BBSE3006: Air Conditioning

g and Refrigeration
g II
http://www.hku.hk/bse/bbse3006/

Air-side Systems: Air Duct Design

Dr. Sam C M Hui
Department of Mechanical Engineering
The University of Hong Kong
E-mail:
E mail: cmhui@hku.hk
cmhui@hku hk
Jan 2008
Contents

• Duct Construction

• Duct Properties

• Air Duct Design and Sizing

• Other Factors
Duct Construction

• Types of air duct

• Supply air duct
• Return air duct
• Outdoor air duct
• Exhaust air
• Duct sections
• Header or main duct (trunk)
• Branch duct or runout
[Source: Kreider, K. F. (ed.), 2001. Handbook of Heating, Ventilation, and Air Conditioning, CRC Press, Boca Raton, FL.]
Duct Construction

• Duct systems
• Max. pressure difference (between air inside the
d and
duct d the
h ambient
bi air)i)
• 125, 250, 500, 750, 1000, 1500, 2500 Pa
• Commercial buildings
• Low-pressure
Low pressure duct system: ≤500 Pa,
Pa max 12 m/s
• Medium-pressure system: 500-1500 Pa, max 17.5 m/s
• Residential buildings: 125 Pa or 250 Pa
• Industrial duct system: ΔP can be higher
Duct Construction

• Duct material: e.g.

e g UL (Underwriters
(Underwriters’
Laboratory) standard
• Class 0: zero flame spread, zero smoke developed
• Iron,, ggalvanized steel,, aluminum,, concrete,, masonry,
y,
clay tile
• Class 1: flame spread ≤ 25
25, smoke developed ≤ 50
• Fiberglass, many flexible ducts
• Class 2: flame spread ≤ 50, smoke developed ≤
100
Duct Construction

• Shapes
p of air duct
• Rectangular
• More easily fabricated on site,
site air leakage
• Round
• Less fluid resistance, better rigidity/strength
• Flat oval
• Flexible
• Multiple
Multiple-ply
ply polyester film w/ metal wire or strips
• SMACNA (Sheet Metal and Air Conditioning
C
Contractors’
’ National
N i l Association)
A i i ) standards
d d
Rectangular duct Round duct w/ spiral seam

Flat oval duct Flexible duct

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
 Transverse joint reinforcement
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Duct Construction

• Duct specification
• Sheet gauge and thickness of duct material
• Traverse joints & longitudinal seam
reinforcements
• Duct hangers & their spacing
• Tapes & adhesive
dh i closures
l
p
• Fire spread and smoke developedp
• Site-fabricated or factory-fabricated
Duct Properties

• Duct heat gain or loss

• Temperature rise or drop
• Duct insulation (mounted or inner-lined)
• Reduce heat gain/loss, prevent condensation, sound
attenuation
• Minimum & recommended thickness
• ASHRAE standard or local codes
• Temperature rise curves
• Depends on air velocity, duct dimensions & insulation
 Temperature rise from duct heat gain
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Duct Properties

• Frictional losses: Darcey

Darcey-Weisbach
Weisbach Equation
• Hf = friction head loss, or Δpf = pressure loss

• f = friction factor (dimensionless)

• L = length of duct or pipe (m)
• D = diameter of duct or pipe (m)
• v = mean air velocity in duct (m/s)
• g = gravitational constant (m/s2)
• ρ = density of fluid (kg/m3)
• g c = dimensional constant, for SI unit, g c = 1
Duct Properties

• Frictional losses
• Friction factor (f)
• ReD (Reynolds number)
• ε= absolute roughness; ε/ D = relative roughness
• Smooth duct & rough duct
• Moody diagram
• Laminar flow (ReD < 2000), f = 64 / ReD
• Critical & transition zone
• Turbulent flow: Rouse limit, ReD = 200 / √[f (ε/ D)]
Moody
diagram
 δ >ε

δ <ε

Mode of airflow when air passes over and around

surface protuberances of the duct wall
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Duct Properties

• Duct friction chart

• Colebrook formula

• Roughness
R h & temperature
t t corrections
ti
• Δppf = Ksr KT KelΔp
pf,c
fc
• Ksr = correction factor for surface roughness
• KT = correction factor for air temperature
• Kel = correction factor for elevation
Friction chart for round duct
(Source: ASHRAE Handbook Fundamentals 2001)
(Source: ASHRAE Handbook Fundamentals 2001)
Duct Properties

• Circular equivalent
• Hydraulic diameter, Dh = 4 A / P
• A = area (mm2); P = perimeter (mm)
• Rectangular
g duct:

• Flat oval duct:

Duct Properties

• Dynamic losses
• Result from flow disturbances caused by duct-
mountedd equipment
i andd fittings
fi i
• Change airflow path’s direction and/or area
• Flow separation & eddies/disturbances
• In dynamic similarity (same Reynolds number &
geometrically similar duct fittings), dynamic loss
i proportional
is ti l tot their
th i velocity
l it pressure
Duct Properties

• Local or dynamic loss coefficient

• Ratio of total pressure loss to velocity pressure
Duct Properties

• Duct fittings
g
• Elbows
• C
Converging
i or diverging
di i tees
t andd wyes
• Entrances and exits
• Enlargements and contractions
• Means to reduce dynamic losses
• Turning angle, splitter vanes
• ASHRAE duct fitting database
• Fitting loss coefficients
(Source: ASHRAE Handbook Fundamentals 2001)
 Region of eddies and
turbulences in a round elbow 5-piece 90o round elbow

(Source: ASHRAE Handbook Fundamentals 2001)

R t
Rectangular
l elbow,
lb smooth
th radius,
di 2 splitter
litt vanes

Mitered elbow and its secondary flow

(Source: ASHRAE Handbook Fundamentals 2001)
 Airflow through a
rectangular
t l converging
i
or diverging wye

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)

Entrance Exit

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)

Abrupt enlargement Sudden contraction

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)

Duct Properties

• Flow resistance, R
• Total pressure loss Δpt at a specific volume flow rate V
pt  R  V 2

• Flow resistance in series: Rs  R1  R2    Rn

• Flow resistance in parallel:

p
1 1 1 1
  
Rp R1 R2 Rn
Total pressure loss and flow resistance of a round duct section
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Flow resistance in series

Flow resistance in parallel

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
 Flow resistance for a Y connection
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Air Duct Design & Sizing

• Optimal
p air duct design
g
• Optimal duct system layout, space available
• S ti f t
Satisfactory system
t balance
b l
• Acceptable sound level
• Optimum energy loss and initial cost
• Install only necessary balancing devices (dampers)
• Fire codes, duct construction & insulation
• Require comprehensive analysis & care for
different transport
p functions
Flow characteristics of a supply duct system
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Air Duct Design & Sizing

• Design velocity
• Constraints: space available, beam depth
• Typical guidelines:
• Main ducts: air flow usually ≤ 15 m/s; air flow noise
must be checked
• With more demanding noise criteria (e.g.
(e g hotels),
hotels) max.
max
air velocity: main duct ≤ 10-12.5 m/s, return main duct
≤ 8 m/s, branch ducts ≤ 6 m/s
• Face velocities for air-handling system components
(Source: ASHRAE Handbook Fundamentals 2001)
Air Duct Design & Sizing

• System balancing
• Air volume flow rate meeting design conditions
• System balancing using dampers only is not
recommended
• Critical path
• Design path of airflow (total flow resistance is
maximum))
• How to reduce the dynamic losses?
Air Duct Design & Sizing

• Reduce dynamic
y losses of the critical path
p
• Maintain optimum air velocity through duct fittings
• Emphasize
E h i reductiond ti off dynamic
d i losses
l nearer to
t
the fan outlet or inlet (high air velocity)
• Proper use of splitter vanes
• Set 2 duct fittings
g as far apart
p as possible
p
• Air duct leakage
• Duct
D lleakage
k classification
l ifi i
• ANSI, SMACNA, ASHRAE standards
Air Duct Design & Sizing

• Fire protection
• Duct material selection
• Vertical ducts (using masonry, concrete or clay)
• When ducts pass through floors & walls
• Use of fire dampers
• Filling the gaps between ducts & bldg structure
• Duct systems for industrial applications
• Any other fire precautions?
Air Duct Design & Sizing

• Design
g procedure
p ((computer-aided
p or manual))
• Verify local codes & material availability
• Preliminary duct layout
• Divide into consecutive duct sections
• Minimise local loss coefficients of duct fittings
• Select duct sizing methods
• Critical total pressure loss of tentative critical path
• Size branch ducts & balance total pressure at junctions
• Adjust supply flow rates according to duct heat gain
• Resize duct sections, recalculate & balance parallel paths
• Ch k sound
Check d level
l l & add dd necessary attenuation
tt ti
Air Duct Design & Sizing

• Duct layout
y
• Symmetric layout is easier to balance
• Smaller main duct & shorter design path
• For VAV systems, duct looping allows feed from
opposite
it direction
di ti
• Optimise transporting capacity (balance points often
f ll the
follow h sun’s
’ position)
ii )
• Result in smaller main duct
• Compare alternative layouts & reduce fittings
• For exposed
p ducts,, appearance
pp & integration
g with
the structure is important
Typical supply duct system with symmetric layout & looping

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)

Air Duct Design & Sizing

• Duct sizing methods

• Equal-friction method with maximum velocity
• Duct friction loss per unit length remains constant
• Most widely used in normal HVAC applications
• Constant-velocity method
• Often for exhaust ventilation system
• Minimum velocity to carry dust is important
• Limit velocity to reduce noise
Air Duct Design & Sizing

• Duct sizing
g methods
• Static regain method
• Normally used with a computer package for high
velocity systems (e.g. in main duct)
• Size air duct so that ↑static pressure nearly offset the
pressure loss of succeeding duct section along main duct
• T method
• Optimising procedure by minimising life-cycle cost
• S
System
t condensing
d i (into
(i t a single
i l imaginary
i i duct)
d t)
• Fan selection (optimum system pressure loss)
• System expansion (back to original duct system)
 Concept of static regain method
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Air Duct Design & Sizing

• Design information required

• Client requirements
• Required supply air condition
• Type of system supplied
• Ambient conditions
• Duct material
• Duct insulation
• Duct system layout
Air Duct Design & Sizing

• Key design inputs

• Design volume flow rate (m3/s)
• Limiting duct pressure loss (Pa/m)
• Limiting flow velocity (m/s)
• Design outputs
• Schematic of ductwork layout & associated plant
• Schedule of duct sizes and lengths,
lengths and fittings
Air Duct Design & Sizing

• Duct system characteristics

• Supply duct, return duct, or exhaust duct systems
with
i h certain
i pressure loss
l in
i branch
b h takeoffs
k ff
• Duct sizing based on LCC & space optimisation
• System balancing through pressure balance of duct paths
• Sound level will be checked & analysed
• Minimise local loss coefficients of duct fittings
• S
Supply
l volume
l flow
fl ratest adjusted
dj t d according
di to t duct
d t
heat gain
 Cost analysis for a duct system
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Air Duct Design & Sizing

• Duct system characteristics

• Supply duct, return duct, or exhaust duct systems in
which
hi h supply
l outlets
l or return grilles
ill either
ih
mounted directly on duct or have very short
connecting duct
• Very small or negligible pressure loss at branch ducts
• System balancing depends mainly on sizes of the
successive main duct sections
 Rectangular
pp y duct with
supply
transversal slots

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)

Air Duct Design & Sizing

• Duct system characteristics

• Industrial exhaust duct systems to transport dust or
other
h particulates
i l
• Require a minimum velocity in all duct sections, such as
12.2 to 20.3 m/s
• Select pproper
p configuration
g of duct fittings
g to provide
p a
better system balance
• Round ducts produce smaller losses & more rigid
• Air velocity must not exceed too much, to avoid energy waste
• Well-sealed joints & seams to reduce air leakage
Other Factors

• Duct liner
• Lined internally on inner surface of duct wall
• Mainly
M i l usedd for
f noise
i attenuation
tt ti & insulation
i l ti
• Fiberglass blanket or boards
• Duct cleaning
• Prevent accumulation of dirt & debris
• Agitation device to loosen the dirt & debris
• Duct vacuum to extract loosened debris
• Sealing of access openings
 Duct breakout noise
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Other Factors

• Pressure and airflow measurements

• Pitot tube
• Two concentric tubes
• Manometers
• U tube or inclined one
• Demonstration
D i off measuring
i instrument
i
 Pitot tube
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
Manometer: U-value

Inclined manometer

(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)

 Pressure measurements in air ducts
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)
M
Measuring
i points
i in i rectangular
l & roundd duct
d transverse
(Source: Wang, S. K., 2001. Handbook of Air Conditioning and Refrigeration)