TM B DCT 001 - Technology Manual of Ducting

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VOLUME : B CHAPTER : DUCTING GROUP
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INDEX
1. OBJECTIVE 3
2. BASIC CONCEPT OF APC EQUIPMENT 3-4
3. DESIGN CRITERIA 5
4. INTRODUCTION 5
5. BASIC CONCEPT OF DUCT WORK 5-8
5.1 CLASSIFICATION
5.2 METHODS TO BE USED
5.3 CIRCULAR DUCT
5.4 RECTANGULAR DUCT
5.5 IMPORTANT NOTES
6. SOME IMPORTANT TERMINOLOGY 8-9
7. VOLUME CALCULATION 9
8. MINIMUM CONVEYING VELOCITIES OF DUST 10
9. DUCT WORK 10 - 11
9.1 REQUIRED CONVEYING VELOCITIES IN DUCT
9.2 WHY WE NEED DUCT VELOCITY
9.3 DUCT SIZING
10. HOODS 11 - 20
10.1 REQUIRED FACE VELOCITIES IN HOOD
10.2 RANGE OF CAPTURE VELOCITIES
10.3 TYPES OF HOODS
10.4 HOODS NOMENCLATURE OF LOCAL EXHAUST
10.5 HOOD TYPES
10.6 EXHAUST HOOD
10.7 TYPES OF EXHAUST HOODS
10.8 DESIGN OF EXHAUST HOODS
10.9 WHY WE NEED SIZING HOOD PROPERLY
10.1.1 HOOD SIZING
10.1.2 HOOD DESIGN FOR SPECIFIC APPLICATIONS
11. BRANCH PIECES 21
11.1 WHY WE NEED SIZING BRANCH PIECE PROPERLY
11.2 PRINCIPLE OF DUCT DESIGN BRANCH ENTRY
11.3 BRANCH PIECE SIZING
12. RECOMMENDED FAN INLET & OUTLET CONNECTIONS 22
13. STACKS 23 - 24
13.1 REQUIRED FAN EXHAUST DUCT HEIGHT
13.2 STACK VELOCITY
13.3 STACK HEIGHT
14. DAMPERS 24 - 25
15. SOME PHOTOS OF INDUSTRIAL INSTALLATIONS 25 - 27
16. GUIDELINE FOR PREPERATION OF DUCTING 28 - 33
16.1 STUDY OF OC
16.2 STUDY OF PLANT/BUILDING AND EQUIPMENTS
16.3 STUDY OF SUCTION POINTS
16.4 DETAILS REQUIRED FOR ANY DE-DUSTING DUCTING LAYOUT
16.5 DESIGN CALCULATION
16.6 FLOW DIAGRAM
DOCUMENT NO REVISION NO PAGE NUMBER

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16.7 PREPARATION OF EQUIPMENT LAYOUT

16.8 PREPARATION OF DUCTING LAYOUT
16.9 PREPERATION OF DUCTING MANUFACTURING DRAWINGS
16.1.1 DO’S
16.1.2 DON’TS
16.1.3 DUCTING LAYOUT CHECK LIST
17. DUCT SUPPORT 33 - 34
18. INSULATION 34
19. DUCT WALL THICKNESS CALCULATION 34 - 35
20. STIFFENER CALCULATION FOR RECTANGULAR DUCT 35 - 37
21. PRESSURE DROP CALCULATION 38 – 47
21.1 PRESSURE BALANCING METHOD
21.2 RELATIVE ADVANTAGES AND DISADVANTAGES OF
THE PRESSURE BALANCING METHOD AND VELOCITY
BALANCING METHOD
21.3 CHOICE OF METHODS
21.4 SYSTEM STATIC PRESSURE
22. WELDING DETAILS & STANDARD NOTES 48
23. SAMPLE DRAWINGS 49 - 59
23.1 FLOW DIAGRAM
23.2 EQUIPMENT LAYOUT
23.3 DUCTING LAYOUT
23.4 MARKING LAYOUT
23.5 ASSMBLY BOM
23.6 CIRCULAR DUCT
23.7 CIRCULAR BEND
23.8 REDUCER
23.9 TRANSITION PIECE OR HOOD
23.9.1 INTERNAL DUCT SUPPORT
24. A CASE STUDY OF SYSTEM EFFICIENCY PROBLEM 60 - 65
FOR IMPROPER DUCTING FABRICATION & ERECTION
AT VISA STEELS LTD., JAJPUR
25. TEN COMMON DUST COLLECTION MISTAKES 67 - 68
26. CONVERSION FACTORS 69 - 70

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1. OBJECTIVE
There are no published standards on duct design. Most of the information
available is in the form of company in-house information, which is generally
evolved over a period of time, based on experience.
We have tried to compile the information available from such sources adding our
own knowledge and experience.
This Manual should help both designer / draftsman in understanding basic
concept in duct design, pressure drop calculation and duct supporting and other
mechanical requirements.
But before start the duct design we require to know the Basic concept of APC
equipment.
2. BASIC CONCEPT OF APC EQUIPMENT

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3. DESIGN CRITERIA
Several design criteria are common to all industrial ventilation systems; use the
ACGIH IV Manual for primary guidance.
ACGIH = American Conference of Governmental Industrial Hygienists.
4. INTRODUCTION
Most control devices are located some distance from the emission sources they
control. This separation may be needed for several reasons. For one thing, there
may not be enough room to install the control device close to the source. Or, the
device may collect emissions from several sources located throughout the facility
and, hence, must be sited at some convenient, equidistant location. Or, it may be
that required utility connections for the control device are only available at some
remote site.
Regardless of the reason, the dust / waste gas stream must be conveyed from
the source to the control device and from there to a stack before it can be
released to the atmosphere.
The type of equipment needed to convey the dust / waste gas are the same for
most kinds of control devices.
These are: (1) hoods, (2) ductwork, (3) stacks, and (4) fans.
Together, these items comprise a ventilation system.
(1) Hood: It is used to capture the emissions at the source;
(2) Ductwork: It is to convey them to the control device;
(3) Stack: To disperse them after they leave the device; and
(4) Fan: To provide the energy for moving them through the control system.
5. BASIC CONCEPT OF DUCTWORK
5.1 Classification: We can classify ductwork as follows:
DUCTWORK
APPLICATION WISE SHAPE WISE

1) De-dusting Ducting 1) Circular Ducting
2) Fume Extraction Ducting 2) Rectangular Ducting

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5.2 Methods to be used

There will be two types of methods for sizing ducting such as:
a) Velocity balancing method. b) Pressure balancing method
We are using Velocity Balancing Method for sizing our ducting.
5.3 Circular Ducting
For most conditions, round duct is recommended for industrial ventilation, air
pollution control, and dust collecting systems. Compared to non-round duct, it
provides for lower friction loss, and its higher structural integrity allows lighter
gauge materials and fewer reinforcing members. Metal thickness required for
round industrial duct varies with classification, static pressure, reinforcement, and
span between supports. Metal thicknesses required for the four classes are
based on design and use experience.
5.4 Rectangular Ducting
Rectangular ducts should only be used when space requirements preclude the
use of round construction. Rectangular ducts should be as nearly square as
possible to minimize resistance.
For circular duct of diameter D, Deq = D
For Rectangular duct A x B, Deq = 2x(AxB) / (A+B)
5.5 Important Notes
 Fixed volume of the gas keep on varying with change in temperature so
for ducting sizing calculation gas flow rate should be considered always in
AM3/Hr
 Normally 18-20M/S velocity is considered for proper designing of ducting
System. If it is less dust will settle in the ducting. If it is more wear of
ducting will take place due to abrasion if we are handling abrasive dust
like clinker also there will be significant increase in the pressure drop.
 When the dust is very abrasive like Clinker/Alumina/Silica, wear of ducting
will take place to cater this thickness of ducting should be selected
properly also suitable lined bend can be provided. Velocity should be
restricted to 16-18 M/S.
 When the dust is very hygroscopic like Lime/Alumina, Duct should be
properly protected from weather there should not be any ingress of water /
moisture all the flange joint should be properly sealed, horizontal duct to
be avoided as far as possible, horizontal ducting shall be provided
wherever possible. Cleaning hatches or Poking holes are necessary to be
given for cleaning. Care shall be taken to operate the system 10º-20ºC
above the DEW point.

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 If the Gas temperature is very high of 200º-250ºC, Ducting should be

insulated well by proper insulating material so that heat transfer to
atmosphere is least and also avoid physical burning of individual by
touching it. Expansion joint shall be provided at adequate location.
 If the dust in the gas stream is COAL, Inert gas purging system shall be
provided throughout the length of the ducting also explosion vent of
adequate size shall be provided to cater sudden increase in pressure
inside ducting. Avoid horizontal ducting as far as possible. Horizontal
ducting is to be cleaned periodically to avoid permanent settling of dust.
 In a cast house were temperature is around 600º - 800ºC, ducting should
be fire brick lined from inside having a skin/Ducting temperature around
60º-80ºC.
 In a process were hot contaminated gases is emitted like Furnace Suction
hood should be located at top of furnace also known as canopy hood
because gases at high temperature will try to rise due to thermal
Buoyancy.
 As far as possible we should avoid flange joint in the ducting system as it
is point of leakage.
 In the ducting system poking hole shall be provided near the bends duct
as settling of material is more likely here. We can provide poking hole at
regular interval in straight duct also if the dust is heavy or hygroscopic and
settling is expected in the straight ducting.
 Hood is provided at every pick up point. Purpose of the hood is to cover
the area of the contaminant gases & to create the low velocity airflow
which will capture the air borne particles only & not the dust being
handled.
 Normally 0.25 – 2.5M/S velocity is considered for proper designing of
hood in de-dusting application which is same as minimum capture velocity
required sucking the contaminant gases in to the hood.
 1½ “ BSP Socket & plug on every hood is provided for measuring Air
Static pressure by means of U tube manometer & velocity pressure by
Pitot tube. Static pressure is used for balancing the system pressure drop.
Velocity pressure is used for calculating the flow rate.
 Damper is provided for balancing the system pressure drop & adjusting
the flow rate by means of throttling.
 In a good ducting system a bend should never followed by another bend
because the dust when moving in the ducting system move with certain
momentum acquired by flowing air stream when there is a direction
change due to bend momentum of the dust particle drops, if immediately it
has to enter another bend the dust can loss all his momentum & settle
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there itself. So to regain the momentum we should keep some length of

straight duct between two bends.
 We should provide flexible connection to arrest the vibration from the
feeder/ screen to the duct.
 We should provide support at both end of Expansion joint.
 In case of small ducts up to 350 diameter, the standard pipes as per
IS:1239 & IS:3589, with suitable thickness can be considered. The
respective pipe ID, shall be checked for the design velocity. If the design
velocity do not matches corresponding pipe ID, the fabricated duct shall
be used.
 Many times it is observed that duct between two equipments is selected
having same size as that of equipment inlet/outlet cross sectional area.
This is incorrect. Inlet/outlet openings of equipments are designed to get
best equipment performance/or to match internal design. The ducts have
to be sized for necessary conveying velocity and minimal pressure drop
and to be connected to the equipment through suitable
reducers/connectors to suit to equipment inlet/outlet sizes.
6. SOME IMPORTANT TERMINOLOGY

Air Pollution: The presence in the atmosphere of gases, fumes, or particulate
matter alone or in combination with each other, in sufficient concentration to
disturb the ecological balance; cause objectionable effects, especially sensory
offenses; cause transient or chronic illnesses; or impair or destroy property.
Static Pressure: It is defined as the pressure in the duct that tends to burst or
collapse the duct or pressure measured perpendicular to the air flow is called as
static pressure. It can be positive or negative.
Velocity Pressure: It is defined as the pressure required to accelerate air from
zero velocity to duct velocity or pressure measured in the direction of the air flow
is called as velocity pressure. It is always positive.
Total Pressure: It is energy content of the air stream or it is algebraic sum of
static pressure & velocity pressure. It can be positive or negative w.r.t
atmospheric pressure. It is maximum at the start & drops as the flow proceeds
down stream to the duct.
Slot Velocity: Air velocity at any point opening in a slot type hood. It is used
primarily as a means of obtaining uniform air distribution across the hood.
Emission: Release of pollutants into the air from a source.
Capture Velocity: The air velocity at any point in front of a hood or at a hood
opening necessary to overcome opposing air currents and to capture the
contaminated air at the point by causing it to flow into the hood.

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Face Velocity: The air velocity at a hood opening.

NM3/Hr: Tempeature, Pressure & Density of the air at this condition are as
follows:
Temperature: 0ºC
Pressure: 1 Atm / (1.013Kg/Cm2)/ (10330 mm of water)/ (760 mm of Hg)/ 1 bar
Density: 1.293 Kg/NM3
Friction Loss: Resistance to air flow through any duct or fitting, given in terms of
static pressure.
7. VOLUME CALCULATION
For frequently used Equipments as per ACGIH Norms
Sl.
Equipment Formula Criterion
No
for Belt speed < 1
1950 m3/Hr x Belt Width in M x Safety Factor
DISCHARGE m/s
END 2785 m3/Hr x Belt Width in M x Safety Factor for Belt speed > 1
m/s
SAME AS DISCHARGE END BUT SAFETY
Belt Conveyor
1 FACTOR IS HEIGHER AND IF Height of
(VS-50-20)
Fall is > 1 m
RECEIPT END to be added IF Width
1700 m3/Hr > 900 mm
to be added IF Width
1200 m3/hr < 900 mm
Magnetic
2 Seperator 2785 m3/Hr x Belt Width in M x Safety Factor
(VS-50-20)
Bucket
3 Elevator Per m2 Casing Cross
(VS-50-01) 1800 m3/Hr x Casing Area x Safety Factor sectional Area
Per M2 of Screen
Vibrating FLAT DECK Area / No increase
4 Screen 920 m3/hr x Screen Area x Safety Factor for Multiple Decks
(VS-99-01) Per M2 of Circular
CYLINDRICAL Cross Sectional Area
1800 m3/Hr x Circular Area x Safety Factor of Screen
Vibratory
5
Feeder 1400 m3/Hr x Width x Safety Factor ** per m of feeder width
Bunkers /
6 Hopper Per M2 of all open
(VS-50-10) 3650 m3/hr x Open Area x Safety Factor Area
** AS PER ACGIH IF WE CONSIDER VIBRATING SCREEN VOLUME, THE VOLUME WILL

BE LESSER. AS PER OUR EXPERIENCE WE CONSIDER ABOVE FOR SAFETY SIDE.

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8. MINIMUM CONVEYING VELOCITIES OF DUST

Type of Dust Vel. in m/s
Vapors, Gases, Smokes, Fumes Any
Fine light dusts, such as Cotton, lint and wood flour (100 mesh and under) 10.2
Dry dusts; Powders, such as fine rubber molding powder, soap dust 12.7
Industrial dusts
Average dusts such as Saw dust, Grinding dust, Coal dust 17.8
Heavy dusts such as Metal turnings, Lead dusts 20.3
Moist dusts and chips, such as Lead dust with chips, Sticky buffing lint, Quick Lime dust 22.9
Note: The velocity for aluminum and magnesium powder shall not be less than
20.3 m/s
9. DUCTWORK
Once the emission stream is captured by either a hood or a direct exhaust
connection, it is conveyed to the control device via ductwork. The term
“ductwork” denotes all of the equipment between the capture device and the
control device. This includes: (1) straight duct; (2) fittings, such as elbows and
tees; (3) flow control devices (e.g., dampers); and (4) duct supports.
9.1 Required Conveying Velocities in Duct

Duct Diameters are based on the consideration of air velocity:
Lime stone, Sand stone, Iron ore and Gypsum laden air: 18 meter/sec
Coal laden air: 18-24 meter/sec
Slag or Clinker laden air: 16 meter/sec (maximum)
Minimum outside diameter of Duct shall be 133mm.
9.2 Why We Need Duct Velocity

Used to size the duct correctly

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9.3 Duct Sizing

Duct sizing is based on following parameters:
a) Gas Air flow
b) Appropriate gas velocity
c) Ease of fabrication & transportation etc. to decide either Circular or
Rectangular shape of ducts.
d) Space available to accommodate the duct.
The relationship between velocity and air flow is defined by the equation:
Q = VA
Where, Q = Air flow in m3/hr.
V = Velocity in m/sec
A = Cross sectional area in m2.
A = Q/V
Q = 8000 m3/hr, target V = 18 m/sec
Duct size = ?
For Circular Duct:
A = Q/V = (8000/3600) m3/sec / 18 m/sec
A = 0.1235 m2
A = π/4xd2 where, d = diameter of duct in m.
d2 = A/(π/4) = 0.1235/0.7854 = 0.1572 m2
d = √0.1572 m = 0.396m = 396mm ≈ 390mm
For Rectangular Duct:
A = Q/V = (8000/3600) m3/sec / 18 m/sec
A = 0.1235 m2
A=axb where, a = length of duct in m & b = width of duct in m.
If b= 300mm then,
a = 0.1235/0.3 m = 0.412m = 412mm ≈ 410mm
Please note Aspect Ratio b/a (the ratio of the width to the length) should be
greater than 0.5.
10. HOODS
Of the several components of an air pollution control system, the capture device
is the most important. This should be self-evident, for if emissions are not
efficiently captured at the source they cannot be conveyed to and removed by a
control device. There are two general categories of capture devices: (1) direct
exhaust connections (DEC) and (2) Local Exhaust hoods. As the name implies, a
DEC is a section of duct (typically an elbow) into which the emissions directly
flow. These connections often are used when the emission source is itself a duct
or vent, such as a process vent in a chemical manufacturing plant or petroleum
refinery.

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Local exhaust systems are designed to capture and remove process emissions
prior to their escape into the workplace environment. The local exhaust hood is
the point of entry into the exhaust system and is defined herein to include all
suction openings regardless of their physical configuration. The primary function
of the hood is to create an air flow field which will effectively capture the
contaminant and transport it into the hood. Figure in next page provides
nomenclature associated with local exhaust hoods.
10.1 Required Face Velocities in Hood

Preferable Face velocities of Hood ≤ 1.5 m/sec and it goes up-to 2.0 m/sec. But
in critical area we sometimes take 2.5 m/sec.
10.2 Range of Capture Velocities

Condition of Dispersion Capture
Examples
of Contaminant Velocity in m/s
Released with practically Evaporation from tanks, degreasing,
0.25 – 0.5
no velocity into quiet air. etc.
Released at low velocity Spray booths; intermittent container
into moderately still air. filling; low speed conveyor transfers; 0.5 – 1.0
welding; plating; pickling
Active generation into Spray painting in shallow booths; barrel
1.0 – 2.5
zone of rapid air motion. filling; conveyor loading; crushers
Released at high initial
velocity into zone of very Grinding; abrasive blasting, tumbling 2.5 – 10.0
rapid air motion.
10.3 Types of Hoods

Although the names of certain hoods vary, depending on which ventilation source
one consults, there is general agreement as to how they are classified. There are
four types of hoods (1) enclosures, (2) booths, (3) captor (capture) hoods, and
(4) receptor (receiving) hoods. Enclosures are of two types: (1) those that are
completely closed to the outside environment and (2) those that have openings
for material input/output. The first type is only used when handling radioactive
materials, which must be handled by remote manipulators. They are also dust
and gas-tight. These kinds of enclosures are rarely used in air pollution control.
The second type, have applications in several areas, such as the control of
emissions from electric arc furnaces and from screening and bin filling
operations. They are equipped with small wall openings (natural draft openings—
”NDOs”) that allow for material to be moved in or out and for ventilation.

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10.4 Hood Nomenclature Local Exhaust

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10.5 Hood Types
10.6 Exhaust Hood

The exhaust hood is the point where dust-filled air enters a dust collection
system. Its importance in a dust collection system cannot be overestimated. It
must capture dust emissions efficiently to prevent or reduce worker exposure to
dusts. The exhaust hood-Encloses the dust producing operation Captures dust
particulates and guides dust-laden air efficiently.

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10.7 Types of Exhaust Hoods

The three general classes of exhaust hoods are-
 Local hoods
Local Hood
 Side, downdraft and canopy hoods
Side Hood Downdraft Hood Canopy Hood
 Booths or enclosures
Booth Hood
Enclosure Hood
Local hoods are relatively small structures. They are normally located close to
the point of dust generation and capture the dust before it escapes. Local hoods
are generally efficient and typically used for processes such as abrasive grinding
and woodworking.
Side, downdraft, and canopy hoods are larger versions of local hoods. They
also rely on the concept of preventing dust emissions beyond the control zone.
They are typically used for plating tank exhausts, foundry shakeouts, melting
furnaces, etc. These hoods are generally less efficient than local hoods.
Booth and enclosure hoods isolate the dust generating process from the
workplace and maintain an inward flow of air through all openings to prevent the
escape of dust. These hoods are the most popular type in minerals processing
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operations because they are very efficient at minimum exhaust volumes. They
are typically used for areas such as vibrating or rotating screens, belt conveyors,
bucket elevators, and storage bins.
10.8 Design of Exhaust Hoods

The design of an exhaust hood requires sufficient knowledge of the process or
operation so that the most effective hood or enclosure (one requiring minimum
exhaust volumes with desired collection efficiency) can be installed.
The successful design of an exhaust hood depends on-
 Rate of airflow through the hood
 Location of the hood
 Shape of the hood
Of the above three factors, the rate of airflow through the exhaust hood (that is,
the exhaust volume rate) is the most important factor for all types of hoods. For
local, side, downdraft and canopy hoods, the location is equally important
because the rate of airflow is based on the relative distance between the hood
and the source. The shape of the exhaust hood is another design consideration.
If the hood shape is not selected properly, considerable static pressure losses
may result.
10.9 Why We Need Sizing Hood Properly

Used to Capture the Suction efficiently
10.1.1 Hood Sizing

The relationship between velocity and air flow is defined by the equation: Q = VA
Where, Q = Air flow in m3/hr.
V = Velocity in m/sec
A = Cross sectional area in m2.
A = Q/V
Q = 8000 m3/hr, V = 1.5 m/sec
A = Q/V = (8000/3600) m3/sec / 1.5 m/sec
A = 1.4815 m2 
A=LxW where, L = Length of opening in m and W = Width of opening in m.
Consider Length & Width to suit available space in that specific equipment to
match the derived area.
Height ‘H’ (minimum) = [L or W (which will be greater) – D] / 2
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10.1.2 HOOD DESIGN FOR SPECIFIC APPLICATIONS

A. INDUCTION FURNACE
C ru c ib le
R oom

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B. CAST HOUSE FOR BLAST FURNACE
CAST HOUSE

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11. BRANCH PIECE

11.1 Why We Need Sizing Branch Piece Properly
Used to Convey the Dust properly
11.2 Principle of Duct Design Branch Entry
Branches should enter at gradual expansions and at an angle of 30º or less

(preferred) to 45º if necessary. Expansion should be 15º maximum.
11.3 Branch Piece Sizing
The relationship between Exit air flow and Entry air flow is defined by the
equation:
Q3 = Q1 + Q2
Where, Q1 = Entry Air flow in m3/hr.
Q2 = Entry Air flow in m3/hr.
Q3 = Exit Air flow in m3/hr.
D = Exit diameter in m.
d = Entry diameter in m.
d1 = Entry diameter in m.
Preferable, L = 2xD
S = 2.5xD
PROPER DUCT SIZE: Size the duct to maintain the selected or higher transport velocity
i.e. diameter D / d / d1 will be sized taking selected or higher transport velocity.
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12. RECOMMENDED FAN INLET & OUTLET CONNECTIONS

FAN INLET CONNECTIONS
FAN OUTLET CONNECTIONS

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13. STACKS
Short stacks are installed after control devices to disperse the exhaust gases
above ground level and surrounding buildings. As opposed to “tall” stacks, which
can be up to 1,000 feet high, short stacks typically are no taller than 120 feet.
Certain packaged control devices come equipped with short (“stub”) stacks, with
heights ranging from 30 to 50 feet. But if such a stack is neither provided nor
adequate, the facility must erect a separate stack to serve one or more devices.
Essentially, this stack is a vertical duct erected on a foundation and supported in
some manner. For structural stability, the diameter of the stack bottom is slightly
larger than the top diameter, which typically ranges from 1 to 7 feet.
13.1 Required Fan Exhaust Duct Height

Fan Exhaust Duct of Nuisance Bag Filter shall be 2 meter higher than the roof of
the Building in which it is installed.
13.2 Stack velocity

1. A good stack velocity is 15 m/s because it:
 Prevents downwash for winds up to 10m/s. Higher wind speeds have
significant dilution effects.
 Increases effective stack height.
 Allows selection of a smaller centrifugal exhaust fan to provide a more
stable operation point on the fan curve (see Chapter 6).
 Provides conveying velocity if there is dust in the exhaust or there is a
failure of the air cleaning device.
2. High exit velocity is a poor substitute for stack height. For example, a flush
stack requires a velocity over 40m/s to penetrate the recirculation cavity
boundary.
3. The terminal velocity of rain is about 10m/s. A stack velocity above 13m/s will
prevent rain from entering the stack when the fan is operating.
4. Locate stacks on the highest roof of the building when possible. If not possible,
a much higher stack is required to extend beyond the wake of the high bay,
penthouse, or other obstacle.
5. The best stack shape is a straight cylinder. If a drain is required, a vertical
stack head is preferred. In addition, the fan should be provided with a drain hole
and the duct should be slightly sloped toward the fan.
6. Rain caps should not be used. The rain cap directs the air toward the roof,
increases the possibility of reentry, and causes exposures to maintenance
personnel on the roof. Moreover, rain caps are not effective. A field study with a
properly installed standard rain cap showed poor performance. A 12-inch
diameter stack passed 16% of all rain and as high as 45% during individual
storms.
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13.3 Stack heights

Ventilation designers should provide the tallest possible exhaust stacks so that
effluent exit velocity can be minimized in order to save energy. The concept of
"available dilution" helps determine the amount of contamination one can expect
from an exhaust stack configuration of a given exit velocity and height. The
minimum stack height above the roof should be at least 10 ft (3.0 m) as per ANSI
Z9.5. However, the stack height, after correction for downwash, must also
protrude above any flow recirculation cavity or obstructions, such as those
typically caused by variation of roof levels, architectural fences, penthouses, and
roof-mounted equipment.
Exhaust Stack Designs
14. DAMPERS
Damper is a device used to throttle or isolate the flow of

gasses in a duct line. Dampers are the mechanism used in
a flow line to either isolate or control the flow of gasses in
the line. So basically dampers are classified as isolating
damper (ON/OFF damper) or control dampers (Regulating
damper).
Every Suction point shall be equipped with a Manual Damper of very simple
design. These Dampers will be used in case of maintenance work during
operation (complete shut off) and / or for Suction Pressure regulation and
Pressure drop balancing in the complete duct work. Electrical / Pneumatic
actuated Dampers to be provided wherever grouping / batching is to be done.
Different types of dampers used regularly by us and its use are given below:

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a. Butterfly Damper
Application:- Basically used for isolation (ON/OFF) applications. It can also be
used as a control damper when sizes are limited to around 800mm flap diameter,
for larger diameters multi vane type dampers are preferred.
b. Guillotine Damper
Application:- Basically used for isolation (ON/OFF) applications. It is preferred in
lines where there are no or negligible dust load and temperatures are high. Main
advantage is being the sealing efficiency as claimed by manufacturers as 99.9%.
It can be used in both circular and rectangular ducts.
c. Multi louver Damper (MLPB)
Application:- Basically used for control duty applications. It is preferred in
rectangular duct lines but can be provided in circular ducts also. Controlling
range is better than single flap butterfly dampers. For fans with inlet box Multi
louver dampers are used for flow / pressure control.
15. SOME PHOTOS OF INDUSTRIAL INSTALLATIONS

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16. GUIDELINE FOR PREPARATION OF DUCTING

Ducting is the most important part of any system in the industry. Any equipment,
process, system is meaningless, if it is not closed or joined with the suitable
ducting. Preferably in the engineering organization like ours, i.e. Thermax Ltd., it
is the most important prerequisite to get the orders. Our core products are flange
to flange Bag filter, ESP, Cyclone etc. But most of our customers are interested
to place the order on us, only when we agree to provide the design and
engineering of the ducting layout & manufacturing drawings of ducting
components, required for their system. In most of the cases ducting is in
customer’s scope of supply. This means, though financially ducting is not
profitable for us, and takes lot of our time, from our core activities, it plays an
important role to get us the orders.
It is very clear that, when we desire to achieve more and more high targets, we
should not neglect the ducting which is also likely to be increased with our core
products. There is a big problem of employee turnover. Also our ducting vendors
are always overloaded, that they are unable to cater our targets. Hence the need
to complete the ducting related OC’s more effectively and efficiently is the
challenging task for us.
Although we provide ducting for all the products mentioned above, here we will
take the most critical type of ducting for our study. Ducting for dust extraction
system (D E system) can be a good example for our study.
16.1 Study of OC
When we get any OC with ducting, from proposals, we have to study the OC.
Here we will consider the study only from the ducting point of view.
1. Scope of supply of ducting – Thermax scope
2. Duct MOC, - IS:2062 Gr.-A, 5 mm Thickness, etc.
3. Surface preparation & painting / scope of painting
4. Insulation: applicable / not applicable
5. Is the plant existing or green field?
6. Plant building/equipments soft copies are available?
7. Site Visit is required or not.
8. Budget for engineering of ducting.
9. Material to be conveyed–Coal, Lime, Cement, Sponge iron etc.
10. If Coal then necessity of any explosion vent.
11. Type of ducting – normal / self cleaning type.
12. Moisture content in the gas / dust.
13. Gas volume for Bag-filter.
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14. Gas volume and St. Pressure for fan are predefined or to be
worked out.
15. Excel Sheet of Gas volume for Suction points is available with
proposals?
16. Various equipments / conveyors involved in the system.
17. Belt width of belt conveyors.
18. Maximum spaces available at conveyor discharge/reception for
mounting of suction hoods.
16.2 Study of Plant / building and equipments

Once we get / prepare the soft copies of the plant / building, we have to study the
customer drawings to define the location of all the suction points in plan,
elevation & end view.
16.3 Study of suction points

Here study all the suction points w.r.t. discharge/reception of the respective belt /
shuttle conveyors, crushers, screens etc. For clarity, use proposal requirements /
table with volumes at each suction point. Preferably mark all the hoods in three
views, on the hard copy of plant / building. Provide tag Nos. like H1, H2, H3 ---
etc. for all the hoods in the system. In case of additional system, if any, in the
same plant, mark the hoods of both the system with different colours, for clear
understanding.
16.4 Details required for any de-dusting ducting layout drgs

1. Plant layout - elevation and plan.
2. Individual building drawings clearly identifying floor levels and member
sizes, cut outs etc.
3. Plan and elevation)- True scale
4. Equipment layout drawings - both plan and elevation
5. Flow diagram indicating the various dust collection points, flow at each
point and line sizes. (Either by Consultant or Thermax).
6. Thermax equipment location clearly identified in the plant layout.
7. Stack OR chimney required to be clearly identified. Stack / Chimney
height to be clearly identified.
8. Equipment drawings on which dedusting hoods to be located.
9. Conveyor drawings to clearly indicate the details of skirt width height etc.
10. Crusher / Vibrating screen drawings to clearly identify the space for
tapping point / hood.
11. Tapping points more than a distance of 50m. from bagfilter should not be
considered in system.
All drawings required in Autocad and to be true scale drawings.

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16.5 Design calculations

For the basic system design, the ACGIH (American conference of governmental
industrial hygienists) norms shall be followed. The same is described in early
pages of this Manual.
16.6 Flow Diagram

After the basic system design is frozen the Flow diagram shall be prepared. The
Flow diagram is the line diagram with Tag Nos. for all the suction hoods,
dampers, ID Fan, expansion joints.
Flow diagram shall be prepared based on the physical locations of hoods
equipments. If required show the small sketches of the conveyor reception /
discharge, screens, crushers, etc. This will improve the understanding of the
users, to the greater extent.
16.7 Preparation of Equipment layout

After the basic system design and duct diameters are frozen, we have to confirm
the location of our equipment layout, based on suitable space in plant, as per
customer’s requirement. This mainly includes bag filter inlet ducting, bag filter,
bag filter outlet plenum, I D Fan & stack / self supported chimney.
Bag filter outlet duct is treated as clean air duct. For bag filter duct & chimney
sizing, velocity @ 16 m/sec may be taken. For exhaust stack, the velocity @ 15
m/sec may be taken. Here the main duct supports within & outside the plant to be
shown. Typical details of supports required from conveyor gallery, building
structure/platform are shown along with the load data, for customer’s reference.
This equipment layout is submitted for customer’s approval.
16.8 Preparation of ducting layout

After the approval of Equipment layout we have to prepare ducting layout.
Preparation of better ducting layout is an art. This can also be developed with the
practice of work, with understanding. This includes the duct routing along with
hoods / dampers / equipments / duct supports & structural building.
Following points shall be considered for the best results:
 Provide clear space for the equipments
 Provide clear space for the operational movements of equipments
 Provide clear space for the passages / access gangways
 Provide clear space for the headroom (at least 2.0 clearance for movement)
 Provide clear space for maintenance of equipments
 Provide damper/valve at operational level. If not provide access for operation
/ maintenance.
 In case, hood size does not fit on equipment, relocate the inspection door &
mark clearly with the note, that inspection door may be relocated for mounting
of hood.
 Provide hoses / expansion joints, if required for the equipments like screen,
crushers etc.
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 Provide notes to clear hood size, in case of movement for handles of

equipments like slide gate etc.
 Provide flange joints, cleaning hatches as required.
 Provide branches for ducting with 30 deg inclination.
 Provide bends for ducting with min. radius of 1.5d
 Provide flange joints for ducting as required.
 Provide sampling ports 100 NB 2 Nos. at 90. for exhaust duct with platform /
access.
 Provide sampling ports, before inlet of bag filter as applicable.
 Provide duct supports locations with load data.
 Provide standard general notes for customer reference
This ducting layout is to be submitted for customer’s approval.
16.9 Preparation of ducting manufacturing drawings
After the approval of ducting layout firstly, we prepare Ducting Marking Layout,
which will prepare taking Ducting Layout drawing and mark individual component
of ducting i.e Hood, Damper,Straight Duct, Bend………………………..etc.
Then we have to prepare ducting manufacturing drawings.
This includes the following ducting components:
Hood (Mkd. as H-1, H-2……) / Damper (Mkd. as D-1, D-2……) / Straight duct
(Mkd. as SD-1, SD-2……) / Straight pipe (Mkd. as SP-1, SP-2……) / Bend (Mkd.
as BE-1, BE-2……) / Reducer (Mkd. as RD-1, RD-2……) / Branch (Mkd. as BP-
1, BP-2……) / Flange with Non asbestos gasket with hardware (Mkd. as FL-1,
FL-2……) / Sampling ports / Internal Duct support (Mkd. as SUP-01-01, SUP-
02-01……) / Tower support (trestle) (Mkd. as DS-1, DS-2……) / Welding & fit up
drawing for ducting and Assembly BOM for all above.
For all the above mentioned ducting components various table drawings with
developmental details & excel BOM’s shall be used. Those give the
developmental drawing with weight of the particular component.
Also, in some cases we use Self cleaning elbow for self cleanng duct which we
will design as per below sketches.
SELF CLEANING ELBOW

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16.1.1 Do’s
 Always provide the shortest route for the duct.
 Always provide minimum bends in the duct route.
 Always provide minimum bend radius as 1.5D
 Always provide min 30º entry or exit to the branch.
 Always provide gradual enlargement or reduction for the smooth gas flow in
the duct.
 Always think for operational levels of dampers.
 Provide canopy for exhaust duct, as applicable.
 Always provide minimum 6D to 8D straight length upstream & minimum 4D
straight lengths down stream the sampling ports, in the exhaust duct.
 Always check for the feasibility of standard pipes to be used in place of
fabricated ducts.
 Always check for electrical / cable tray fouling with duct locations, if
information for the same is available.
 Always provide meaningful titles for plan / sections / levels
i.e. Plan @ 0.000 m Lvl, Section-AA, View from-B, etc.
16.1.2 Don’ts
 Do not provide bend radius less than 1.0D, if required due to space
constraint.
 Do not block the passages with ducts / duct supports.
 Do not allow sudden enlargement or reduction for the duct.
 Do not forget to provide sampling ports with accessibility for exhaust stack.
 Do not provide any ducting / structure nearby ID fan, which will be a
constraint for the removal of the fan impeller.
 Do not decide the orientation I D fan unless it is confirmed by customer.
16.1.3 Ducting Layout Check List

1. Check any special requirement of name plate by Consultant / Customer.
2. Check that System No., Client & Consultant Name, Project Name and Site
location are indicated in Title Block.
3. Check overall dimensions and whether North direction indicated or not.
4. Check Suction Volume detail with Working Logic.
5. Check clear space for the equipments.
6. Check clear space for the operational movements of equipments.
7. Check clear space for the passages / access gangways.
8. Check clear space for the headroom (at least 2.0 clearance for movement)
9. Check damper/valve at operational level. If not provide access for operation /
maintenance.
10. In case, hood size does not fit on equipment, relocate the inspection door &
mark clearly with the note, that inspection door may be relocated for mounting
of hood.

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11. Check for provision hoses/expansion joints, if required for the equipments like
screen, crushers, silo top etc.
12. Provide notes to clear hood size, in case of movement for handles of
equipments like slide gate etc.
13. All elevation & change in direction should be marked w.r.t. building/existing
equipment.
14. Check fouling of ducts with equipment & building.
15. Check that ducting is not rotated in two planes simultaneously, as far as
possible.
16. Provide flange joints, cleaning hatches as required.
17. All branches should enter the main ducting not to exceed 45° with 30°
preferred inclination.
18. Provide bends for ducting with min. radius of 1.5d.
19. Provide 100 NB 2 Nos. at 90º apart ports at both Inlet & Outlet of Bagfilter.
20. Provide 100 NB 2 Nos. at 90º apart sampling ports at least 8 stack or duct
diameters downstream and 2 diameters upstream from any flow disturbance
for exhaust duct, with platform/access.
21. Provide duct supports with Load Data (Load Data in revised drawing).
22. Provide adequate clearance between ducts and ceilings walls and floors for
installation and maintenance.
23. Provide standard general notes for customer reference.
24. Check the pressure loss in the ducting matches with fan selection with
minimum 15% margin.
17. DUCT SUPPORT

The last component to consider is the ductwork support system. However, it is far
from being the least important. Provide duct supports of sufficient capacity to
carry the weight of the system plus the weight of the duct half filled with material
and with no load placed on connecting equipment. As the Sheet Metal and Air
Conditioning Contractors’ National Association (SMACNA) HVAC Duct
Construction Standards manual states, “The selection of a hanging system
should not be taken lightly, since it involves not only a significant portion of the
erection labor, but also because [the erection of] an inadequate hanging system
can be disastrous.” As a rule, a support should be provided for every 8 to 10 feet
of duct run. Ductwork can be suspended from a ceiling or other overhead
structure via hangers or supported from below by girders, pillars, or other
supports.
A suspension arrangement typically consists of an upper attachment, a hanger,
and a lower attachment. The upper attachment ties the hanger to the ceiling, etc.
This can be a concrete insert, an eye bolt, or a fastener such as a rivet or nailed
pin. The hanger is generally a strap of galvanized steel, round steel rod, or wire
that is anchored to the ceiling by the upper attachment. The type of hanger used

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will be dictated by the duct diameter, which is proportional to its weight per lineal
foot.
For instance, wire hangers are only recommended for duct diameters up to 10
inches. For larger diameters (up to 36 inches), straps or rods should be used.
Typically, a strap hanger is run from the upper attachment, wrapped around the
duct, and secured by a fastener (the lower attachment). A rod hanger also
extends down from the ceiling. Unlike strap hangers, they are fastened to the
duct via a band or bands that are wrapped around the circumference. Duct of
diameters greater than 3 feet should be supported with two hangers, one on
either side of the duct, and be fastened to two 1-12 circumferential bands, one
atop and one below the duct. Moreover, supports for larger ductwork should also
allow for both axial and longitudinal expansion and contraction, to accommodate
thermal stresses.
18. INSULATION
Insulation can be either installed on the outer surface of ductwork or the ductwork
itself can be fabricated with built-in insulation. In the first case, the amount of
insulation required will depend on several heat transfer variables, such as: the
temperature, velocity, composition, and other properties of the waste gas; the
ambient temperature; the duct diameter, wall thickness, and thermal conductivity;
and the desired surface (“skin”) temperature.
Insulation Thickness Calculation as per IS-7413 (1981)
L = (K / F) x [(T h – Te) / (T e – Tm)]
Where, L = Insulation thickness in cm
K = Conductivity value in mW/cm ºC = 0.4187 for Mineral Wool
having average density of 100-200kg/m3
F = Surface coefficient in mW/cm2 ºC = 0.57 for Al cladding
Th = Gas design Temperature in ºC
Te = Expected Skin Temperature in ºC
Tm = Maximum Ambient Temperature in ºC
19. DUCT WALL THICKNESS FOR GAS PRESSURE

Gas Pressure = p kg/cm2
As per theory of thin cylinder
f = pd/2t where,
f = Allowable stress in Kg/cm2
d = duct diameter in cm
t = duct thickness in cm
Therefore, t = pd/2f
So, Wall Thickness of Duct = t (calculated) in mm + Tce (Corrosion allowance) in
mm
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For Allowable Stress values refer Table-1 & Corrosion Allowance refers Table-2.
Table-1 Allowable Stress Value for IS:2062
Temperature in ºC Allowable Stress in Kg/cm2
Up to 50 1400
Up to 100 1400
Up to 150 1360
Up to 200 1230
Up to 250 980
Up to 300 900
Up to 350 810
Table-2 Corrosion Allowance Tce

Corrosion Allowance, in
Degree of Corrosion Expected
mm
Design Life
External, Tce 10 yrs 20 yrs
1) None (that is, paint, insulation, cladding or
NIL NIL
similar protection available always)
2) Above average (that is, unprotected) 1.5 3.0
20. STIFFENER CALCULATION FOR RECTANGULAR DUCT

The stiffener span is calculated using Stress criterion (Eqn.1), Static Plate
deflection (Eqn.2), Dynamic plate deflection (Eqn.3) and Vibration criterion
(Eqn.4) methods.
Stress Criterion:
S=2t √(Ys/2P)+2” (1)
Static Plate deflection:

S = 4√(29.304Et4/P)+2” (2)
Dynamic plate deflection criterion:

S = 4√[{Δ384(t3/12)E}/(1-2)P´]+ 2’’ (3)
Plate vibration criterion:

S =√[(893t√E)/f]+ 2” (4)
Where,
S= Stiffener spacing
t= Plate Thickness
Ys= Yield Strength
P= Design Pressure
E= Young’s Modulus
= Poisson’s Ratio
Δ= Plate Deflection
p´= Expected Pressure Pulsation
f= Natural Frequency

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Among the values from these four criteria, the minimum value is identified as the
maximum stiffener spacing. Then for each stiffener size, the span (depth or
width) to be stiffened can be calculated using stress criterion (Eqn.5), Stiffener
deflection (Eqn.6) and Stiffener vibration methods (Eqn.7).
Stiffener stress criterion
L ≤ √(8MB/PS) + S2/3 (5)
Stiffener deflection criterion

L ≤ 3√(384EIK / 5x46xPS) (6)
Stiffener vibration criterion

L ≤ √[1834{√(EI/A)}/f] (7)
Where
M= combined section modulus of (plate + stiffener)
B = allowable bending stress
L = Maximum allowable stiffener length
I = combined moment of inertia of (plate + stiffener)
K = length factor, k=1 for uniform stiffener length
k=2 for multiple length
A = combined cross sectional area of (plate + stiffener)
A table has been prepared which gives size of the stiffener for given span of the
panel (both channel and I sections) for various duct plate thickness.
For each individual panel of the duct shell, for different channel / beam size, the
stiffener size is selected from the stiffener table.
Taking a duct made of 4mm plate for analysis, stiffener spacing and stiffener
sizes are calculated for a maximum transport length of duct as 2500mm.
Applying Eqn. 1,2,3 and 4 for Stress criterion, Static Plate deflection, Dynamic
plate deflection and Vibration criterion for the specified conditions the values
obtained are 1962mm, 1093.6mm, 1195mm and 698mm. The minimum value is
found to be maximum stiffener spacing which is 698mm for the case considered
for analysis.

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a) If uniform stiffener spacing is considered,

Stiffeners = length/Max_sp = round(3.5) = 4
Stiffener Spacing (S1) = 2500/4 = 625mm
Number of stiffeners (n) = 3
b) If non-uniform stiffener spacing is considered,

Max. Stiffener spacing (N1) = 630mm
N2 = 620mm
Number of stiffeners (n) = 3
Table 2 is prepared for number of stiffeners required to stiffen the duct span
keeping the duct length as 2500mm. The data are found for uniform and non-
uniform stiffener spacing.
Table 2: Stiffener requirement and spacing for various duct plate thickness

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21. PRESSURE DROP CALCULATION

VP (VELOCITY PRESSURE) = (½ x ρ x V2) / 9.81 mmWg
Where, V= Velocity in m/sec
ρ= Density of Air at certain temperature in Kg/m3
Frictional Pressure Drop in Straight Duct in mmWg = Hf x L x VP
Where, Hf = Friction Factor = a x (Vb / Qc)
Q = Volumetric Flow rate in m3/sec.
L = Duct length in meter.
Duct Material a b c
Galvanized 0.0307 0.533 0.612
Black iron, Aluminum, PVC, Stainless steel 0.0425 0.465 0.602
Flexible (fabric covered wires) 0.0311 0.604 0.639

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TABLE: A HOOD ENTRY LOSS

θ ROUND RECTANGULAR
15 0.15VP 0.25VP
30 0.08VP 0.16VP
45 0.06VP 0.15VP
60 0.08VP 0.17VP
90 0.15VP 0.25VP
120 0.26VP 0.35VP
150 0.40VP 0.48VP
180 0.50VP 0.50VP
TABLE: B BRANCH ENTRY LOSS

θ LOSS IN BRANCH
10 0.06VP
15 0.09VP
20 0.12VP
25 0.15VP
30 0.18VP
35 0.21VP
40 0.25VP
45 0.28VP
50 0.32VP
60 0.44VP
90 1.00VP

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TABLE: C 90º ROUND ELBOW LOSS
R/D STAMPED 5 - PIECE 4 - PIECE 3 - PIECE

0.5 0.71VP - - 0.90VP
0.75 0.33VP 0.46VP 0.50VP 0.54VP
1.0 0.22VP 0.33VP 0.37VP 0.42VP
1.5 0.15VP 0.24VP 0.27VP 0.34VP
2.0 0.13VP 0.19VP 0.24VP 0.33VP
2.5 0.12VP 0.17VP 0.23VP 0.33VP

60º elbow = 2/3 loss

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TABLE: D SQUARE & RECTANGULAR ELBOW LOSS
ASPECT RATIO W/D

R/D
0.25 0.5 1.0 2.0 3.0 4.0
0.5 1.36VP 1.21VP 1.05VP 0.95VP 0.84VP 0.79VP
1.0 0.45VP 0.28VP 0.21VP 0.21VP 0.20VP 0.19VP
1.5 0.28VP 0.18VP 0.13VP 0.13VP 0.12VP 0.12VP
2.0 0.24VP 0.15VP 0.11VP 0.11VP 0.10VP 0.10VP
3.0 0.24VP 0.15VP 0.11VP 0.11VP 0.10VP 0.10VP
60º elbow = 2/3 loss / 45º elbow = 1/2 loss / 30º elbow = 1/3 loss
ACCELERATION FACTOR : 1.0VP

DAMPER LOSS : 0.2VP
TABLE: E
PROPERTIES OF AIR
KINEMATIC VISCOCITY
ºC ρ (DENSITY IN KG/M3)
(M3/SEC)X106
0 1.293 13.28
10 1.247 14.16
20 1.205 15.06
30 1.165 16.00
40 1.128 16.96
50 1.093 17.95
60 1.060 18.97
70 1.029 20.02
80 1.000 21.09
90 0.972 22.10
100 0.946 23.13
120 0.898 25.45
140 0.854 27.80
160 0.815 30.09
180 0.779 32.49
200 0.746 34.85
250 0.674 40.61
300 0.615 48.33
350 0.566 55.46
400 0.524 63.09
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21.1 PRESSURE BALANCING METHOD

The Pressure loss of each duct segment is calculated from an exhaust hood to
the junction with the next branch based on hood design data, fittings and total
duct length. At each junction SP for each parallel path of air flow must be the
same. Where the ratio of the higher to the lower SP is greater than 1.2, redesign
of the branch with the lower pressure loss should be considered. This may
include a change of duct size, selection of different fittings and/or modifications to
the hood design. Where static pressures of parallel paths are unequal, balance
can be obtained by increasing the air flow through the run with the lower
resistance. This change in flow rate is calculated by nothing that pressure losses
vary with the velocity pressure and therefore as the square of the flow rate, so:
Qcorrected = Qdesign√(SPgov/SPduct)
Where the governing” SP is the desired SP at the junction point and the “duct”
SP is that calculated for the duct segment being designed.

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21.2 RELATIVE ADVANTAGES AND DISADVANTAGES OF THE

PRESSURE BALANCING METHOD AND VELOCITY BALANCING
METHOD
PRESSURE BALANCING METHOD VELOCITY BALANCING METHOD

1. Flow rates cannot be changed easily by workers or at 1. Flow rates may be changed relatively easily. Such
the whim of the operator. changes are desirable where pickup of unnecessary
quantities of material may affect the process.
2. There is little degree of flexibility for future equipment 2. Depending on the Fan and motor selected, there is
changes or additions. The duct is ‘tailor made’ for the somewhat greater flexibility for future changes or
job. addition s.
3. The choice of exhaust flow rates for a new operation 3. Correcting improperly estimated exhaust flow rates is
may be incorrect. In such cases, some duct revision relatively easy within certain ranges.
may be necessary.
4. No unusual erosion or accumulation problems will 4. Partially closed dampers may cause erosion thereby
occur. changing resistance or causing particulate
accumulation.
5. Duct will not plug if velocities are chosen correctly. 5. Duct may plug if damper insertion depth has been
adjusted improperly.
6. Total flow rate may be greater than design due to 6. Balance may be achieved with design flow rate,
higher air requirements. however the net energy required may be greater than
for the Pressure balancing method.
7. The system must be installed exactly as designed, 7. Moderate variation in duct layout is possible.
with all obstructions cleared and length of runs
accurately determined.

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21.3 CHOICE OF METHODS

The Pressure Balancing Method is normally selected where highly toxic materials
are controlled to safeguard against tampering with dampers and consequently
subjecting personnel to potentially excessive exposures. This method is
mandatory where explosives, radioactive dusts and biological are exhausted
because the possibility of accumulations in the system caused by a damper
obstruction eliminated.
21.4 SYSTEM STATIC PRESSURE

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22.
ELEVATION
ELEVATION
TM-B-DCT-001
DOCUMENT NO
ELEVATION PLAN
PH-1 - PIPE 50NB UPTO 300NB DUCT PH-1 - PIPE 50NB UPTO 300NB DUCT
PH-4 - PIPE 200 NB ABOVE Ø1000 mm PH-4 - PIPE 200 NB ABOVE Ø1000 mm
TECHNOLOGY MANUAL
CHAPTER : DUCTING
0
MANUFACTURING
REVISION NO
GROUP
AUX - BF
-SD- -SD- -SD-
JSG SK PGD A3 20
04.04.2013 04.04.2013 04.04.2013 FOR FABRICATION & ERECTION OF DUCTING
ENGINEERING
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WELDING DETAILS & STD. NOTES FOR DUCTING
1 1 E100412009 0
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23.
VOLUME : B
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23.1
SAMPLE DRAWINGS
TECHNOLOGY MANUAL
CHAPTER : DUCTING
     

 
    
 
      

       

      
0
      

       

      
FLOW DIAGRAM
      


       

      
 
REVISION NO
GROUP
AUX - BF
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23.2 EQUIPMENT LAYOUT
DCC-2
HAMMER MILL
FLUX PRIMARY GRINDING
CL
DCC-2
FLUX PRIMARY GRINDING

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TECHNOLOGY MANUAL
CHAPTER : DUCTING
 
0
 
 
     

   
     
 
       

         

REVISION NO
       
       

         

 
DUCTING LAYOUT (SHHET-1)
     

      

        

      
   
GROUP
AUX - BF
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23.3 DUCTING LAYOUT (SHEET-2)

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23.4 MARKING LAYOUT

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23.5 ASSEMBLY BOM

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23.6 CIRCULAR DUCT

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23.7 CIRCULAR BEND

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23.8 REDUCER

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23.9 TRANSITIONPIECE OR HOOD

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BILL OF MATERIAL OF SUP-01-01 FOR EACH SET BILL OF MATERIAL OF SUP-02-01 FOR EACH SET BILL OF MATERIAL OF SUP-03-01 FOR EACH SET
TECHNOLOGY MANUAL
BILL OF MATERIAL OF SUP-01-02 FOR EACH SET

BILL OF MATERIAL OF SUP-02-02 FOR EACH SET BILL OF MATERIAL OF SUP-03-02 FOR EACH SET
CHAPTER : DUCTING
0
REVISION NO
23.1.1 INTERNAL DUCT SUPPORT
GROUP
AUX - BF
BAGFILTER
ENGINEERING
JSG SK PGD A1 NTS

2 6.02.2013 26.02 .2013 2 6.02.2013 (TYPICAL INTERNAL DUCT SUPPORT)
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24. A CASE STUDY OF SYSTEM EFFICIENCY PROBLEM FOR

IMPROPER DUCTING FABRICATION & ERECTION AT VISA STEELS LTD.
AT INTERMEDIATE BIN AREA – (DE-2)

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AT PRODUCT TRANSFER HOUSE JH-1 AREA – (DE-2)

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AT COOLER DISCHARGE I & II AREA – (DE-2)
SUCTION POINT LEAKAGES FOR DE-2 AREA
MATERIAL OPEN TO ATMOSPHERE AND NO APPROACH AT DE-2 BAGFILTER AREA

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LOCATION OF BAGFILTER AT DE-2 SYSTEM
ID FAN FOR DE-2 SYSTEM

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Conclusion
It is cleared from the above report, the System can not run properly and dust choking
also occurred if the system will run with so much problems and deviations from
actual design at various areas.
Solution to the Problems

 We recommend the ducting at Bag filter inlet for DE-1 be modified as per
drawing for the system to perform as expected.
 Proper rectification to be done as per drawing from the deviations indicated in
the photograph with proper connections.
 Proper pressure balancing to be done for all the suction hoods.
 Proper sealing to be ensured at all the hoods / suction points.
 Ensure provision on skirt boards on all the conveyors.
 The velocities / flow in the hood / ducts to be as per design values.
 Maintain to run the both systems at 2 nos. ID Fan running condition.
 Do as many as possible cleaning arrangements as per the given drawings in
the critical area with accessible platforms as per site requirement.
 Proper maintenance of the System is also required for healthy operation for
the system.
 Dust in the working area found very sticky, which was very much surprising.
At first view dust gives oily affect & seems to be carbon content in dust are
very much high in the dust which makes it excess sticky. VSL to provide the
dust samples for further investigations & accordingly TL will suggest
additional system or process modification if required.
 Proper house keeping should be maintained to keep the system healthy. This
will increase the moral of the working peoples in the same area.
 Please Check the all ID Fans by our ID Fan Vendor to ensure that the ID Fan
can be working with the given Technical Specification.

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25. TEN COMMON DUST COLLECTION MISTAKES

1. Attitude
2. Buying from an unreliable vendor
3. Not enough Suction Volume
4. Noise
5. The wrong collector
6. Poor ducting
7. Poor zoning
8. Bad filtration
9. Leaky Rotary Airlock Valves
10. Economical, price-foolish
1: Attitude
The tree from which many dust collection problems stem isn’t mechanical, it’s the
attitude behind the system’s purchase. Customers purchase systems without having
analyzed the plant’s requirements.
2: Buying from an unreliable vendor

Dust collection is often viewed as a purchase to be made and gotten over with as quickly
as possible; some buyers get stuck with lemons. Unfortunately, there are a handful of
companies out there that have a sales force that isn’t as knowledgeable about dust
collection as they should be.
3: Not enough Suction Volume

When it comes to total Suction Volume, or the system’s overall air capacity, it is better to
err on the side of caution and spend little extra money on the larger system.
4: Noise
Noise is something that needs to be considered inside and outside of the plant, which
gets a lot of calls from customers saying that their neighbors are complaining of the
noise.
5: The wrong collector

While dust collection is naturally associated with a certain level of noise, a lot of noise
can mean that you have a larger problem on your hands. Too much noise could be a
sign that you have purchased the wrong collector altogether.
6: Poor ducting
What a lot of people forget is that the duct system is as critical as the dust collector itself.
If your duct system is wrong, you are only going to get 60 percent, maybe less, of what
the system is capable of collecting.
Generally, bad duct design is the result of two things: machinery additions and the use of
improper materials.
a) First: Changes in your machinery layout or machinery additions need to be
accompanied by the same modifications to your ducting systems. Often the original duct
design is fine, but then machines are added or moved around and the original design no

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longer applies. When this happens, bringing in the original planner or another expert to
make a few modifications to the ducts will often cure the problem.
b) Second: Professionals should handle the system’s ducting.
A lot of people just don’t know that there are right and wrong pipes to use. They think
that a pipe is just a pipe and they end up using heating ducts with 90 degree
intersections, short elbows or the corrugated black-plastic pipe used for gutters. While
improper ducting is a large problem, there are bigger mistakes that can be made. If you
do your own duct work and make a big mistake.
7: Poor zoning
Dust collection has to start at the dust’s source. You need to pick up the dust as you are
making it, and nine times out of 10, people piecemeal things together and then the dust
is escaping the hood, or, even worse, it isn’t getting collected at all.
8: Bad filtration
Air-to-cloth ratio, that is, the total air volume divided by the square meter of cloth, should
not exceed 1 to 1.5.
9: Leaky Rotary Airlock Valves

One of the most common of these breaks has been the introduction of a negative
system in which the blower is put on the clean-air side of the collector. However, when
this is done, it is important to make sure that the flex-tip blades in the airlocks are
changed on a regular basis, sometimes as much as twice a year.
10: Economical, price-foolish

Most of the mistakes I see are because people were economical and price-foolish when
buying their dust collection system. They think that it is no big deal because in their mind
dust collection is just something they have to do, and, in the end, it ends up costing them
more than it should.

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25. CONVERSION FACTORS

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TM B DCT 001 - Technology Manual of Ducting

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THERMAX ENVIRO

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16.7 PREPARATION OF EQUIPMENT LAYOUT

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2. BASIC CONCEPT OF APC EQUIPMENT

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APPLICATION WISE SHAPE WISE

2) Fume Extraction Ducting 2) Rectangular Ducting

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5.2 Methods to be used

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 If the Gas temperature is very high of 200º-250ºC, Ducting should be

there itself. So to regain the momentum we should keep some length of

6. SOME IMPORTANT TERMINOLOGY

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Face Velocity: The air velocity at a hood opening.

** AS PER ACGIH IF WE CONSIDER VIBRATING SCREEN VOLUME, THE VOLUME WILL

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8. MINIMUM CONVEYING VELOCITIES OF DUST

9.1 Required Conveying Velocities in Duct

9.2 Why We Need Duct Velocity

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9.3 Duct Sizing

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10.1 Required Face Velocities in Hood

10.2 Range of Capture Velocities

10.3 Types of Hoods

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10.4 Hood Nomenclature Local Exhaust

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10.5 Hood Types

10.6 Exhaust Hood

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10.7 Types of Exhaust Hoods

 Side, downdraft and canopy hoods

Side Hood Downdraft Hood Canopy Hood

10.8 Design of Exhaust Hoods

10.9 Why We Need Sizing Hood Properly

10.1.1 Hood Sizing

10.1.2 HOOD DESIGN FOR SPECIFIC APPLICATIONS

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B. CAST HOUSE FOR BLAST FURNACE

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11. BRANCH PIECE

11.2 Principle of Duct Design Branch Entry

Branches should enter at gradual expansions and at an angle of 30º or less

12. RECOMMENDED FAN INLET & OUTLET CONNECTIONS

FAN OUTLET CONNECTIONS

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13.1 Required Fan Exhaust Duct Height

13.2 Stack velocity

13.3 Stack heights

Exhaust Stack Designs

Damper is a device used to throttle or isolate the flow of

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15. SOME PHOTOS OF INDUSTRIAL INSTALLATIONS

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