1 DUCT SIZING METHODS

The design of the ductworks in ventilation systems are often done by using the

Velocity Method Constant Pressure Loss Method (or Equal Friction Method) Static Pressure Recovery Method

The Velocity Method

Proper air flow velocities for the application considering the environment are selected. Sizes of ducts are then given by the continuity equation like: A=q/v where A = duct cross sectional area (m2) q = air flow rate (m3/s) v= air speed (m/s) A proper velocity will depend on the application and the environment. The table below indicate commonly used velocity limits: Type of Duct Main ducts Main branch ducts Branch ducts Comfort Systems 4 - 7 m/s 3 - 5 m/s 1 - 3 m/s Industrial Systems 8 - 12 m/s 5 - 8 m/s 3 - 5 m/s High Speed Systems 10 - 18 m/s 6 - 12 m/s 5 - 8 m/s (1)

Be aware that high velocities close to outlets and inlets may generate unacceptable noise.

The Constant Pressure Loss Method (or Equal Friction Loss Method)
A proper speed is selected in the main duct close to the fan. The pressure loss in the main duct are then used as a template for the rest of the system. The pressure (or friction) loss is kept at a constant level throughout the system. The method gives an automatic velocity reduction through the system. The method may add more duct cross sectional changes and can increase the number of components in the system compared to other methods.

The Static Pressure Recovery Method

With the static pressure recovery method the secondary and branch ducts are selected to achieve more or less the same static pressure in front of all outlets or inlets. The major advantage of the method are more common conditions for outlets and inlets. Unfortunate the method is complicated to use and therefore seldom used.

2 Equal friction method

The equal friction method of sizing ducts is often preferred because it is quite easy to use. The method can be summarized to 1. 2. 3. 4. 5. 6. 7. Compute the necessary air flow volume (m3/h, cfm) in every room and branch of the system Use 1) to compute the total air volume (m3/h, cfm) in the main system Determine the maximum acceptable airflow velocity in the main duct Determine the major pressure drop in the main duct Use the major pressure drop for the main duct as a constant to determine the duct sizes throughout the distribution system Determine the total resistance in the duct system by multiplying the static resistance with the equivalent length of the longest run Compute balancing dampers

1. Compute the air volume in every room and branch

Use the actual heat, cooling or air quality requirements for the rooms and calculate the required air volume - q.

2. Compute the total volume in the system

Make a simplified diagram of the system like the one above. Use 1) to summarize and accumulate the total volume - qtotal - in the system. Note! Be aware that maximum load conditions almost never occurs in all of the rooms at the same time. Avoid over-sizing the main system by multiplying the accumulated volume with a factor less than one (This is probably the hard part - and for larger systems sophisticated computer-assisted indoor climate calculations are often required).

3. Determine the maximum acceptable airflow velocity in the main ducts

Select the maximum velocity in the main duct on basis of the application environment. To avoid disturbing noise levels - keep maximum velocities within experienced limits:

comfort systems - air velocity 4 to 7 m/s (13 to 23 ft/s) industrial systems - air velocity 8 to 12 m/s (26 to 40 ft/s) high speed systems - air velocity 10 to 18 m/s (33 to 60 ft/s)

Use the maximum velocity limits when selecting the size of the main duct.

4. Determine the static pressure drop in main duct

Use a pressure drop table or similar to determine the static pressure drop in the main duct.

5. Determine the duct sizes throughout the system

Use the static pressure drop determined in 4) as a constant to determine the ducts sizes throughout the system. Use the air volumes calculated in 1) for the calculation. Select the duct sizes with the pressure drop for the actual ducts as close to the main duct pressure drop as possible.

6. Determine the total resistance in the system

Use the static pressure from 4) to calculate the pressure drop through the longest part of the duct system. Use the equivalent length which is

the actual length + additional lengths for bends, T's, inlets and outlets

7. Calculate balancing dampers

Use the total resistance in 6) and the volume flow throughout the system to calculate necessary dampers and the theoretical pressure loss through the dampers.

Note about the Equal Friction Method

The equal friction method is straightforward and easy to use and gives an automatic reduction of the air flow velocities throughout the system. The reduced velocities are in general within the noise limits of the application environment. The method can increase the numbers of reductions compared to other methods, and often a poorer pressure balance in the system require more adjusting dampers. This may increase the system cost compared to other methods.

Example - Equal Friction Method

The equal friction method can be done manual or more or less semi automatic with a spreadsheet as shown in the table below.

The table is based on the diagram above. Air flow and friction loss from a diagram is added. Minor pressure loss coefficients must be summarized for for the actual applications. The pressure loss in each path is summarized on the right and pressure loss is added manually in the dampers to balance the system.

3 MINOR LOSS COEFFICIENTS FOR AIR DUCTS COMPONENTS

Minor Loss - Head or Pressure Loss in Air Duct Components - can be expressed as hminor_loss = v2/ 2 g where hminor_loss = minor head loss (m, ft) = minor loss coefficient v = flow velocity (m/s, ft/s) (1)

g = acceleration of gravity (m/s2, ft/s2) Minor loss can also be expressed as pressure loss instead of head loss. Minor loss coefficients for different components common in air duct distribution systems

Component or Fitting

Minor Loss Coefficient -1.3 0.7

90o bend, sharp 90o bend, with vanes 90o bend, rounded radius/diameter duct <1 90o bend, rounded radius/diameter duct >1 45o bend, sharp 45o bend, rounded radius/diameter duct <1 45o bend, rounded radius/diameter duct >1 T, flow to branch (applied to velocity in branch) Flow from duct to room Flow from room to duct Reduction, tapered Enlargement, abrupt (due to speed before reduction)

0.5

0.25

0.5

0.2

0.05

0.3

1.0 0.35 0 (1 - v2 / v1)2

(v1= velocity before enlargement and v2 = velocity after enlargement) Enlargement, tapered angle < 8o (due to speed before reduction) 0.15 (1 - v2 / v1)2 (v1= velocity before enlargement and v2 = velocity after enlargement) Enlargement, tapered angle > 8o (due to speed before reduction) (v1= velocity before enlargement and v2 = velocity after enlargement) Grilles, 0.7 ratio free area to total surface Grilles, 0.6 ratio free area to total surface Grilles, 0.5 ratio free area to total surface Grilles, 0.4 ratio free area to total surface Grilles, 0.3 ratio free area to total surface Grilles, 0.2 ratio free area to total surface

(1 - v2 / v1)2

10

20

50

4 AIR DUCTS FRICTION LOSS DIAGRAM

Friction loss (head loss) in standard air ducts are indicated in the diagram below:

The diagram is based on standard air 0.075 lb/ft3 in clean round galvanized metal ducts.

1 inch water = 248.8 N/m2 (Pa)= 0.0361 lb/in2 (psi) = 25.4 kg/m2 = 0.0739 in mercury 1 ft3/min (cfm) = 1.7 m3/h = 0.47 l/s 1 ft/min = 5.08x10-3 m/s 1 inch = 25.4 mm = 2.54 cm = 0.0254 m = 0.08333 ft

Example - Friction Loss in Air Duct

The friction loss in a 20 inches duct with air flow 4000 cfm can be estimated to approximately 0.23 inches water per 100 feet duct as shown in the diagram below. The air velocity can be estimated to approximately 1850 feet per minute.

5 DESIGN OF VENTILATION SYSTEMS

A ventilation system may be designed more or less according the following procedure: 1. 2. 3. 4. 5. 6. 7. 8. Calculate heat or cooling load, including sensible and latent heat Calculate necessary air shifts according the number of occupants and their activity or any other special process in the rooms Calculate air supply temperature Calculate circulated mass of air Calculate temperature loss in ducts Calculate the outputs of components - heaters, coolers, washers, humidifiers Calculate boiler or heater size Design and calculate the duct system

1. Calculate Heat and Cooling Loads

Calculate heat and cooling loads by

Calculating indoor heat or cooling loads Calculating surrounding heat or cooling loads

2. Calculate Air Shifts according the Occupants or any Processes

Calculate the pollution created by persons and their activity and processes.

3. Calculate Air Supply Temperature

Calculate air supply temperature. Common guidelines:

For heating, 38 - 50oC (100-120oF) may be suitable For cooling where the inlets are near occupied zones - 6 - 8oC (10-15oF) below room temperature For cooling where high velocity diffusing jets are used - 17oC (30oF) below room temperature

4. Calculate Air Quantity

Air Heating
If air is used for heating, the needed air flow rate may be expressed as qh = Hh / cp (ts - tr) where qh = volume of air for heating (m3/s) Hh =heat load (W) cp = specific heat capacity of air (J/kg K) ts = supply temperature (oC) tr = room temperature (oC) = density of air (kg/m3) (1)

Air Cooling
If air is used for cooling, the needed air flow rate may be expressed as qc = Hc / cp (to - tr) where qc = volume of airfor cooling (m3/s) Hc =cooling load (W) to = outlet temperature (oC) where to = tr if the air in the room is mixed (2)

Example - heating load:

If the heat load is Hh = 400 W, supply temperature ts = 30 oC and the room temperature tr = 22 oC, the air flow rate can be calculated as:

qh = (400 W) / (1.2 kg/m3) (1005 J/kg K) ((30 oC) - (22 oC)) = 0.041 m3/s = 149 m3/h

Moisture
If it is necessary to humidify the indoor air, the amount of supply air needed may be calculated as: qmh = Qh / (x2 - x1) where qm = volume of air for humidifying (m3/s) Qh = moisture to be supplied (kg/s) = density of air (kg/m3) x2 = humidity of room air (kg/kg) x1 = humidity of supply air (kg/kg) (3)

Dehumidifying
If it is necessary to dehumidify the indoor air, the amount of supply air needed may be calculated as: qmd = Qd / (x1 - x2) where qmd = volume of air for dehumidifying (m3/s) Qd = moisture to be dehumified (kg/s) (4)

Example - humidifying
If added moisture Qh = 0.003 kg/s, room humidity x1 = 0.001 kg/kg and supply air humidity x2 = 0.008 kg/kg, the amount of air can expressed as: qmh = (0.003 kg/s) / (1.2 kg/m3) ((0.008 kg/kg)- (0.001 kg/kg)) = 0.36 m3/s Alternatively the air quantity is determined by the requirements of occupants or processes.

5. Temperature loss in ducts

The heat loss from a duct can be expressed as: H = A k ( (t1 + t2) / (2 - tr) ) (5)

where H = heat loss (W) A = area of duct walls(m2) t1 = initial temperature in duct (oC) t2 = final temperature in duct (oC) k = heat loss coefficient of duct walls (W/m2 K) (5.68 W/m2 K for sheet metal ducts, 2.3 W/m2 K for insulated ducts) tr = surrounding room temperature (oC) The heat loss in the air flow can be expressed as: H = q cp (t1 - t2) where q = mass of air flowing (kg/s) cp = specific heat capacity of air (kJ/kg K) (5) and (5b) can be combined to H = A k ((t1 + t2) / 2 - tr)) = q cp (t1 - t2) (5c) (5b)

For large temperature drops should logarithmic mean temperatures be used.

6. Selecting Heaters, Washers, Humidifiers and Coolers

Units as heaters, filters etc. must on basis of of air quantity and capacity be selected from manufactures catalogues.

7. Boiler
The boiler rating can be expressed as: B = H (1 + x) where B = boiler rating (kW) H = total heat load of all heater units in system (kW) x = margin for heating up the system, it is common to use values 0.1 to 0.2 Boiler with correct rating must be selected from manufacturer catalogues. (6)

8. Sizing Ducts

Air speed in a duct can be expressed as: v=Q/A where v = air velocity (m/s) Q = air volume (m3/s) A = cross section of duct (m2) Overall pressure loss in ducts can be expressed as: dpt = dpf + dps + dpc where dpt = total pressure loss in system (Pa, N/m 2) dpf = major pressure loss in ducts due to friction (Pa, N/m 2) dps = minor pressure loss in fittings, bends etc. (Pa, N/m2) dpc = minor pressure loss in components as filters, heaters etc. (Pa, N/m 2) Major pressure loss in ducts due to friction can be expressed as dpf = R l where R = duct friction resistance per unit length (Pa, N/m2 per m duct) l = length of duct (m) Duct friction resistance per unit length can be expressed as R = / dh ( v2 / 2) where R = pressure loss (Pa, N/m2) = friction coefficient dh = hydraulic diameter (m) (10) (9) (8) (7)

6 A rough guide to maximum air volume capacity of circular ducts in comfort, industrial and high speed ventilation systems
Maximum air velocity in the ducts should be kept below certain limits to avoid unacceptable generation of noise.

The values from the table below can be used to rough sizing of ducts in comfort, industrial and high speed ventilation systems. Maximum Air Volume Flow (m3/h) Comfort systems Industrial systems High speed systems

Diameter Area (mm) (m2)

Main Secondary Connecting Main Secondary Connecting Main Secondary Connecting ducts ducts ducts ducts ducts ducts ducts ducts ducts Speed (m/s) 5.5 4 45 72 2 22 36 10 112 181 6.5 73 118 4 45 72 14 157 253 9 101 163 6.5 73 118

63 80

0.003 0.005

62 99

100 125 160 200 250 315 400 500 630 800 1000 1250

0.008 155 0.012 243 0.020 398 0.031 622 0.049 971 0.078 1542 0.126 2487 0.196 3886 0.312 6169 0.502 9948 0.785 15543 1.227 24286

113 177 289 452 707 1122 1809 2826 4487 7235 11304 17663

57 88 145 226 353 561 904 1413 2243 3617 5652 8831

283 442 723 1130 1766 2804 4522 7065 11216 18086 28260 44156

184 287 470 735 1148 1823 2939 4592 7291 11756 18369 28702

113 177 289 452 707 1122 1809 2826 4487 7235 11304 17663

396 618 1013 1583 2473 3926 6330 9891 15703 25321 39564 61819

254 397 651 1017 1590 2524 4069 6359 10095 16278 25434 39741

184 287 470 735 1148 1823 2939 4592 7291 11756 18369 28702

7 Equivalent diameters for rectangular and circular ducts - air flows between 100 - 50,000 cfm

The table below can be used to compare equivalent diameters for rectangular and round circular ducts. The table is based on the ducts friction loss formula.

The rectangular dimensions and the air flow volume are adapted to the equal friction loss method of sizing ventilation duct systems. An approximate friction loss of 0.8 inches water gauge per 100 ft duct (6.6 Pa/m) is used.

Air flow -qRectangular Duct (Cubic Feet per Sizes Minute, cfm) (Inches) (m3/s)

Equivalent Diameter Round Duct Sizes - de (Inches) 4.9 4.9 5.7 6.0 6.4 6.4 6.6

Velocity -v(ft/min) (m/s)

Friction Loss (Inches water gauge per 100 ft duct)

200 (0.09) 300 (0.14)

3x7 4x5 4x7 5x6 4x9 5x7 6x6

1527 (7.8) 1635 (8.3)

0.88

0.82

400 (0.19)

1736 (8.8)

0.80

500 (0.24)

6x7

7.1

1819 (9.2)

0.78

750 (0.35)

5 x 12 6 x 10 7x8 7 x 10 8x9 8 x 10 9x9 8 x 12 10 x 10 8 x 14 9 x 12 10 x 11 8 x 15 10 x 12

8.3 8.4 8.2 9.1 9.3 9.8 9.8 10.7 10.9 11.5 11.3 11.5 11.8 12.0

1996 (10.1)

0.77

1000 (0.47) 1250 (0.59) 1500 (0.71)

2166 (11) 2386 (12.1) 2358 (11.9)

0.79

0.88

0.77

1750 (0.83)

2469 (12.5)

0.78

2000 (0.94)

2589 (13.2)

0.81

2500 (1.2) 3000 (1.4) 3500 (1.7) 4000 (1.9) 4500 (2.1)

10 x 14 12 x 12

12.9 13.1

2712 (13.8) 2767 (14.1) 3010 (15.3) 2938 (14.9) 3068 (15.6)

0.8

12 x 14

14.1

0.75

12 x 15

14.6

0.84

10 x 22 14 x 15 12 x 19 14 x 16 10 x 25 12 x 20 15 x 16 14 x 20 15 x 18 12 x 26 16 x 20 12 x 30 14 x 25 12 x 34 15 x 25 12 x 36 16 x 25 20 x 20 12 x 45 16 x 30 20 x 24 16 x 36 18 x 30 23 x 25 16 x 40

15.9 15.8 16.4 16.4 16.9 16.8 16.9 18.2 17.9 19.0 19.5 20.2 20.2 21.4 21.0 21.9 21.7 21.9 24.1 23.7 23.9 24.7 25.2 26.2 27.0

0.73

0.76

5000 (2.4)

3248 (16.5)

0.82

6000 (2.8) 7000 (3.3) 8000 (3.8) 9000 (4.3)

3358 (17.1) 3482 (17.7) 3595 (18.3) 3671 (18.6)

0.8

0.8

0.8

0.78

10000 (4.7)

3858 (19.6)

0.83

12500 (5.9)

4012 (20.4)

0.8

15000 (7.1)

4331 (22)

0.87

17500

4337

0.79

(8.3)

20 x 32 25 x 25 20 x 35 25 x 28 16 x 55 20 x 43 25 x 38 20 x 50 30 x 32 20 x 55 30 x 35 25 x 48 30 x 40

27.5 27.3 28.6 28.9 31.0 31.5 33.5 33.7 33.9 35.2 35.4 37.4 37.8

(22)

20000 (9.4)

4483 (22.8)

0.79

25000 (11.8)

4709 (23.9)

0.78

30000 (14.2) 35000 (16.5) 40000 (18.9) 45000 (21.2) 50000 (23.6)

4815 (24.5) 5179 (26.3) 5243 (26.6) 5397 (27.4) 5222 (26.5)

0.74

0.81

0.77

32 x 40

39.1

0.77

32 x 45 35 x 40

41.3 40.9

0.66

8 Friction loss or major loss in ducts - equations and online calculator for rectangular and circular ducts - imperial units

The major loss, or friction loss, in a circular duct in galvanized steel with turbulent flow can for imperial units be expressed p = (0.109136 q1.9) / de5.02 where p = friction (head or pressure loss) (inches water gauge/100 ft of duct) (1)

de = equivalent duct diameter (inches) q = air volume flow - (cfm - cubic feet per minute) For rectangular ducts the equivalent diameter must be calculated.

Air Ducts Friction Loss Calculator

The friction loss calculator below is based on formula (1):
80

Air Volume Flow - q - (cfm)

10

Equivalent duct diameter - de - (inches)

Pressure loss and air flow velocity for some common duct sizes and air flow volumes can be taken from the table below: Pressure Loss (inches water gauge per 100 feet duct) Air velocity (ft/min) Duct Size (inches) Air Volume (cfm) 4 0.65 100 1146 733 0.8 200 1467 1019 1.19 400 2037 1146 733 0.34 800 1467 1019 573 509 0.14 286 0.03 573 0.28 367 0.09 255 0.04 0.01 509 0.32 286 0.08 183 0.02 0.01 5 0.21 6 0.09 8 0.02 10 0.01 12 16

0.12 1600 1146

The air velocity should not exceed certain limits to avoid unacceptable noise generation.

9 Hydraulic diameter of ducts and tubes

The hydraulic diameter - dh - is used to calculate the dimensionless Reynolds Number to determine if a flow is turbulent or laminar. A flow is

laminar if Re < 2300 transient for 2300 < Re < 4000 turbulent if Re > 4000

The hydraulic diameter is also used to calculate the pressure loss in a ducts or pipe. The hydraulic diameter is not the same as the geometrical diameter in a non-circular duct or pipe and can be calculated with the generic equation dh = 4 A / p where dh = hydraulic diameter (m, ft) A = area section of the duct (m2, ft2) p = wetted perimeter of the duct (m, ft) Note! Inches are commonly used in the Imperial unit system. (1)

Hydraulic Diameter of a Circular Tube or Duct

Based on equation (1) the hydraulic diameter of a circular duct can be expressed as:

dh = 4 r 2 / 2 r =2r where r = pipe or duct radius (m, ft) As we could expect the hydraulic diameter of a standard circular tube or duct is two times the radius. (2)

Hydraulic Diameter of a Circular Tube with an inside Circular Tube

Based on equation (1) the hydraulic diameter of a circular duct or tube with an inside duct or tube can be expressed as dh = 4 ( ro2 - ri2) / (2 ro + 2 ri) = 2 (ro - ri) where ro = inside radius of the outside tube (m, ft) ri = outside radius of the inside tube (m, ft) (3)

Hydraulic Diameter of Rectangular Tubes or Ducts

Based on equation (1) the hydraulic diameter of a rectangular duct or pipe can be calculated as dh = 4 a b / (2 (a + b))

= 2 a b / (a + b) where

(4)

a = width/height of the duct (m, ft) b = height/width of the duct (m, ft)

Rectangular to Circulate Duct/Tube Hydraulic Diameter Calculator

The calculator below is based on formula (4) an can be used to calculate the hydraulic diameter of rectangular duct or tube. The formula is generic and any unit can be used.