DuctConstructionandDesign

ImpactsOnEnergyUse

FactorsthatImpactEnergyuse

Whattopay
attentiontofor
savingenergy
inductsystems

Layout

Fanenergyuse

Airtightness

Fanenergyuse,ventilationlosses

Insulation

Conductionlosses

Lowpressure
drops

Fanenergyuse

Fans

Fanefficiencyandsystemeffect

Controls

Therightamountofair,totherightplace,
attherighttemperature,andhumidity,and
attherighttime

Coils

Fouling

Heatrecovery

Fanenergyuse,convectiveandconductionlosses

FactorsthatImpactEnergyuse

Whattopay
attentiontofor
savingenergy
inductsystems

Layout

Fanenergyuse

Airtightness

Fanenergyuse,ventilationlosses

Insulation

Conductionlosses

Lowpressure
drops

Fanenergyuse

Fans

Fanefficiencyandsystemeffect

Controls

Therightamountofair,totherightplace,
attherighttemperature,andhumidity,and
attherighttime

Coils

Fouling

Heatrecovery

Fanenergyuse,convectiveandconductionlosses

LoweringthePressureDrop
DuctDesignBasics
Duct
Fittings

DuctDesignBasics
Oneoftenmisunderstoodideaisthecritical
legorcriticalpath.
Allotherpathsareoverpressurizedbydesign
Unlessallpathsarethesame(greatbutnotlikely)

Symmetryisideal moreonthislater
Thepointisthatfittingsusedinthenon
criticalpathswillnotimpacttheenergy
requiredforthesystemunless,byusingthe
fitting,thecriticalpathchanges.

DuctDesignBasics

Fittingsandlayoutchangeswill
notimpactthefanunlessthey
impactthecriticalpath

DuctDesignBasics

Changingafittingorlayoutcanresultin
changingthecriticalpath

Duct
Therealityisthatpressuredropsarefairly
insignificantinthestraightsectionsofduct
Howevertherearesomegoodguidelinesto
follow
Therearesomemisconceptionsaswell

Duct
Roundductshouldbethebasisofdesign
Systemsshouldbedesignedinroundandthen
convertedwherenecessary

Fornonroundductkeeptheaspectratioas
closeto1:1aspossible
Thisimpactscostandpressuredrops(energy)

Misconceptions
Foragivenfootprintroundducthasless
resistance(pressuredrop)thansquareduct.
Isthistrue?Letsdoanexamplecalculation
1600CFM,compare12inchroundto12x12
rectangular

Misconceptions
Firstconverttherectangulartotheequivalent
round(SMACNADuctDesignorASHRAE
handbook)
0.625
1.3(ab)
De
0.250
( a b)
12x12rectangular=13.1inchround
Pleasenotethatequivalentareaisnotacorrect
waytoconvert

Misconceptions
Velocityfortheroundduct
V=Q/A=1600/.785(ft3/min,ft2)=2037fpm

Velocityforsquareduct
V=Q/A=1600/1(ft3/min,ft2)=1600fpm

Misconceptions
Pressuredropfor100feetof12inchround@
1600CFM~0.5
Pressuredropfor100feetof12x12inch
rectangular@1600CFM~0.3in.w.g.
Thatsalmost40%lessfriction

Misconceptions
Whataboutflatoval?
1.55 AR 0.625
De
P 0.250

Oval24x12in.~17.7in.round
Rectangular24x12in.~18.3in.round

Misconceptions
VelocityintheOval@1600CFM
V=Q/A=1600/1.79=896FPM

VelocityinRectangular
V=Q/A=1600/2=800FPM

Pressuredropfor100feet
Oval~0.066
Rect~0.057
14%lessfrictionbutactuallyinsignificant

Fittings
Fittingsarewherethemajorityofpressure
lossesoccur.
Selectingtheproperfittingsintheproper
placescanhaveasignificantimpactonenergy
use,andevencostimpact
Rememberourdiscussiononthecriticalpath?

Fittings
Tovaneornottovane
Oftenspecificationsrequiretheuseofturning
vanesinallmiteredelbows
Thisisokbutonelbowsatlowvelocity,or
notonthecriticalpaththiscouldbewasting
moneywithoutaddingbenefit
Specificationsshouldindicatethenumberof
splittervanesrequired(ifrequired)theseare
notturningvanes.

PressureLoss
Toevaluatethepressurelost(used)asair
movesthroughafittingyoushouldfirst
determinethevelocitypressureVP
V
VP

4005

VP (in.w.g.)whichisasquarefunctionofV
V(fpm)

ElbowComparison

ExampleScenario
Asdesignedtheplansindicatethata24x12
radiusedelbow(r/w=1.5)beused.Becauseof
fieldconditionsthatradiusedelbowwillnot
fit.Thecontractorisfacedwithfindingan
acceptablealternativethatfits
Thedesignerwantstoknowwhattheimpact
ofchangingtheelbowhasonthesystem

ExampleScenario
Itisfairlycommonforcontractorstosimply
findanelbowthatfits.Becauseofjob
scheduletheyareoftenreluctanttosendan
RFIaboutthesekindsofsituations.
Manytimesspecificationsarewrittentoforce
aparticulartypeofelbowtobeused.

FittingComparison
Velocity(fpm)

2000

4000

P (in. w.g.)

P (in. w.g.)

0.2

0.05

0.20

squarethroatradheel

1.38

0.34

1.38

miterednovanes

1.27

0.32

1.27

miteredvanes(single@3.25)

0.33

0.08

0.33

radiusedthroatheel,r/w=1.0

0.25

0.06

0.25

miteredvanes(single@1.5)

0.11

0.03

0.11

Elbow
radiusedthroatheel,r/w=1.5

LowVelocity
Velocity(fpm)

800

1000

1200

P (in. w.g.)

P (in. w.g.)

P (in. w.g.)

Elbow

radiusedthroatheel,r/w=1.5

0.2

0.01

0.01

0.02

squarethroatradheel

1.38

0.06

0.09

0.12

miterednovanes

1.27

0.05

0.08

0.11

miteredvanes(single@3.25)

0.33

0.01

0.02

0.03

radiusedthroatheel,r/w=1.0

0.25

0.01

0.02

0.02

miteredvanes(single@1.5)

0.11

0.00

0.01

0.01

Layout
Ductlayouthasanimpactontheenergyuse
ofasystem.
Routingofductsinthemostdirectway
Reducesthenumberoffittings(losses)
Reducesthesurfaceareawhichreducesleakage,heat
loss/gain

Symmetry
Reducesoverpressurization

Layout

Canbehardtobalance
theserunsespeciallyif
theyhavealowerflow
rate(overpressurized).
Mayhaveissueswith
noiseaswell.
Highflow(atthisend)
requiresahigh
pressure,largerfan

Layout
Itisbesttohavethefanascentrallylocatedas
possible,orasclosetothehighestairflow
requirementsaspossible.
Sometimesthisisnotpossiblebecauseof
noiseconcernsfromtheequipment,orsimply
thephysicallayoutofthebuilding

Layout

Thisapproachisbetterbecauseit
canreduce/eliminateover
pressurization,andismucheasier
tobalance

Layout

Muchtoughertobalance
Overpressurized

Layout
Physicalsymmetryisnotrequired,youwant
pressuresymmetry.
Havingphysicalsymmetrymakesiteasierto
havepressuresymmetry.
Ifsymmetryisimpossiblethentrytoplacethe
fanclosesttothehighestflowareas

Layout

Trickyspot

SystemEffect
Fieldmeasurementsoffanperformanceoften
indicatelowervaluesthanmanufacture's
ratings.
Arethemanufacturerslying?No.

Threemaincausestolowerfieldvalues
Improperoutletconditions
Nonuniforminletflow
Swirlatthefaninlet

SystemEffect
OutletConditions
Fansforductedsystems,testedtoAMCA210
orASHRAE51,haveoutletductinplace
For100%recoveryuse100%effectivelength

SystemEffect
EffectiveLength
Dependsonvelocity
IfV<=2500fpm

Ao
Le
4.3

IfV>2500fpm

Vo Ao
Le
10,600

SystemEffect
Using60x30inchduct
@30,000CFM
V=2400fpm
Le=10ft.

@50,000CFM
V=4000fpm
Le=16ft.

Using60x50inchduct
@30,000CFM
V=1440fpm
Le=12.7ft.

@50,000CFM
V=2400fpm
Le=13ft.

SystemEffect
Nonuniforminletflow
Majorimpactonfanperformance
Createsanewfancurve

Useinletduct3to8diameters
Dependsonvelocitybutlosseswithoutanyinlet
ductcanadd3.5inchesofpressureloss

SystemEffect
Inletconditions
Abruptinletsactuallyreducetheeffectiveinlet
areabecauseofvenacontractaeffect

SystemEffect
Ifductisntusedtryusingabellmouthor
othersmoothinlet

Idealusesa
smoothinlet
withstraight
sectionofduct

Agoodoptionat
leastprovidesa
smooth
transitioninto
thefan

SystemEffect
Inletboxesarenotideal
butwillreducesystem
effect

Avoid

SystemEffect
Swirl
Inthedirectionofthe
impellerreducesthe
pressure/volumecurve
Oppositethedirectionof
theimpelleractually
increasesthe
pressure/volumecurve
slightlybutgreatly
increasesthepower
consumed

SystemEffect
Toaddressswirlyoucanincreasetheinlet
ductlength,orusevanestocorrectthespin

SystemEffect
Thebestwaytoeliminateorreducesystemeffect
istoprovidespace.Thebettertheinletand
outletconditionsthebetterthefanwillperform.
Evenprovidingductlengthsof25%oftheideal
lengthcanresultin80%gains,50%lengthsshow
upto90%gains
Leaveroomforexpansion,asequipment
becomesmoreefficientittypicallyincreasesin
size

SystemEffect
Adequatespacenot
provided
Lessthanidealinletand
outletconditions
Detaileddiscussionon
Systemeffectcanbe
foundinChapter6of
SMACNAsDuctDesign
Guide

AirTightness/Leakage
DuctLeakage
AccessoryLeakage
EquipmentLeakage

AirTightness/Leakage
DuctLeakage Asthetermshouldimplyis
theleakageofairfromtheduct
AccessoryLeakage Leakageofairfrom
accessories(dampers,accessdoors)
EquipmentLeakage Leakageofairfrom
equipment(AHU,VAV)
SystemLeakageisthecombinationofthe
above

AirTightness/Leakage
Costforairleaks Itisdifficulttoputanexact
costonleakagebecauseitdependsonenergy
costs,wheretheleakoccurs,environmental
conditions,evenaltitude.Itissafetosaythat
leakagedoesnotprovideabenefitandshould
bereducedasappropriatefortheapplication

AirTightness/Leakage
Avoidarbitrary%todesignaspassfailforduct
tests.Itisperfectlyacceptabletodesignwith
a%ofleakage,butthisshouldbeconverted
toaleakageclassforductfieldtests.
Usingaleakageclassprovidesawayto
determinepass/failforportionsofductandat
differentpressures

AirTightness/Leakage
Ifyouendupwithleakageclassesbelow3you
arenotaskingforgoodductyouareasking
forhighperformanceductwhichwilllikely
haveacostimpact.
Contractorsnotawareofthisrequirementare
likelytohavedifficultypassingaleakagetest
withtheselowerleakagerates
Makesuretoprovideallowancefor
accessoriesiftheyareincludedinthetest

Misconceptions
Leakagetestsprovidetheactualleakagerate
underoperatingconditions
Nottrue,traditionaltestswouldtypicallyprovide
ratesthatarehigherthanactualleakageunder
operatingconditionsbecausetheleakageis
measuredatahigherpressurethanoperating
pressure.

Misconceptions
Valuesforlowleakagedampersshould
providebetterperformanceforleakagetests
Thisdependsonwhatkindofleakageisbeing
referenced
Mostdamperleakageratesrefertotheleakage
acrosstheblade(s)whenthedamperisclosed
Thesevaluesdonotrepresentsleeveleakage
whichistheleakageofairfrominsidethesystem
tooutsidethesystem

Recommendations
RequirethatallductbesealedtoSealClassA
Becarefulnottocreateapass/failsolowthat
meetingitwouldrequirevoidinglistingsor
warranties leakageclassisbestforduct
Testsomeportionoftheduct
10 20 100

Focusoncriticalareas
Testearlyintheprocess

Insulation
Mostcodesrequiresomeoftheductworkto
beinsulated.
Insulationreducestheeffectsofheatgain/loss
astheductmovesconditionedair.
Internallinerscanprovidethermalresistance
Becarefulaboutthroughmetal

Consultthemanufacturersdatafor
performance,makesuretouseinstalled
values

Insulation
75of24roundduct@6,500CFM
V=2070fpm
Desiredoutlettemp120F
Airtempwhereductrunislocated65
Thetemprequiredatthestartoftheduct123F
Theheatlossis26,000Btu/hour
7,643watts(76 100wattlightbulbs)

Insulation
75of24roundduct@6,500CFM
withR6(2inchesofinsulation)
V=2070fpm
Desiredoutlettemp120F
Airtempwhereductrunislocated65
Thetemprequiredatthestartoftheduct121F
Theheatlossis5,800Btu/hour
1,700 watts(17 100wattlightbulbs)
78%reduction inheatloss

Insulation
Remembertoaccountfortheweightof
insulationwhenspecifyingductconstruction
1in.w.g.=5.2lbs./ft2

Ductlinerprovidesthermalbenefit,main
purposeissoundattenuation
Becarefulofthroughmetal(condensation)

Summary
Provideproperinletandoutletconditionsfor
thefan Spaceinthemechanicalroom
Useaductlayoutthatisefficient(direct)with
asfewfittingsaspossible
Fittingchoicesareimportantinthecritical
path.Otherpathsarenotsocritical
SpecifysealclassAforductsandfittings
Insulate

Tools
Leakageapp
www.smacna.org/dalt
Free

DuctDatabase
SMACNADuctDesignManual
ASHRAE~$160
AppStore($9.99)

Resources
AIRWAYS EfficientairductsystemsinEurope
ASHRAEHandbook2009Chapter21,DFD
AMCAPublication201,203
Eurovent2/21996
SMACNAHVACSystemsDuctDesign
SMACNAHVACAirDuctLeakageTestManual

THANKYOU

Questions?