A full cone nozzle spray distribution test checks whether liquid reaches the intended target area with an acceptable pattern under the actual operating conditions. The test should record flow, pressure, distance, orientation, liquid condition and collection method so results can be repeated and compared.
This method supports model selection and header commissioning. It does not replace a customer-defined process qualification, safety review or performance standard.
What the Test Should Answer
- Does the spray reach the required footprint?
- Is the centre and edge distribution suitable for the process?
- Are there dry zones, heavy zones or distorted areas?
- Does each nozzle on a header receive comparable pressure and flow?
- Does the pattern remain stable across the intended operating range?
Information to Record Before Testing
| Nozzle | Series, model, orifice, connection, material and orientation |
|---|---|
| Operating condition | Pressure measured near the nozzle, flow, liquid and temperature |
| Geometry | Nozzle-to-target distance, angle, target size and header spacing |
| Supply system | Pump condition, pipe size, filter, valves and number of active nozzles |
| Test method | Collection layout, collection time, measuring equipment and units |
Seven-Step Full Cone Distribution Test
- Define the acceptance question. State what acceptable coverage means for the process. Do not invent a uniformity limit after viewing the results.
- Prepare the system safely. Confirm that the test area, drainage, electrical equipment and personnel are protected. Depressurize the system before changing nozzles or fittings.
- Install and identify the nozzle. Record model, orientation, connection, mounting distance and header position.
- Stabilize flow and pressure. Run the system until the reading near the nozzle is stable. Record both pressure and total or per-nozzle flow.
- Collect the spray. Use a defined grid of containers, a test plate or another repeatable collection method across the target area. Keep the collection time consistent.
- Map and compare the result. Record the amount collected at each position. Look for dry zones, centre or edge concentration, asymmetry and header-to-header variation.
- Repeat after one controlled change. Change only one variable—such as pressure, distance, orientation, spacing or model—then repeat the same procedure.
How to Interpret an Uneven Pattern
| Observation | Possible checks |
|---|---|
| Pattern is smaller than expected | Pressure at nozzle, model angle, mounting distance and blockage |
| Pattern is distorted to one side | Orientation, damaged orifice, debris, cross-flow or installation obstruction |
| Header has wet and dry bands | Nozzle spacing, rotation, overlap and pressure balance |
| Flow changes during the test | Pump stability, filter restriction, valve position and supply demand |
| Repeated cleaning does not restore the pattern | Wear, erosion, damaged geometry or unsuitable material |
Testing Square and Round Full Cone Patterns
For a round full cone, map the centre, intermediate radius and outer edge. For a square full cone, also record pattern orientation and corner coverage. In a multi-nozzle square layout, rotate each nozzle consistently before adjusting spacing.
Header Commissioning
Test a single nozzle first to establish a reference, then test the complete header at the intended operating condition. Pressure near the first nozzle does not prove that the last nozzle receives the same condition. Record representative positions across the header.
Use the Result for Model Selection
If the current pattern is too compact, review the wide-angle full cone nozzle. If the target requires longer reach or a smaller footprint, review the BBG narrow-angle full cone nozzle. For square header coverage, review the BB square full cone nozzle.
What to Send for Engineering Review
Provide the nozzle model, recorded pressure and flow, liquid details, mounting drawing, collection layout, result table and photographs or video of the test. State the process requirement and the problem observed.
Send your full cone distribution data for review
Related: Full cone nozzle selection guide | Full cone nozzle products
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