Workplace, but also leads to greater employee
satisfaction. In this work, fume extractor is designed to capture the unwanted gases at the point of
production. The main objective our project is to keep the welder's breathing area as clean as possible.
Welding smoke consists of gases and fine particles.

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 CHAPTER - TWO

2. LITERATURE REVIEW

P.o. babalola and M.Oriyomi (2018): The system was designed using American Society of
Heating, Refrigerating and Air-conditioning Engineers (ASHRAE) standard among others. The booth
volume, hood size, hood location, duct size and fan size were designed, selected and fabricated. The
designed static pressure of the system is 164.412 Pa and the design volumetric flow is 6.126 m³/min. The
ventilation system was tested by using thermos anemometer, thermometer and a measuring tape.
Volumetric flow test on the flexible duct shows that at 150 mm extension, maximum air flow of 4.217
m³/min is achievable with this system while at full extension, 5.376 m³/min is achievable. Results, shows
that welding at 0 mm to 100 mm from the hood extract smoke from the source whilst between 200 mm to
400 mm distance from the hood were significant lagged in extracting the smoke but at 500 mm, smoke
reaches the welder’s breathing zone.

Welding processes produce fumes which are known to be dangerous to human health. In order for welders
to work in a safe environment, a means of removing these fumes from the welding environment must be
provided during the welding process. This is the purpose for which this paper has been developed. Fume
extractors are generally known to be fixed to the walls of factories and places where fumes need to be
extracted from. With the increase in welding needs outside the workshop environment, the need to have
mobile fume extractors has become imperative. This need has been addressed in this paper. Materials for
design and fabrication of the fume extractor were selected based on cost, safety, functionality, ease of
availability and affordable maintainability. The fabricated fume extractor was tested on several welding
sites and found to be very effective in extracting fumes from welders breathing zone. It was also observed
that the function of the extractor did not adversely affect the welding process .

Meeker et al. (2007): conducted both experimental and field evaluations of a commercially available
portable LEV unit (Mini flex Portable High Vacuum Fume Extraction Unit, Lincoln Electric, and
Cleveland, OH, USA). The unit was equipped with a small bell-shaped hood and was operated at
approximately 103–110 cfm (0.049–0.050 m3 s−1). The unit had a rated filter efficiency of 99.97%. The
experimental testing was done in a semi-enclosed booth at a local training center of the Plumbers and
Pipefitters union. Small sections of 6-inch (15.2 cm) diameter carbon steel pipe were welded (SMAW)
using E6010 and E7018 electrodes. Each run was 50–60 min in duration and consisted of two welds; arc

- 15 -
times were on the order of 30 min. five randomized trials were done for each condition of LEV and no
LEV; a single welder performed all tasks. The experimental results showed statistically significant
reductions (P = 0.002) in mean Mn exposures on the order of 75% (0.051 versus 0.013 mg m−3). TP
reductions were about 60% (1.83 versus 0.74 mg m−3, P = 0.002). The experiment demonstrated the
efficacy of the LEV for reducing fume exposures.

Susi et al. (2000): reported on personal exposure measurements of metal fumes to boilermakers, iron
workers, and pipe fitters during welding and thermal cutting from 1995 to 1996. In 1996, two different
local exhaust systems were used: ‘one was a small portable unit with flexible duct for both capturing and
exhausting contaminant’ and it was not equipped with filtration. The second larger unit was equipped with
a High-Efficiency Particulate Air (HEPA) filter, and the hood was attached to a movable elbow joint. The
mean TP exposure when local exhaust was used was 1.99 mg m−3 (n = 6); for natural ventilation, the result
was 5.39 mg m−3 (n = 56); for no ventilation, 9.45 mg m−3 (n = 1); and for mechanical ventilation, 1.72
mg m−3 (n = 16). Here ‘mechanical ventilation’ refers to fans and blowers used to mix the air or dilute the
concentration as opposed to LEV where an exhaust hood is located proximal to the source to remove the
fumes prior to entry into the breathing zone. The authors compared the combined mechanical and LEV
results with the combined natural and no ventilation data and found a statistically significant difference
(P = 0.0001).

Dryson EW, Rogers DA (1991), sixteen welders, welding under typical New Zealand conditions, had
ambient air within their welding helmets sampled and analyzed for ozone, nitrogen oxides, fluoride,
carbon monoxide, aluminum, chromium, iron, nickel, zinc and total dust. Post shift urinary metals were
also analyzed, and a respiratory questionnaire completed for each welder. Levels above the New Zealand
Workplace Exposure Standard (WES) were found for nitrogen dioxide in four welders (two TIG, one
MMA and one plasma cutter), and for total chromium in one plasma cutter, who also had a nickel level of
24% of the WES. Dust levels were highest in the plasma cutters, with one reaching 8.67 mg/m3 (WES =
5 mg/m3). Urinary levels however did not indicate excessive short or long term uptake. Where efficient
fume extraction was in use, levels of air contaminants were lower than with natural ventilation.
Respiratory symptoms were reported by 67% of welders, 38% meeting criteria for chronic bronchitis
(relative risk = 2.0). Smoking welders reported more symptoms than nonsmoking welders.

- 16 -
Fume Exhaust gadget is utilized to catch perilous synthetic vapors, gases, cleans, fogs and metal exhaust
in a work procedure. These frameworks help wipe out or bring down human presentation to dangerous
vapor. The exhaust and metallic gases are transmitted from the work piece, which make the contamination
and danger a specialist, when gases were breathed in or ingested. This will cause respiratory impacts, for
example, lung work changes, bronchitis and conceivable of lung growth. A major security and modern
cleanliness guideline is to control introduction to dangers with designing and regulatory controls
previously actualizing individual defensive gear. The present work manages the planning and
Development of smoke deplete Device with carbon and furthermore check the execution, for e xa mple,
productivity of the framework, filtrate ion limit, and natural agreeable, amid the welding procedure. The
framework outlined basic and less financially savvy which can be helpful for Micro, Small and Med ium
Enterprises.

Els, L, Coetzee, C., and Vorster, O. 2017, Latest Mn and psychiatric disease issues reinvigorated
attempts to regulate lower rates of welding gases. The primary engineering regulation for external hoods
equipped to regulate welding fume is Local Exhaust Ventilation, and design standards are in place, which
work minimum velocities within the range of 0.50 to 0.87ms-1 i.e (100 to 170 fpm).

[Dokka et al., 2003]. (Historically, natural ventilation has been used in various forms to ventilate
buildings, but over the last 50 years, mechanical ventilation has been the most commonly used principle
due to increased air tightness of buildings to reduce heat losses. These changes will lead to higher initial
costs, but since ventilation systems remain in service for 30 years, the lower operational costs for energy
will outweigh the higher installation and purchase costs.

[Jacobs at el (2008)] In measurements were carried out in a test facility resembling a small classroom,
but the measurements included no quantifiable measurements of air temperature and velocity or
ventilation efficiency. Also report experiences and measurements from a pilot study where a diffuse
ceiling inlet was installed in a school classroom were also reported. The measurements however only
included the CO2- concentration and a questionnaire to the occupants about perceived air quality, but did
not investigate how the improved air quality and comfort affected the pupil‘s ability to perform school
tasks. Previous studies on air quality effect on the occupants has mostly focused on adults performing
office work, and most studies have been carried out in laboratories where the subjects knew they were not
performing real office work only realistic examples of it. It is well established that adult‘s performance
can be improved up to 5 % by maintaining the CO2-concentration below 1000 ppm.

- 17 -
Research Gap.

Previous time society not use fume extraction system and machine was not discovered before 1997
E.C But they knows about ventilation system and their uses. so at that time Most of literature consider
first efficiency of air gating for source of air or sucking air by machine gradually fume extractor system
developed .at this time there is extractor system but not develop just like application and human needs the
only problem is such consideration development technique however Our design considers such different
consideration selected based on cost, safety, functionality, ease of availability and affordable
maintainability than previous works, cost effectiveness, less material uses for high sucking rate, shape,
position of machine, filtration system, clearance and portability this are our project development or
assumption.

- 18 -
 CHAPTER - THREE

3. DETAIL DESIGN OF COMPONENT

Table 2. Conceptual design

Part Material Investigation

Duct Vulcanized rubber /PVC Circular shape remark flexible,

movable(mobile), less cost than other
Magnetic sucking Vulcanizes rubber Remark rectangular type hood position
hood 30º from exhaust fume, stationary due
to magnetic supporter and fixed than
other hood type
Frame Mild steel Remark mild steel (2mm or
1mm)thinness for frame due to strength
and less cost and it can be formable to
any shape than other types of metal
Centrifugal Remark sustained driver and driven
blower fan and ------------- motor and blower fan selection due to
motor amount of speed sucking air application
area,
Filter paper Wood pulp(cartridge filter )and Square shape Selecting filter mostly
clothe filter used for very fine particle at high
pressure and they have different spot
size, less price classification so very
selective that other.
Rivet pin Stainless steel It has high impact and fatigue strength,
and fixed semi permanently, with low
handling access.
Front and rear Rubber Small size Circular wheel type To get
Castor wheel flexibility and movability from one
place to another and less price.
Hand lever Mild steel Round shape for caring or pushing
easily machine.
Motor supporter Mild steel Rectangular shape type used for caring
box motor to adjust central parts of fan. Less
price easy to work.
Exhaust volute Low mild steel Circular and rectangular shape for
case transferring exhaust air to front filter.
Less price easy to work.

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 Figure 9. Conceptual design

3.1 SPECIFICATION OF THE PROJECT

Based on ace industrial product manual we can take some necessary specifications [10].

Table 3. Specification of the project

No Name Specification

1 Fume extraction machine type portable and mobile unit

2 Exhaust blower 1HP,3500rpm

3 Sucking duct / Vulcanized rubber of 3m length

4 Filter cloth 40 micron m, with spot holes

5 Cartridge filter 5 micron the spot hole size and 2micro

6 welding type and method Arc welding and gas metal arc welding (MIG)

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 7 electrode type for arc welding 3.2diameter, 10 gauge

8 Test plate (base metal) Mild steel

9 fume extraction hood Positioned at an angle of 450 with magnetic setup

10 operating temperature T= 400 𝐶- 45℃

11 Duct velocities ≤ 2500 fpm

3.1.1 Material selection 1

The various materials selected and reasons for their selection [10]
Table 4. Summary of material selection and its properties

S/N Machine Criteria for Selection Material Selected Reasons for Selection
Component
1 Frame Formability and Weld ability Mild steel Low cost, good
formability,
weld ability and readily
Available.
2 Pan Weld ability, durability and Mild steel Low cost, readily
Formability available and can be
easily welded.
3 Hose Flexibility and durability Vulcanized Easy movement from one
rubber/ point to another without
stress.

4 Air Filter Low cost and easy Paper-based Ability to trap large
maintenance amounts of
Fumes from the welding
zone.

5 Centrifugal High Static pressure and Radial bladed Ability to handle heavily
Blower suitability centrifugal blower Contaminated airstreams.
for high temperature

- 21 -
 6 Air duct Flexibility and durability PVC/Vulcanized Effective and easy
rubber passage of fumes.
7 Storage tank Strength, low cost and weld Mild steel Ability to be rolled and
ability welded
8 Electric Ability to overcome shear 1hp electric motor Regulates, speed, and
motor stress, durability, regulates generates torque.
speed and torque
9 Rivet pins High fatigue and impact Stainless steel Readily available
strength

10 Paint Corrosion resistance and Corrosion For good aesthetics,

good texture resistant paint Preservative ability.

3.2 DESIGN FRAME

Mild steel: is a type of carbon steel with a low amount of carbon – it is actually also known as “low
carbon steel.” Although ranges vary depending on the source, the amount of carbon typically found in
mild steel is 0.05% to 0.25% by weight, whereas higher carbon steels are typically described as having a
carbon content from 0.30% to 2.0%. If any more carbon than that is added, the steel would be classified
as cast iron [11].

Most important mild steel properties

 The modulus of elasticity calculated for the industry grade mild steel is 210,000 MPa. It has an
average density of about 7860 kg/m3.
 Mild steel is a great conductor of electricity. So it can be used easily in the welding process.
 Because of its malleability, mild steel can be used for constructing pipelines and other construction
materials. Even domestic cook wares are made of mild steel. It is ductile and not brittle but hard.
 Mild steel can be easily magnetized because of its ferromagnetic properties. So electrical devices
can be made of mild steel.
 Mild steel is very much suitable as structural steel. Different automobile manufacturers also use
mild steel for making the body and parts of the vehicle.
 Mild steel can be easily machined in the lathe, shaper, drilling or milling machine. Its hardness
can be increased by the application of carbon. [11]

- 22 -
 So we take assumption dimension by considering operation room and space uses to become easily
portable.

Where: L=Length of machine W=Width of machine H= Height of machine where,

L=1.20m W=0.8m H=1.0m

Volume of the machine is calculated by

𝐿∗𝐻∗𝑊 =𝑉 =1.20𝑚 ∗ 0.8𝑚 ∗ 0.85𝑚

𝑽𝒐𝒍𝒖𝒎𝒆 = 𝟎. 𝟖𝟏𝟔𝒎𝟑

Figure 10. Solid work Frame

3.3 SELECTION OF FILTER PAPER

Filter paper is a semi-permeable paper barrier placed perpendicular to a liquid or air flow. It is used to

separate fine substances from liquids or air. It is used in science labs to remove solids from liquids. This

can be used to remove sand from water.

Properties of filter paper

Filter paper has various properties. The important parameters are wet strength, porosity, particle retention,
volumetric flow rate, compatibility, efficiency and capacity.

- 23 -
Types
 Air filters

The main application for air filters are combustion air to engines. The filter papers are transformed into
filter cartridges, which then is fitted to a holder. The construction of the cartridges mostly requires that
the paper is stiff enough to be self-supporting. A paper for air filters needs to be very porous and have a
weight of 100 - 200 g/m2. Normally particularly long fibrous pulp that is mercerized is used to get these
properties. The paper is normally impregnated to improve the resistance to moisture. Some heavy duty
qualities are made to be rinsed and thereby extend the life of the filter [7].

Figure 11. Air filter

 Coffee filter:

Coffee filters of paper are made from about 100 g/m2 crepe paper. The creping allows the coffee to flow
freely between the filter and the filtration funnel. The raw materials (pulp) for the filter paper are coarse
long fiber, often from fast growing trees. Both bleached and unbleached qualities are made. Coffee filters
are made in different shapes and sizes to fit into different holders. Important parameters are strength,
compatibility, efficiency and capacity. Fuel filters: The paper used for fuel filters is a crepe paper with
controlled porosity, which is pleated and wound to cartridges. The raw material for filter paper used in
fuel filters are made of a mixture of hardwood and softwood fibers. The basis weight of the paper is 50 -
80 g/m2 [1].

 Laboratory filter

A scan of Whitman Filter Paper 4 Qualitative taken at 840 magnifications under a scanning electron
microscope.

- 24 -
 Filter papers are widely used in laboratory experiments across many different fields, from biology to
chemistry. The type of filter used will differ according to the purpose of the procedure and the chemicals
involved. Generally, filter papers are used with laboratory techniques such as gravity or vacuum filtration
n [8].

Figure 12. Laboratory filter

 Qualitative filter paper

Qualitative filter paper is used in qualitative analytical techniques to determine materials. There are
different grades of qualitative filter paper according to different pore size. There are total 13 different
grades of qualitative filter paper. The largest pore size is grade 4; the smallest pore size is grade 602 h;
the most commonly used grades are grade 1 to grade 4 [9].

Grade 1

Grade 1 qualitative filter paper has the pore size of 11 μm. This grade of filter paper is widely used for
many different fields in agricultural analysis, air pollution monitoring and other similar experiments [9].

Grade 2

Grade 2 qualitative filter paper has the pore size of 8 μm. This grade of filter paper requires more filtration
time than Grade 1 filter paper. This filter paper is used for monitoring specific contaminants in the
atmosphere and soil testing [9].

Grade 3

Grade 3 qualitative filter paper has the pore size of 6 μm. This grade of filter paper is very suitable for
carrying samples after filtration [9].

- 25 -
 Grade 4

Grade 4 qualitative filter paper has the pore size of 20~25 μm. This grade of filter paper has the largest
pore size among all standard qualitative filter papers. It is very useful as rapid filter for cleanup of
geological fluids or organic extracts during experiment [9].

Grade 602 h

Grade 602 h qualitative filter paper has the pore size of 2 μm. This grade of filter paper has the smallest
pore size among all standard qualitative filter papers. It is used for collecting or removing fine particles
[9].

 Quantitative Filter Paper

Quantitative filter paper, also called ash-free filter paper, is used for quantitative and gravimetric analysis.
During the manufacturing, producers use acid to make the paper ash-less and achieve high purity [4].

 Chromatography Papers

Chromatography is a method chemists use to separate compounds. This type of filter paper has specific
water flow rate and absorption speed to maximize the result of paper chromatography. The absorption
speed of this type of filter paper is from 6 cm to 18 cm and the thickness is from 0.17 mm from 0.93 mm
[8].

Figure 13. Filter paper uses for paper chromatography

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 Extraction Thimbles
Extraction thimbles are rod-shape filter paper often used in extractors or atomized extractors. It is ideal
for very sensitive detection, the performance it depends on the thickness of inner diameter. Also, it is
usually used in areas of food control and environmental monitoring [4].

 Glass Fiber Filters

Glass fiber filter has the pore size of 1 μm, it is useful for filtering highly contaminated solutions or
difficult-to-filter solution. Also, glass fiber filter has extends filter life, wide range of particulate loads and
can prevent sample contamination. In addition, different types of glass fiber filter are suitable for different
filtration situation. There are 7 different types of glass fiber filters and the major difference is thickness
[10].

Quartz Fiber Filter

Quartz fiber filter paper has a high resistance to chemicals, does not absorb NOx and SOx dioxides, is
unaffected by humidity and is easily sterilized. Thus, it is mostly used for air pollution analysis [4].

 PTFE filter

Polytetrafluoroethylene (PTFE) filter has wide operating temperature (-120 °C~260 °C) with high air
permeability. The resistance to high temperature makes PTFE filter paper suitable for use in autoclaves.
It is often used to filter hot oils, strong solvents and collecting airborne particulates [4].

 Oil filters
Oil filter cut-away with paper visible inside Engine oil is filtered to remove impurities. Filtration of oil is
normally done with volume filtration. Filter papers for lubrication oils are impregnated to resist high
temperatures [7].

- 27 -
 Figure 14. Oil filter

Our design Selection 1: we used three filter paper on this design first two martial-wood pulp filter paper
with (5 and 2) micro meter spot whole size and the third content 40 micro meter spot hole size and air
filter model BS022 with (500 ∗ 500)𝑚𝑚 size both .each weight (100 − 200)𝑔/𝑚^2.so total weight
summation is 50𝑔/𝑚^2* 3 =150 𝑔/𝑚^2 for those three filter type.

Figure 15 . Solid work air filter

3.4 DESIGN OF DUCT

Duct Materials

Ducting is generally formed by folding sheet metal into the desired shape. Traditionally, air conditioning
duct work is made of galvanized steel, next in popularity is aluminum. Other metals used under special

- 28 -
circumstances are copper and stainless steel. That are used extensively depend on the application of the
duct and are listed below [11].

Metals:

Galvanized Steel: It is a standard, most common material used in fabricating duct work for most
comfort air conditioning systems.
Aluminum: It is widely used in clean room applications. These are also preferred systems for moisture
laden air, special exhaust systems and ornamental duct systems.
Stainless Steel: It is used in duct systems for kitchen exhaust, moisture laden air, and fume exhaust.
Carbon Steel (Black Iron): It is widely used in applications involving flues, stacks, hoods, other high
temperature and special coating requirements for industrial use.
Copper: It is mainly used for certain chemical exhaust and ornamental duct work.

Nonmetal:
Fiberglass Reinforced Plastic (FRP); It is used mainly for chemical exhaust, scrubbers, and
underground duct systems.
Vulcanized rubber (VR) is used for chemical exhaust medium Flexible, between pitches, on
blocking, stiffness, light weight, reputable bending, good abrasion resistance, high temperature
(thermal) resistance, Soft and smooth, easy to thread and install and locate, prevent internal wires from
abrasion.
Polyvinyl Chloride (PVC): it is used for exhaust systems for chemical fumes and underground
duct systems. Advantages include resistance to corrosion, light weight, and ease of modification.
Limiting characteristics include cost, fabrication, code acceptance, thermal shock, and weight.
Fabric: Fabric ducting, also known as textile ducts, is usually made of special permeable polyester
material and is normally used where even air distribution is essential. Due to the nature or the air
distribution, textile ducts are not usually concealed within false ceilings. Condensation is not a
concern with fabric ducts and therefore these can be used where air is to be supplied below the
dew point without insulation.
Flex Duct: Flex ducts consist of a duct inner liner supported on the inside by a helix wire coil and
covered by blanket insulation with a flexible vapor barrier jacket on the outside.

- 29 -
DUCT CLASSIFICATION
Ducts are classified in terms of velocity and pressure [11].

 Velocity Classification

Ducts are classified into 3 basic categories:

1. Low Velocity Systems: They are characterized by air velocities up to 2000 fpm.

2. Medium Velocity Systems: They are characterized by air velocities in the range of 2,000 to 2,500 fpm.

3. High Velocity Systems: They are characterized by air velocities greater than 2,500 fpm.

 Pressure Classification

Duct systems are also divided into three pressure classifications, matching the way supply fans are
classified.

1. Pressure: The term low-pressure applies to systems with fan static pressures less than 3 inches WC.
Generally, duct velocities are less than 1,500 fpm.

2. Medium Pressure: The term medium pressure applies to systems with fan static pressures between 3
to 6 inches WC. Generally, duct velocities are less than or equal to 2,500 fpm.

3. High Pressure: The term high pressure applies to systems with fan static pressures between 6 to 10
inches WC. Usually the static pressure is limited to a maximum of 7 inches WC, and duct velocities are
limited to 4,000 fpm. Systems requiring pressures more than 7 inches WC are normally unwarranted and
could result in very high operating costs [11].

Velocity Classification vs. Pressure Classification

1. Duct pressure classification influences the duct strength, deflection and air leakage.

2. Duct velocity classification influences noise, vibration, friction losses and fan power.

Advantages of round ductwork include:

• Round shape results in lower pressure drops, thereby requiring less fan horsepower to move the air and,
consequently, smaller equipment.

- 30 -
• Round shape also has less surface area and requires less insulation when externally wrapped.

• Round ducts are available in longer lengths than rectangular ducts, thereby eliminating costly field joints
[11].

So the following design of duct sizing is based on the American Society of Heating, Refrigeration and
Air-condition Engineers/ASHRAE/ 2005 duct design and HVAC - How to Size and Design Ducts text
book. By considering the machines occupied area (frame) with specified height of the machine, the
estimated volume is calculated as in the following.

Standard Duct Sizes

Standard air conditioner moves 400 cfm of air per ton. One ton of refrigeration equates to the heat
extraction rate of 12,000 Btu’s per hour. British thermal unit (Btu) is the measurement of heat. It takes
one Btu to raise the temperature of water to one degree Fahrenheit. A 6-inch duct and an 8-inch (0.15-0.2
m) duct carry about 100 cfm and 200 cfm (cubic feet per meter) of cool air respectively. Here are some
sizes for the supply duct that can be used [11].

Table 5. Standard air flow characteristics w.r.t duct size

Air flow Duct diameter Duct size 1 Duct size 2 Tonnage

100 cfm 6” round 5”×6” 4”×8”

200 cfm 8” round 6”× 8” 4”×12” ½ ton

300 cfm 9” round 10”×7” 5”×14” ¾ ton

400 cfm 10” round 8”×10” 6”×14” 1 ton

600 cfm 12” round 10”×12” 8”×14” 1 ½ ton

800 cfm 13” round 10”×14” 8”×18” 2 ton

1000 cfm 14” round 10”×16” 12”×14” 2 ½ ton

1200 cfm 16” round 10”×20” 12”×16” 3 ton

1400 cfm 16” round 12”×18” 10”×20” 3 ½ ton

- 31 -
Table 6. Application verses velocity table[11].

Comfort Systems Industrial Systems High Speed Systems

Velocity (fpm) Velocity (fpm) Velocity (fpm)

Main duct 1000 - 1500 1500 - 2400 2000 - 3600

Main branch duct 700 - 1000 1000 - 1600 1200 - 2400
Runout duct 400 - 600 600 - 800 800 - 1000
The flow rate of air that is sucked by the centrifugal fan from working benches

 We select velocity of speed of air = 2000 fpm from above description. =10.16m/s so that means low
velocity and pressure duct system. Also select
 Volume of air flow from above table v=1000cfm=0.4719m3/s and duct diameter Dc=14inch=
0.3056 m. area A=𝐴 = 𝜋𝑑 2) /4 =𝟎. 𝟎𝟗𝟗𝟑𝒎𝟐=153.86in^2

Flow rate of air (Q) =velocity of speed of air flow*area

𝑄 = 𝐴𝑉. 0.0993𝑚2 ∗ 10.16𝑚/𝑠= 260(According to the above data)

𝑸 = 𝟏. 𝟎𝟎𝟖𝟖𝒎𝟑 /𝒔. = 60.54m^3/min=2137.8cft/m

Let s change the unit into liter per second (l/s);

1m3 =1000 liter and 1hr=3600seconds Thus, m3 /hr.=1000liters/ 3600seconds

1m3 */hr.=0.2778 l/s=

Therefore, the equivalent flow rate in l/s;

1.0084∗1000 𝟖𝒍
𝑄= 𝑸 = 𝟏𝟔. 𝒎 = Is the total amount of flow rate 590l/s sucked by the fan?
60

5hr working =300m*16.71l/m= 5013 l/m sucked per day

Having in mind this air flow rate, using ASHRAE friction chart for round duct

(Density of air =1.2 kg/m3 *, and friction factor e= 0.09mm) with respect to feet

10gauge= 68.95kpas, =1psi rea

- 32 -
Table 7.Thickness of aluminum and steel for duct[11].

Rectangular Duct Round Duct

Greater G. Steel Al (gauge) Diameter G. Steel Al (gauge)
Dimension (gauge) (gauge)
Up to 30 24 22 Up to 8 24 22
inch inch
31 – 60 22 20 9 – 24 22 20
inches inches
61 – 90 20 18 25 – 48 20 18
inches inches
> 91 18 16 49 – 72 18 16
inches inches

24 gauge = 1.156 lbs./sq.-ft. 22 gauge = 1.406 lbs./sq.-ft.

20 gauge = 1.656 lbs./sq.-ft. 18 gauge = 2.156 lbs./sq.-ft.

Cost of galvanized steel = $16 per lb.

PRESSURE LOSSES IN AIR DISTRIBUTION SYSTEM

The system resistance in duct work has three components:
1. Friction loss (resistance to air flow caused by duct size, roughness of duct walls, and air velocity).

2. Dynamic loss (resistance to air flow caused by changes in air velocity and direction).

3. Equipment pressure loss (resistance to air flow caused by components such as diffuser, coils, and
filters).
1. Duct Friction Losses
Any type of duct system offers frictional resistance to the movement of air. Resistance to air flow produces
certain friction losses that vary with:
a. Velocity of air

b. Size of duct (smaller diameter duct has more friction)

c. Roughness of the material

d. Length of the duct

- 33 -
  =0.09(12 ∗ 3)/0.3048(1.2)(10.16/1097)^2 =0.121pas
 By length 3m* 1pa/m= 3pas loss
 Number of elbow = number *0.121= 3*0.121= 0.363pas
2. Duct Fitting Dynamic Losses
Dynamic losses in duct systems are pressure losses caused by:
• The change in air direction from elbows, offsets, and take-offs.

• Restrictions or obstructions in the air stream such as dampers, filters, and coils.

• Changes in air velocity because of changes in duct size.

k= 0.5 from round duct manual table as Air-condition Engineers/ASHRAE/ 2005 duct design cause of
bending angle 45 degree if it is 90 k= 1

10.16 2
 =0.5 ( 4005 ) =0.003pas

 Total pressure drop=0.0032+0.363+3+0.121=3.48pas

3. Equipment pressure loss: equipment loss due to filter may exist or may not because of position
of filter. It setup at the end of blower so back filter doesn’t affect this much. But ideally front big
whole filter gate dose affect pressure loss up to 0.005pas

- 34 -
 Figure 16 .Solid work Duct

3.5 DESIGN OF CENTRIFUGAL BLOWER

A large number of blowers for high pressure applications are the centrifugal type. It consists of an impeller
which has fixed between the inner and outer diameters the functions of blower are to increase the pressure
of the air, to provide conditions favorable for combustion and expansion of the hot gases through the
engine.
Centrifugal blowers are fundamentally high speed machines. The recent advances in steam turbine,
electric motor, and high speed gearing design have greatly increased in their usage and application. A
centrifugal pump or blower consists essential of one or more impellers equipped with vanes, mounted on
a rotating shaft and enclosed by a casing.
All rotating dynamic machines have a rotating part called the impeller, through which the fluid flow is
continuous [12].
3.5.1 DIFFERENT TYPE OF BLOWER
Centrifugal blower may be classified into three basic types according to blade configuration:
1. Forward curve
2. Backward inclined

- 35 -
3. Radial or straight blade
Each type has its own application range and limits. Modifications of these basic types include radial tip,
mixed flow, and tangential flow [12].

Figure 17. Types of blower curve

Radial Blade Blower

Steel plate and paddle wheel are two of the common names for radial blade fans. The impeller blades are
generally narrower, deeper and heavier than forward curve and backward inclined blades. A radial blade
impeller usually comprises six to twelve equally spaced flat blades extending radially from the center of
the hub.

Table 8. Differences pressure ratio between fans and blowers

Equipment Pressure Ratio Pressure rise (mm H2O)

Fans Up to 1.1 1136
Blowers 1.1 to 1.2 1136-2066

Design Specification of Radial Type Centrifugal Blower

This research work is based on an industrial requirement for university of Gondar fasil campus (uog) fasil
workshop, aero vent. Radial blades have lower unit blade stress for a given diameter and rotational speed
hence lighter in weight. There is equal energy conversion in impeller and diffuser so it gives high-pressure
ratio with good efficiency. Looking to these realization and facts radial blade fan is selected for this study.
The input parameters for the design of radial tipped centrifugal blower are as following,
Or for selection of centrifugal fan motor from MBD serious selection manual [13].or from ASP centrifugal
manual [14].

- 36 -
Gauge pressure + atmospheric pressure = absolute pressure
For example, if the gauge reads 10 psig then, using the above equation, the absolute pressure would be
24. 7 psia: gravitational acceleration, g=9.81 m/s2, air constant, R=287 J/kg K
10 psig + 14.7 psi = 24.7 psia
 Flow Discharge Q = 2137.8 ft3/min=1.0084m^3/S
 Static Suction Pressure (pa)= 14.7 psi (absolute)
 Static Delivery Pressure (pg)= 1psi (gauge)
 Static Pressure Gradient ΔPs = 1000 Pa
 Speed of impeller rotation N = 3500 rpm
 Air Density = 1.2 kg/m3
 Outlet Blade Angle β2 = 90°
 Suction Temperature Ts= 60°F= (60 + 460)=520°R
 Atmospheric Pressure Patm (pi)=101352.9pas =14.7psi
 In (operate) Atmospheric Temperature Tatm = 40°C = 313° K [8]
These parameters are kept identical for each design methodology prescribed here in.
This design procedure is based on the fundamental principles of fluid flow with continuity and energy
equations. To accelerate the flow at impeller inlet, converging section is designed after inlet duct. Energy
balance is established at fan inlet, intermediate stage of impeller and outlet stage of volute/scroll casing.
During this process stage velocity, pressure and discharge at different stages are calculated. Flat front and
back shrouds are selected for ease of impeller fabrication. Design procedure and calculations for above
referred input parameters are presented below:

1. Overall pressure ratio

: 𝜀𝑝 = 𝑝𝑎+𝑝𝑔 = 1.1
𝑝𝑎

2. Total adiabatic head

1 𝑅𝑇𝑖 1 287∗313
Total adiabatic head: 𝐻𝑎𝑑 =𝑔 × 0.287 ( 𝜀𝑝0.287 − 1) =9.81 × 0.287 ( 1.10.287 − 1) =885.4ft=269.35m

3. Specific weight of air

Where, 𝜌𝑖 is design of air and it is expressed by; 𝜌𝑖= 𝑃𝑖 𝜌𝑖=101352.9 0.09628

𝑅𝑇𝑖 287∗313

- 37 -
 𝑄𝜌𝑖
Weight flow of gas is; 𝑤 = = (2137.8*0.09628)/60=3.43ib/se
60

𝑤𝐻𝑎𝑑
4 .Adiabatic horsepower is determined by, 𝑎. ℎ𝑝 = = ℎ𝑝 =〖3.43*885.4〗/746= 4hp
746

II. IMPELLER INLET DIMENSIONS AND VANE ANGLE

The velocity in the pipes for the design condition is usually between 60 and100 ft/sec constant; whereas
the velocity at the flanges generally lies in the range from 100 to 200 ft/sec.

Therefore, the velocity through the impeller eye is assumed as 𝑉𝑜 =100 ft/sec velocity head; and then,
the

0 𝑉2
1. Velocity head of impeller eye is; 𝐻𝑂 = 2𝑔 = 𝐻𝑂 =(〖100〗_^2)/ (2*9.81) =155.3ft=47.35m

2. Pressure ratio between impeller inlet and impeller eye

0.287×𝐻 0.287×155.3
𝜀𝑝0.287 − 1 = = 𝜀𝑝0.287 − 1 = =0.00489
𝑅𝑇𝑖 287∗313𝑖

𝑝𝑎
3. Pressure at impeller eye is: 𝑃𝑜 = 𝜀 =14.7/1.001 = 14.7𝑝𝑠𝑖
𝑝𝑖

𝑖 𝑇
4. Temperature at impeller eye is: 𝑇𝑜 = 𝜀0.283 =520/1.378 = 519.8𝑅
𝑝𝑖

5. The specific weight of the air in the impeller eye

𝑃
6. The density of the impeller eye is: 𝜌0 =𝑅𝑇0 = 14.7/287 ∗ 519.8 = 0.67𝑝𝑎𝑠 = 0.0972𝑝𝑠𝑖
0

𝑊
7. Volume flow through impeller eye: 𝑄0 = =3.43/0.0972 = 𝑚3/𝑠.= 35.288cft/s
𝜌0

8. Air horse power: hp=4hp ɳoverall = 70%

9. Brake horse power: ɳoverall/ h p =70/4 = 18ℎ𝑝
6300×𝑏.ℎ𝑝
10. Torque T = the torsional moment can be estimated by, 𝑇 = = (6300 ∗ 18)/ (3500)= 32.4
𝑛

Ib/in
From kurmi material selection allowable shear stress steel =Ss= 300psi

- 38 -
 3 16𝑇 3 16∗180
11. The shaft diameter at the hub section: 𝐷𝑠 = √ 𝜋𝑆 =√3.14∗300 = 1.45in= standards= 1.5in=0.0381m
𝑠

standardized =40mm (table A-26 shingly design book)

The shaft diameter Ds, is based upon the critical speed and deflection. It will be amply strong in torsion
and bending if it is made 1.5 in, in diameter. The hub diameter Ds ma then be made 2.5 in. The Impeller
eye diameter:
The hub diameter; 𝐷𝐻 = 𝐷𝑆 + (19.05 𝑡𝑜 50.88) =1.5+1=2.5in=62.5mm=63mm

The inlet velocity through the impeller eye V0 is made slightly greater than the suction flange velocity.
4 𝑄
The impeller eye diameter: 𝐷0 √𝜋 × 𝑉0 + 𝐷𝐻2 =
0

√ (4/π) × (144*35.28)/〖100〗_0 +〖2.5〗_^2 = 8.66in=220mm

Be made slightly greater than the eye diameter 𝐷𝑜 . The vane inlet diameter D1 may diameters, D1: 8.75
𝜋𝐷1 𝑛
in may be selected. The vane inlet diameter 𝐷1 can the impeller inlet speed; 𝑈1 =
60

3500∗3.14∗8.75
= =133.56ft/s= 40.7m/s the inlet velocity is assumed to be radial, i.e. And is made equally
720

is 100 ft. /sec. The inlet and outlet blade angle of impeller as shown in V1=V0=100ft/sec=30.48m/s

Figure 18. Inlet and Outlet Velocity Diagram of the Impeller

𝑉
Impeller Blade Inlet angle, 𝑡𝑎𝑛𝛽1 = 𝑈1 = (100ft/se)/ (133.56ft/se)=36.8
1

Impeller Blade Inlet angle, 𝛽1 = 37°

The relative inlet velocity √𝑈12 + 𝑉12 = √133.562 + 1002 =V1=166.85ft/se= 50.85m/se
In calculating the impeller areas, the flow must be increased because of leakage past the impeller. This
leakage may be assumed to be about 72 percent of the flow, subject to connection after the impeller
dimensions have been established.

- 39 -
 35.5∗1.072∗144
12. The inlet area of the impeller: 𝐴1 = = 54.5in^2=1.38m^2
100

Assuming the vane has constant thickness t: 0.25 in the inlet vane thickness factor: 0.85.

𝐴1
The impeller inlet width is 𝑏1 = 54.5/3.14* 8.75*0.85=2.33in=0.0592m
𝜋𝐷1 𝜀1

III. SELECTION OF THE VANE DISCHARGE ANGLE

The vane outlet angle β2 is usually made larger than the inlet. The outlet vane angle β2, ma be selected
within fairly wide limits. It is made slightly larger than the inlet angle β1 to obtain a smooth, continuous
passage. The outlet angle, can theoretically be selected freely within a wide range. An angleβ2 >90°leads
to backwards curved blades, β2=90° means radially ending blades and β< 90° means forward curved
blades.

IV. IMPELLER OUTLET VANE ANGLE AND DIMENSIONS

The outside diameter of the impeller assuming the value of K′. The overall pressure coefficient K′ may
be between 0.5 and 0.65.

1300×√𝐻𝑎𝑑𝑔
Take K′ = 0.6. 𝐷2 = = 𝐷2 = 14.3in= 14in= 0.4m
𝑛√𝑘

The impeller outlet width is 𝑏2 = 54.5/ (3.14*14*0.85) = 1.458in=0.037m

The outlet vane angle is 90°.

𝐷 +𝐷 𝛽1 +𝛽2
1. The Blade number: 𝑍 = 6.5 × 𝐷2 −𝐷1 × 𝑠𝑖𝑛 = 20vanse the impeller tip speed at the outlet:
2 1 2
𝜋𝐷2𝑛
𝑈2 = = (3.14 ∗ 14 ∗ 3500)/720 = 214𝑓𝑡/𝑠𝑒 = 65.13m/se
720

𝜋𝑠𝑖𝑛𝛽2
The circulatory flow effect reduces the tangential 𝑊𝑧 = 𝑈2 * (214 ∗ 3.14 ∗ 𝑠𝑖𝑛90)/20=33.6ft/se
𝑧

The tangential component of V2 based upon a finite number of vanes, ⋁ 𝑢2 = 𝑉𝑢2 + 𝑊2 =

4.4380ft/se+33.6ft/se=74.836ft/se

The absolute outlet velocity √𝑉𝑟 2 + 𝑉𝑢2 √74.8362 + 632 =V2=98.69ft/se

V^2=√𝑉𝑟 2 + 𝑉^𝑢2 =√98.692 + 632 =116.4ft/se

- 40 -
 𝑉𝑟2
The absolute outlet impeller angle:𝑡𝑎𝑛𝛼2 = = 63/65.13= 28.4º.
𝑈2

After this impeller calculation we can select centrifugal blower from standard based on data we gate
similar to impeller result

Figure 19 . Solid work Impeller

3.6 DESIGN OF VOLUTE CASING

In determining the cross sectional area of the volute at any point, the problem consists in finding the area
of the section that will pass the volume Q/360 with a velocity Vu = C/R. Q is that of delivered flow.

Figure 20. Volute passage cross section.

𝑑𝑄∅ = 𝑑𝐴𝑉𝑢 = 𝑏𝑑𝑅𝑉𝑢

But 𝑉𝑈 = C/R, hence 𝑑𝑄∅ = b dR C/R, and the total flow past the section becomes

- 41 -
 𝑅∅ 𝑅∅
𝑑𝑅
𝑄∅ = ∫ 𝑑𝑄 = 𝐶 ∫ 𝐶
𝑅2 𝑅2 𝑅

Where, 𝑅∅ is the outer radius of a section at  from the theoretical tongue Substituting for 𝑄∅ the term
Q/360 there results?
360𝐶 𝑅∅ 𝑑𝑅 360𝑅2 𝑉𝑢2 𝑅∅ 𝑑𝑅
∅° = ∫𝑅2 𝑏 = ∫𝑅2 𝑏
𝑄 𝑅 𝑄 𝑅

𝐴𝑎 = 30º
𝑅
log10
𝑅2
For the tongue radius R= Rt tongue angle Tongue angle: ∅𝑡 =132 .
𝑡𝑎𝑛𝛼2

𝑅 = 𝑅𝑡 𝑅𝑡 = (5 − 10%) 𝑅2

𝐿𝑒𝑡 𝑅𝑡 = 8 ∗ 7𝑖𝑛 = 56% = 𝑅,

132log_10〖0.56/7_ 〗/〖tan28.4〗_ = 293.8º

Flow rate through volute case =293.88º ∗ 2137.8𝑐𝑓𝑡/𝑚 = 296.3𝑚^3/𝑠𝑒

3.6.1 FAN CASE COVER DESIGN
Design of fan case based on duct and impeller dimension is circular shape used to cover and protect
impeller, eye from chips unwanted exhaust material it has 4mm hole size and with double circular shape
the smaller is 430mm and largest 490mm. smallest fixed externally with duct and internally with fan.

3.6.2 PIPE HOOD DESIGN

It used for collecting and remove inlet exhaust west particle to different types of filter unit to realize pure
air for surrounding. Its dimension width =500 and height= 230 with 150 degree central rectangular pipe
shape and its thickness of 30mm.

Storage tank for storing electrode and flexible duct and also other material product material type is mild
steel.

3.7 DESIGN OF RIVET PIN

The design parameters in a riveted joints are d, p and m Diameter of the hole (d): When thickness of the
plate is more than 8 mm, Unwin’s formula is used, D= 6√𝑡𝑚𝑚

- 42 -
 𝜋
For double riveted zigzag joint, this implies; 𝑆𝑐 𝑡 = 4 𝑑𝑆𝑠 (valid for t < 8 mm)

pitch (p): Pitch is designed by equating the tearing strength of the plate to the shear strength of the rivets.
𝜋𝑑2
For double riveted lap joint 𝑆𝑡 (𝑃 − 𝑑 )𝑡 = 𝑆𝑠 × 2( )
4

But p ≥ 2d in order to accommodate heads of the rivets. Margin (m): m d =1.5. In order to design boiler
joints, a designer must also comply with Indian Boiler Regulations (I.B.R.). (pb: usually 0.33 0.67 p + d
mm).

Efficiency of the single riveted joint can be obtained as ratio between the maximum ofP1, P2 and P3 , and
the load carried by a solid plate which is𝑆𝑡 𝑃𝑡. Thus

min(𝑃1 ,𝑃2, 𝑃3)

Efficiency (η) = 𝑆𝑡 𝑃𝑡

Since, the diameter of the rivet hole is selected equating shear strength to the crushing strength, i.e., t =
𝜋
7mm < 8mm 2( 4 𝑑 2 )𝑆𝑠 = 2𝑑𝑡𝑆𝑐

Yielding d =17.8mm According to IS code, or shingly design guide the standard size is d =19 mm and the
corresponding rivet diameter is 18mm.

Internal D= 18mm External D= 36mm

Length =60mm t = 7mm

For stainless steel material (𝑡𝑒𝑎𝑟 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ )𝑆𝑡 = 90 MPa (𝑠ℎ𝑒𝑎𝑟 𝑠𝑡𝑒𝑟𝑛𝑔ℎ𝑡 )𝑆𝑆 = 60 MPa,
(𝑐𝑟𝑢𝑠ℎ𝑒 𝑠𝑡𝑒𝑟𝑒𝑛𝑔ℎ𝑡 )𝑆𝑐 =120MPa

𝜋
Pitch is obtained from the following; 𝑆𝑡 (p-d) t = 2𝑆𝑠 ( 𝑑 2 ) , where d =19 mm
4

p = 54+19= 73mm

(a) Tearing resistance of the plate in outer row:

P1 = (p − dHole )tST =

(73 − 19) 7 X 90 = 34.020𝐊𝐍

𝜋
(b) Shearing resistance of the rivet: P2 = 2 × 4 × 192 ∗ 60 =
4

- 43 -
 136.02 𝐤𝐍

(c) Crushing resistance of the rivets P3 = 5 × dtSc =

79.8 𝐤𝐍

(d) Shear failure of the outer row and tearing of the rivets in the second row

π
P4 = (P − 2dHole )tST + d2 SS =
4

𝟑𝟗. 𝟎𝟓𝟑 𝐤𝐍

𝒎𝒊𝒏(𝑷𝟏 , 𝑷𝟐 , 𝑷𝟑 , 𝑷𝟒 )
𝜼=
𝑷𝒕𝑺𝑻

𝟎𝟐𝟎
𝟑𝟒. ∗ 𝟕 ∗ 𝟗𝟎 = 𝟕𝟑. 𝟗% Efficiency of rivet pin
𝟕𝟑

Figure 21 . Solid work Rivet

3.8 DESIGN OF PRESSURE
Duct systems are also divided into three pressure classifications so our design operates at medium pressure
point.

1. Low Pressure: duct velocities are less than 1,500 fpm.

2. Medium Pressure: duct velocities are less than or equal to 2,500 fpm.

3. High Pressure: and duct velocities are limited to 4,000 fpm.

- 44 -
 3.9 DESIGN PF TEMPRETURE
The strength of metals decreases with increasing temperature so the maximum allowable design stress
will depend on the material temperature 40~45

Table 9. Properties of stainless steel

Physical properties of stainless steels

Designations Density Modulus Mean Thermal Specific Electrical
3
(kg/dm ) of coefficient of conductivity heat resistivity
elasticity thermal (W/m·K) (J/kg·K) (Ω·mm2/m)
(GPa) expansion
(10−6·K−1)
EN AISI/ASTM at 20 °C at 20 °C 20– 20– at 20 °C at 20 °C at 20 °C
[№] 200 °C 400 °C
Austenitic stainless steels
1.4301 304 7.9 200 16.5 17.5 15 500 0.73
1.4401 316 8.0 200 16.5 17.5 15 500 0.75
Duplex stainless steels
1.4462 2205 7.8 200 13.5 14.0 (g) 15 500 0.80
1.4362 2304 7.8 200 13.5 14.0 (n) 15 500 0.80
1.4501 7.8 200 13.5 (n.r.) 15 500 0.80
Ferritic stainless steels
1.4512 409 7.7 220 11.0 12.0 25 460 0.60
1.4016 430 7.7 220 10.0 10.5 25 460 0.60
Martensitic stainless steels
1.4021 420 7.7 215 11.0 12.0 30 460 0.60
1.4418 7.7 200 10.8 11.6 15 430 0.80
Precipitation-hardened stainless steels
1.4542 630 7.8 200 10.8 11.6 16 500 0.71

COST ANALYSIS
Cost of materials

This is the cost spend in order to purchase the materials required to prepare this simple (portable) welding
fume extraction system. Thus, the current price for an s mild steel in the world market on average is

- 45 -
3.9$/meter. And price round vulcanized rubber material for duct 1.67 $/meter we have a total length for
those ducts around 3m. Therefore the price for sheet metals is;

Material cost = 3.9$/m × (1.2 + 0.8 + 1 + 1.5) = 17.55$ for frame

Duct=3m×1.67= 4.95$
The cost of centrifugal fan which is estimated by Sodeca fan manufacturers for model of

Neolineo 250/V is 295.5$ (recommended retail price). To drive this centrifugal fan, the recommended
electric motor type having a specific code of 10378 and its type is / Motor -631-2T/ price is 80.1$.

Types of air filters model number-BS022 filter cloth and material- wood pulp filter paper(cartridge
filter), soft thick paper current sum price is 10$.

Thus, the total cost of materials is = 17.55$+4.9+295.5$+80.1$+10$=408.1$

Labor cost

The work shop is enriched by technical as well as engineers so that external labor is not needed. Thus,
assuming that the construction of tube takes one-fourth of a day and giving for those two employees 3$
per hour, then;

Labor cost = (2 *3$)/Hr. ×6Hr

= 36$

Maintenance cost

We are supposed for the maintenance of this project during operation about 20$.

Total cost

The total cost can be estimated as;

=materials cost +labor cost +maintenance cost

= 408.1$+36$+20$

= 464.5$

Additional simple material cost such as rivet, caster wheel, covers 600 up to 800 birr

- 46 -
Currently, the currency exchange between USA dollar and Ethiopian birr is;

1$=41Birr Thus, the total price of this project in our birr is:

=464.1$×41Birr/$+800biir

=19, 8226.1 birr

- 47 -
 CHAPTER –FOUR

4. SOFTWARE ANALYSIS

Figure 22. Fan case

- 48 -
Figure 23. Impeller

- 49 -
Figure 24. Fan case cover

- 50 -
Figure 25. Duct

- 51 -
Figure 26. Air filter

- 52 -
Figure 27. Pipe hood

- 53 -
Figure 28. Frame

- 54 -
Figure 29. Drawer

- 55 -
Figure 30. Pipe hood 2

- 56 -
Figure 31. Rivet pin

- 57 -
Figure 32. Assemble drawing

- 58 -
 CHAPTER –FIVE

5. RESULT AND DISCUSSION

5.1 RESULT
Technical characteristics of motor:

Rated mechanical power (KW) 0.746, Hz/phases 50/1Motor DC

 Maximum current (A) 220-240

 Speed(rpm) 3500
 Approximate weight (Kg)=9
 Total flow rate sucked by fan=590.028l/s.

Thus, the volume occupied volume by machines is;

 𝑉=1.152m3
 𝑄=2137.8𝑐𝑓𝑡/𝑚 =60.54m^3/m.
 𝐷𝑑=14in=355mm
 𝐿𝑑. = 3m length of duct
 𝑝𝑟𝑒𝑠𝑠𝑢𝑟𝑒 𝐿𝑜𝑠𝑠= 3.4Pa

Table 10. Calculated results of radial type centrifugal blower

No Descriptions Value Unit

1 Shaft diameter, Ds 37.50 Mm
2 Hub diameter, 𝐷𝐻 63 Mm
3 Eye diameter, 𝐷𝑜 203 Mm
4 Eye velocity, 𝑉𝑜 21 m/sec
5 Flow through eye, 𝑄𝑜 1 𝑚3 /𝑠𝑒𝑐
6 Vane inlet diameter, D 210 Mm
7 Velocity at vane inlet, 𝑉1 50.85 m/sec
8 Impeller inlet width,𝑏1 60 Mm
9 Inlet vane thickness factor, ∈1 0.85 -
10 Inlet vane angle, 𝛽1 36.8 Degree

- 59 -
 11 Number of vanes, Z 20 -
12 Impeller inlet tip speed, 𝑈1 40.71 m/sec
13 Outside diameter of impeller, 𝐷2 400 Mm
14 Radial outlet velocity,𝑉𝑟2 63 m/sec
15 Impeller width at outlet, 𝑏2 37.04 Mm
16 Outlet vane thickness correction 0.95 -
factor,∈2
17 Impeller outlet tip speed, 𝑈2 65.13 m/sec
18 Vane outlet angle, 𝛽2 90 Degree
Result Data of Volute Casing

Aa= 30º
𝑅𝑡 = 8 ∗ 7𝑖𝑛 = 𝑅=56%
Tongue angle: ∅𝑡 = 293.8º
Flow rate through volute case =296.3m^3/sec.

Calculated Results of Design of Rivet pin

D= 18mm
t = 7mm
p =73mm
P1 = 34.0201KN
P2 = 136.02 kN
P3 = 79.8 kN
P4 = 39.053 kN
𝜂 = 0.739 = 73.9%

- 60 -
5.2 DISCUSSION

For our project we have selecting the right materials for a specific design thus are; Mild steel,
vulcanized rubber, Paper-based filter, Radial bladed centrifugal blower, 1hp (746watt) electric motor,
Stainless steel, Corrosion resistant paint. The design and fabrication of portable welding fume extraction
system has taken a role model of vacuum cleaner. Which is a system utilizing a fan which can be
used as a motor to pull a small Particles into a filtration system cleaning the environments from
harmful dirty particles. And also it has a hose to transport a small particles through it. Just like this system
,the designed portable welding fume extraction system pull the fume through the duct when the fan
starting to rotate the blade and done their work properly And according to the calculation design it satisfies
the standard of Occupational Safety and Health Administration (OSHA). The limiting gas can be
given off to environment are 5 and 50 ppm for Oxides of Nitrogen and Carbon Monoxide respectively. In
addition this design of welding fume extractor creates comfortable working environments so the workers
done their work properly as a result increased the product with in a given working time interval.

- 61 -
 CHAPTER SIX

CONCLUTION AND RECOMMENDATION

6.1 CONCLUSION
As far the extent problem that we have seen in our campus workshop room, the present work deals
with reduction of emission rate of welding fumes and create a better health Environmental during the
welding process in technical institute and Industrial application. As concerned with results the emission
rate like oxides of sulfur, Oxides of Nitrogen, Carbon monoxide and Carbon Dioxide has been reduced,
when the filter has been installed to a Welding fumes Extraction System. The design was done in
accordance with standard design specifications and carried out indicated a high level of performance
in the extraction of welding fumes.

1 horse power electric motor was selected to drive the centrifugal blower. It can vary in size from a few
feet in diameter, depending on their application. Centrifugal blower are very useful in many industries,
factories and many engineering fields. Although the centrifugal blowers are existing machines in many
respective fields and also the machine can be portable and The machine is safe and easy to operate
and does not require any special technical training on how to operate it however it required special
skill to make (manufacture) . Also the filters can be simply remove and clean with time then operate it
again. The machine components were coated with aluminum silver spray to make them corrosion
resistant with different very small hole size. The micro type small hole used for to test and to clean intake
pollute air up to clean same with surrounding air. The machine will find extensive use in both local
workshops and industries which are involved in welding, soldering, and brazing processes. So, this
research would be very useful and applicable Also it is cost effective and portable.

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6.2 RECOMMENDATION

We strongly recommended for welder (welding operators) to use this machine appropriately. Most of
welder in our country not consider health (safety) issue they are in risky. During the work it is necessary
to use personal protective equipment such as protective clothe, gloves and breathing apparatus with in
corporate etc... So as to avoid contact with hazardous dust and in order to minimize environmental effects.
This portable fume extractor machine may not operates in industrial application due to material and
assumptions (given) we used. It used and designed for our campus workshop. Also it can be portable,
enlarge or minimize more than this our project. There are different types of filter paper based of application
we use it may be for sucking of air, chips iron, sand etc… also there are different types of duct material
such as PVC, aluminum PVC, stainless steel, vulcanized rubber etc. … each have their own benefit and
application. The next researcher should consider part, position, filter unit, motor unit frame material and
duct type to get more portable machine.
Generally we recommend for this machine to be tangible (physical work) due to financial and time we
couldn’t work physical unit of machine and adjusting arm be at 45º of fume.to get more comfortable
working condition and area.

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 REFERENCE
[1] R. V Albert, “Fume generation in gas metal arc welding,” 1996.
[2] “No Title.”
[3] I. Pires, R. M. Miranda, and J. F. Gomes, “Fume emissions during gas metal arc welding,” no.
June 2014, 2006, doi: 10.1080/02772240600720472.
[4] No Title. .
[5] P. Selection, “Gas Metal Arc Welding.”
[6] P. O. Babalola and M. Oriyomi, “The Development of Fume Extractor for a Welding Booth The
Development of Fume Extractor for a Welding Booth,” no. September, 2018, doi: 10.1088/1757-
899X/413/1/012018.
[7] P. Science, “Paper and Board Grades.”
[8] F. Techniques and G. Filtration, “Filtration techniques,” pp. 1–5.
[9] Q. F. Papers, C. Papers, E. Thimbles, G. F. Filters, and Q. F. Filters, “A P P L I C AT I O N S : C
O N V E R S I O N S – Q U A L I TAT I V E P A P E R S.”
[10] E. Methods, E. Thick, G. Fiber, and W. Binder, “Glass Fiber Filters Description.”
[11] A. Bhatia, “HVAC - How to Size and Design Ducts,” no. 877.
[12] A. Y. E. M. Y. A. Thandar, P. M. I. N. Than, N. S. Mya, and P. A. P. A. Minn, “Design of 5 kW
Radial Type Centrifugal Blower ( Impeller ),” vol. 3, no. 2, pp. 250–256, 2019.
[13] A. Information, “MB.”
[14] S. Width and S. Inlet, “Centrifugal fans.,” 1981, doi: 10.1016/s0026-0576(98)80326-7.

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 APPENDEX

Elbow assembling technics and application

Duct alignment system

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SMACNA standard hood and duct alignment

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. Velocity pressure noise ratio for rectangular duct with respect to air flow
Air flow 50 60 70 85 95 110 120
(cfm)
Velocity 400 500 600 700 800 900 1000
(fpm)
Pressure 0.056 0.090 0.131 0.175 0.225 0.290 0.355
drop
(inwc)

Noise 14 20 24 28 32 35 38
(NC)
Throw 5-8-13 7-9-12 8-12-19 9-13-18 10-15-21 12-17-24 13-19-31
(ft)

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. Selection of different steel duct
Rectangular Duct Round Duct
Greater G. Steel Al (gauge) Diameter G. Steel Al (gauge)
Dimension (gauge) (gauge)
Up to 30 24 22 Up to 8 inch 24 22
inch
31 – 60 22 20 9 – 24 22 20
inches inches
61 – 90 20 18 25 – 48 20 18
inches inches
> 91 inches 18 16 49 – 72 18 16
inches

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