4 DUCT DESIGN 4.1 Introduction The aim in the previous chapter is to direct the conditioned air in an efficient manner within a given space. The aim here is to deliver the right amount of conditioned air to the space so that the diffusers can do their job. This can be accomplished through proper design of air.supply and return ducts. Proper duct design means that the duct runs must be the shortest possible, the design contains the least possible fittings, and the duct design adheres to the maximum available pressure drop. The most persisting constraint the designer has to cope with is the building structural constraint. Duct systems fall under two general classifications, namely: * Low velocity duct systems. * High velocity duct systems. Figure 4.1 lists the recommended velocity and pressure drop ranges for each system. The low velocity duct systems will generally have pressure drop of less than 0.15 inch-H,O per 100 ft of straight duct run (1.23 Pa/m), while the high velocity duct systems can go up to about 0.7 inch-HO per 100 ft of straight duct run (5.7 Pa/m). FJ-100Ar lowest 001 oof 200 Gag 02 o204 ooo8 Jehan 300000) MY oS Sp | giana ‘sees x. \ i “| sono FF" AY KE 2000 Wie ANN wg See re eee Figure 4.1 Suggested Velocity and Friction Rate Design Limits FJ-1014.2 Low-Velocity Duct System Design The velocity duct systems apply to residential and light commercial buildings. There are two duct design methods for the low-velocity duct systems, namely, the Equal-Friction Method and the Balanced-Capacity Method, with the equal friction method being the most widely used in practice due to its ease of application. 4,.2-a Equal-Friction Method The main objective of this method is to make the pressure drop per unit length the same for each duct run. This can hardly be accomplished in real life due to the fact that usually a duct system will contain long and short runs, which will dictate the use of dampers to make possible pressure equivalency. The steps for applying this method proceed according to the following: 1 The available pressure for the duct system must be known before hand. This is usually supplied in the manufacturer's catalog data of the HVAC equipment. The listed pressure developed by the fan of the cooling unit (in the case of a packaged unit) less the pressure drop for the diffuser (usually will not exceed 0.05), air filters, and the heating/cooling coils will constitute the available pressure drop for the entire duct system (supply and return). This pressure drop is divided in the ratio of 2:1 supply to return. 2 Identify the longest run in the duct system. After making a sketch drawing of the proposed duct run on the plans of the building, it is possible to identify the longest duct run 3. Compute the equivalent length for this run Le. The term equivalent length refers to a straight run equivalent for a real duct run which might contain elbows, tees, and all other types of fittings. The total equivalent length is constituted from the straight run portion of the duct run plus the equivalent length for all the fittings in the duct run. Figure 4.2 contains a sample of the equivalent lengths for several types of fittings; reference 1 contains a very comprehensive list. FJ-102‘minimum 511.8) (18) 50. (1.8) anas »®D Te 1083) 30:(9) 50118) sus) 5t8) Figure 4-2 Equivalent Lengths of Common Duct Fittings in Feet with Meters in Parentheses. FI-1034. Select the appropriate velocities for the run and branches, Table 4.1 gives the recommended and the maximum velocities for the main duct run, branches and risers. For a deluxe design with optimum quietness, the recommended velocities should be chosen. This usually translates into slightly larger sizes duct runs. If you're short on cash you may select the maximum velocities bearing in mind that there will be slight tolerance in the noise and the air speed criteria, Table 4-1 Recommended and Maximum Duct Velocities for Low Velocity Systems Recommended Velocities, Fpm School, Designation Residences Theaters Industrial Public Buildings Buildings Outdoor Air Intakes 500 500 500 Filters 250 300. 350. Heating Coils 450 _500 600 | Cooling Coils 450 500 600 Air Washers 500 500 500 Fan Outlets 1000 - 1600 1300-2000 _| 1600 - 2400 Main Ducts 700 - 900 1000 - 1300] 1200-1800 | Branch Ducts 600 600 — 900 800 — 1000 Branch Risers 500 600 - 700 800 Maximum Velocities, Fpm Outdoor Air Intakes 800 900. 1200 Filters 300 350 350 | Heating Coils 500 600 700 Cooling Coils 450 500 600 Air Washers 500 500 500 | Fan Outlets 1700 1500 - 2200 _| 1700 — 2800 Main Ducts 800 - 1200 1100 - 1600] 1300-2200 Branch Ducts 700 - 1000 800-1300 | 1000 — 1800 Branch Risers 650 - 800 800 - 1200 1000 - 1600 FJ-104Compute the design pressure drop per unit length for the duct run. The design pressure drop AP, = 100(AP paugy/d (inch-H,O per 100 ft; Pa/m). Use the AP, to size the entire supply duct, section by section. With the aide of Figures 4.3-a, b, c and d, the APq can be used in conjunction with the volume flow rate (cfm), or air velocity through each section, to size the entire duct section by section. Check that the pressure drop and the velocity constraints are adhered to. A case study is presented here to further demonstrate the use of the equal friction method. CASE STUDY 4.1 Size the duct run shown in Figure 4.4 if the available pressure is 0.094 inch-H20. {}100 fim b oft 120 cfm Figure 4-4 Duct System Layout FJ-105003 006 01 oar oor 0 gon 02 e204 oson1 2 2 « Sees, Bells] & Se Oe SES oe RSIS S LH aaa ' hee soo bE of g 8 8 8 3888 8 \31 . SAS 1 & LAT ee 003 0.08 01 Figure 4-3a Lost Head Due to Friction of Galvanized Stee! Ducts. FJ-106Air towel eae Oo: 008 02 0304 06087 003 0.05 01 Friction tos, om. 30 ne 100 ts Figure 4-3b Lost Head Due to Friction of Galvanized Steel Ducts (Higher Volume Flow rates) FJ-1070102 0304 oso! 152 34 6 a1 1520 3040 60 90100 os cP os os os os 0s oa on os os 02 oz ous oss a0 a0 % 000 0s E ons aoe E 005 os 2 om o.0s 00s Joos aoe oor cos aos 2.010 oo 0.008 o008 0.008 ooos tT I 01 02 0304 ofa! 1s2 34 6 81 % 20 2040 cO0;KO Friction loss, Pa per m Figure 4-3c Lost Head Due to Friction of Galvanized Steel Ducts (SI Units). FI-108too Of 92 0304 06081 152 34 6 9% 5 20 2040 60 soKY, oo 80 80 © ee Pelebbete[ Sak So SL S15 oo 30 uy 30 40 40 20 e 30 20 20 5 s ee ° ge . 3° S en ‘ 3 3 z 2 1s is 0 to os os os heat ofsiere = oF 02 030% O6081 52 34 6 BW 20 3040 6000K0 Friction toss, Pa per m Figure 4-3d Lost Head Due to Friction of Galvanized Steel Ducts ST Units and Higher Volume Flow Rates). FJ-109Solution to Case Study 1 Compute the equivalent length L, for each section to determine the longest run. The equivalent length from the plenum to end of section 1, Lig is, L, oi = Lplenum + straight run = 35+20 =55 ft. Lo. Lplenum + Ly + st run of 90° divergence + La Lgq = 35 +2045 412= 72 ft. = Lg tst run of 45° divergence + 2(45° elbow+ es) =72+5+2(5)+31= 118 ft. co = Leg.y + 90° divergence +L, = 55 +50= 105 ft. cor t 45° y-div + 45° elbow + L,=72 +35 +5 + 15= 127 ft. The longest run is therefore section 0-5 with L_, ,= 127 ft. 2. Compute the design pressure AP, . AP, = 100(0.094/127) = 0.074 inch-H,O per 100 ft. 3. Use AP, to size the entire duct with the aide of Figure 43. The results are portrayed in the table below. yore? Section # | Le(i) | Q(efm) ] Diameter AP/Le* AP required Gin) in-H,0/100° a Oe i 35 300 10 0.053, 0.029) 2 17 220 9 0.05 0.0085 3 46 100 7 0.043, 0.02 4 60 80 6 0.058 0.053 3 55 120 7 0.058 0.032, * AP/L¢ is obtained from table 4.3 since only whole sizes are selected. FI-110** AP =(AP/L,)(L,/100) Checking the total pressure drop for each section: AP, , = 0.029 + 0.053 = 0.082 inch-H20 AP, ,, = 0.029 + 0.0085 + 0.02 = 0.0575 inch-Hy0 AP 55 = 0.029 + 0.0085 + 0.032 = 0.0695 inch-H2O 125 Note that all pressures are well below the available pressure. Also note that the duct sizes are given in diameter of circular ducts of which the rectangular equivalencies are given in Table 4.4. 4.2-b Balanced Capacity Method This method attempts to balance the pressure in the entire duct system despite its title which hints at balance of the volume flow rate. The steps to utilizing this method are: 1. Use the equal friction method to size the main, or the longest run. 2. Equate the pressure loss of each of the other branches adjacent to the design branch and use this pressure drop to size these branches. 3. Follow the procedure in step 2 until all branches are sized. 4. Check your design for velocity and pressure drop constraint adherence. CASE STUDY 4.2 Design the duct layout in Case Study 4.1 using the Balanced Capacity Method. 1. From the solution of Case Study 4.1, the longest run is 1-2-5. And A P, is 0.032 inch-H,O. FIL2. Equating the pressure drop APs to the adjacent branch AP3 and using the resulting design pressure drop to size branch 3, 6s3 AP, = AP, = 0.032 inch-H,O; L,=46 ft. — <* the resulting design pressure drop for run # 3 is: AP, , = 0.032(100)/46 = 0.07 inch-H0 per 100 ft. using this pressure drop in Figure 4.3, the D, = 6.4" and V,= 470 fpm .0085 + 0.032 0.0405 inch-H,O next, equate the pressure drop AP, = AP,+ AP, the resulting design pressure drop for run # 4 is: AP, , = 0.0405(100)/60 = 0.068 inch-H0 per 100 ft. using this pressure drop in Figure 4.3, the D, = 5.9" and V,= 430 fpm The table below shows the result for the entire duct. Section # | Le (i) | Q(cm) | Diameter Velocity AP required (in) fémin in-H0** 1 35 300 10 540 0.029 2 17 220 9 500 0.0085 3 46 100 64 470 0.032 4 60, 80 59 430 0.032. 3 35 120 7 450 0.032 Checking the total pressure drop for each section: AP, = 0.029 + 0.0085 + 0.032 = 0.0695 inch-H,O AP , = 0.029 + 0.032 = 0.061 inch-H,O APos = 0.029 + 0.0085 + 0.032 = 0.0695 inch-H,O It can be seen that the pressure drop in all the sections is well below the available pressure. Also there is more uniformity in the pressure drop through the various runs. 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