Duct Design

AIR
DUCT
DESIGN
1
INSPIRING CREATIVE AND INNOVATIVE MINDS Mohd Kamal Ariffin/2011
Air Duct Design
TOTAL, STATIC AND VELOCITY

PRESSURES
Static pressure is the pressure that is exerted by a liquid or gas,

such as water or air. Specifically, it is the pressure measured
when the liquid or gas is still, or at rest
Velocity pressure is the kinetic energy of a unit of air flow in an
air stream. Velocity pressure is a function of both air velocity
and density
2
Air Duct Design

PRESSURES
Lets begin with the steady flow energy equation for flow through a pipe
or duct :
⎛V2 ⎞
dh + d ⎜ ⎟ + gdz = dq − dw
⎜ 2 ⎟
⎝ ⎠
W = 0 and heat transfer is negligible, the enthalpy change in a reversible
adiabatic process is given by
1
dh = υdp = dp
ρ
Then,
1 ⎛V 2 ⎞
dp + d ⎜ ⎟ + gdz = 0
ρ ⎜ 2 ⎟
⎝ ⎠
Integrating, then
p V2
+ + gdz = cons tan t ⇒ Bernoulli' s equation
ρ 2
3
Air Duct Design

PRESSURES
Rewritten, then
ρV 2
p+ + ρgz = cons tan t
2
p – static pressure (SP) or ps
ρV2/2 – velocity pressure (VP), pv
ρgz – pressure due to the datum head, pz
Then we can write
pS + pV + pZ = pT = constant
Neglecting the pZ, then pS + pV = pT = constant

If the velocity pressure is measured in mm H2O and velocity in m/s and ρ = 1.2
kg/m3, then
2 2
1.2V 2 ⎛ V ⎞ ⎛ V ⎞
pv ( 9.81 ) = ⇒ pv = ⎜ ⎟ mm H2O = ⎜ ⎟ Pa
2 ⎝ 4.04 ⎠ ⎝1.29 ⎠
Note : 1 mm H2O = 9.81 Pa 4
Air Duct Design
STATIC PRESSURE REGAIN, SPR
Static pressure increases in the direction of flow if the velocity decreases.

This caused by the conversion of velocity energy to static energy, called `static
regain’.
Considering the duct as in the figure, then
2 2
⎛ C ⎞ ⎛C ⎞
pS1 − pS 2 = pV 1 − pV 2 = ⎜ 1 ⎟ − ⎜ 2 ⎟ C1 , pS1 C2 , pS 2
⎝ 1.29 ⎠ ⎝ 1.29 ⎠
Because there is always some friction loss, the actual static regain is never as
high as in the equation.
The proportion of the static regain can be recovered called the `recovery
factor’, R. Thus the actual static pressure regain,
⎡⎛ C ⎞2 ⎛ C ⎞2 ⎤
SPR = R ⎢⎜ 1 ⎟ − ⎜ 2 ⎟ ⎥ Pa
⎣⎢⎝ 1.29 ⎠ ⎝ 1.29 ⎠ ⎦⎥
The value of R is between 0.7 and 0.9, R = 0.75 is used in many cases.
5
Air Duct Design
FRICTION LOSS IN DUCTS
Frictional losses are usually expressed using D’ Arcy’s Formula or the Fanning
equation.
∆pf fLC 2
= gH f =
ρ 2 Dm
Where ∆pf - frictional pressure drop

Hf – frictional head or loss in metres of air
ρ - Density of air
f – Friction factor
C – Mean duct velocity
Dm – Mean diameter = cross sectional area/perimeter = A/P
For circular duct, A = πD2/4 and P = πD, then Dm = D/4

4 fL ⎛⎜ C 2 ⎟⎞ 4 fL
∆pf = ρgH f = = pv
2 D ⎜⎝ 2 ⎟⎠ D
6
Air Duct Design
FRICTION CHART
7
Air Duct Design
FRICTION CHART
Ve
loc
i ty
(m
/s)
Air Quantity (L/s)
Friction Loss (Pa/m)

m)
(m
r
ete
iam
c tD
Du
8
Air Duct Design
RECTANGULAR EQUIVALENTS OF
ROUND DUCTS
Air ducts are usually sized first for round sections.

If rectangular ducts are required, ducts are sized to provide the same flow
rates and pressure drops as for round ducts.
From friction loss,
∆pf ⎛ ρC 2 ⎞ P
ρC 2
=f=f⎜ ⎟
L 2 Dm ⎜ 2 ⎟A
⎝ ⎠
& / A then,
Substituting, C = Q
v
⎛ ∆pf ⎞ A
3
2
Q& v = ⎜ ⎟
ρf ⎝ L ⎠ P
Because both round and rectangular ducts have the same flow rate and
friction rate, then
⎡ A3 ⎤ ⎡ A3 ⎤
⎢ ⎥ =⎢ ⎥
⎢⎣ P ⎥⎦ round ⎢⎣ P ⎥⎦ rect
9
Air Duct Design
ROUND DUCTS
If a and b are the large and small dimensions of the rectangular duct,
⎡ A3 ⎤ ⎡ A3 ⎤
⎢ ⎥ =⎢ ⎥
⎣⎢ P ⎦⎥ round ⎣⎢ P ⎥⎦ rect
3
⎟ x 1 = (ab )
⎛ πD 2 ⎞ 3
⎜
⎜ 4 ⎟ πD 2 (a + b )
⎝ ⎠
1/ 5
⎟ = 1.265 ⎢ (ab ) ⎥ (ab )0.6
⎛ 32 a 3 b 3 ⎞ ⎡ 3 ⎤
D=⎜ 2 x = 1.265
⎣⎢ (a + b )⎦⎥
⎜π a + b ⎟⎠ (a + b )0.2
⎝
The normal expression used is,
(ab )0.625
D = 1.3
(a + b )0.25
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Air Duct Design
ROUND DUCTS
Equivalents Round Ducts Table
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Air Duct Design
ROUND DUCTS
Equivalents Round Ducts Table
12
Air Duct Design
DYNAMIC LOSSES
Air Flow In Fittings
Whenever a change in area or direction occurs or when the flow is
divided and diverted into a branch, substantial losses in total
pressure may occur.
Dynamic losses are conveniently represented by
2
∆po = Co pv = Co ⎛⎜
C ⎞
⎟ Pa
⎝1.29 ⎠
Where Co is the coefficient of pressure loss
Co can be determined by using the tabulated pressure loss for
fittings.
13
Air Duct Design
PRESSURE LOSSES IN FITTING

Elbow
14
Air Duct Design

Elbow
15
Air Duct Design

Diverging-T
16
Air Duct Design

Transition
17
Air Duct Design
INTRODUCTION DUCT SYSTEM
The air handling system consists of :

• The air distribution system comprising various inlets for recirculated air and
outlets for the supply air.
• The duct system including the return duct, supply duct and air conditioning
apparatus comprising of dampers, cooling coil, air washer and etc.
• The fan which provides the necessary energy to move the air
18
Air Duct Design
COMPONENT OF DUCT SYSTEM
Animation
19
Air Duct Design

AIR HANDLING UNIT (AHU)
20
Air Duct Design

AIR HANDLING UNIT (AHU)
21
Air Duct Design

SUPPLY AND RETURN DUCT
SUPPLY AIR
AHU RETURN AIR
22
Air Duct Design

23
Air Duct Design

24
Air Duct Design
OUTLETS/DIFFUSERS
25
Air Duct Design
OUTLETS/DIFFUSERS
26
Air Duct Design
RETURN AIR GRILL/OPENING
27
Air Duct Design
DUCT SHAPE CONSIDERATIONS

Round Ducts
Advantages
provides maximum air-carrying capacity for the pressure loss incurred
have a smaller pressure drop per unit area
stiffer than rectangular and therefore much quieter during operation
lower installation costs
easier to insulate
can be sealed more easily than rectangular ducts
the most cost effective - saves about 20% in metal weight compared
to rectangular duct
Disadvantages
expensive fittings and takeoffs
larger heights for a given cross-sectional area than needed for
rectangular ductwork
28
Air Duct Design

Round Ducts
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Air Duct Design

Rectangular Ducts
Advantages
easily shipped when broken down or nested
provide flat surfaces for tap-ins and hangers and they are
conveniently fabricated
Disadvantages
create higher pressure drop
use more kg of metal for the same air-flow rate as round duct
joints are more difficult to seal are more costly to install than
round ones
fixing a noise problem in rectangular ductwork is more difficult
than in round ductwork.
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Air Duct Design

Rectangular Ducts
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Air Duct Design
PRESSURE CLASSIFICATIONS
• Low pressure system :

• Velocities less than 600 mpm and
• Static pressure less than or equal to 5 cm H2O gauge
• Medium pressure system :

• Velocities less than 600 mpm or
• Static pressure up to 15 cm H2O gauge
• High pressure system

• Velocities more than 600 mpm or
• Static pressure less than over 15 cm and up to 23 cm H2O
gauge
32
Air Duct Design
MAXIMUM AIR VELOCITY
Table 1 : RECOMMENDED MAXIMUM DUCT VELOCITY (LOW

VELOCITY SYSTEM
Applications Controlling Controlling factor : Friction
Factor : Noise Main Ducts Branch Ducts
Main Ducts Supply Return Supply Return
Residences, 180 300 240 180 180
Apartments,
Hotel Rooms
Hospital 300 450 390 360 300
Offices, 360 600 450 480 360
Libraries
Theatre 240 390 330 300 240
Stores, Banks
Restaurants 450 600 450 480 360
Cafetarias 540 600 450 480 360
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Air Duct Design
ECONOMIC FACTORS
INFLUENCING DUCT LAYOUT
The following items directly influence the

first and operating cost :
Heat gain or loss from the duct
Aspect ratio of the duct
Duct friction rate
Type of fittings
Heat gain or loss :

Larger aspect ratios contribute higher heat gain
Ducts carrying small air quantities at a low velocity have the greatest
heat gain
Insulating the duct with a good material can reduces heat gain up to
90%.
Good practice to design the duct system for low aspect ratios and
higher velocities to minimize heat gain.
34
Air Duct Design
ECONOMIC FACTORS
Aspect Ratio :
The ratio of the long side to the short
side of a duct
The installed or first cost depends on
the amount of materials used and the
difficulty in fabricating the ducts.
For best economics the duct system
should be designed for the smallest
aspect ratio.
A rectangular duct with an aspect ratio
of 1 should be used if the round duct
cannot be used because of space
limitations.
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Air Duct Design
ECONOMIC FACTORS
Lowest operating cost occurs

where round duct is used.
36
Air Duct Design
DUCT DESIGN METHODS
VELOCITY REDUCTION METHOD (VRM)

To select a suitable velocity in the main duct from sound level
considerations
Arbitrary reductions are made in the air velocity as we go down
the duct run.
The starting velocity selected should not exceed as
recommended (Table 1)
Using the friction chart, the equivalent diameters are
determined.
The fan static pressure required for the supply is determined
using the longest duct run including all elbow and fittings.
Not normally adopted unless the person using it has
considerable practical experience and knowledge to design
within reasonable accuracy.
Should be used only for most simple layouts. 37
Air Duct Design
DUCT DESIGN METHODS
EQUAL FRICTION METHOD (EFM)

The frictional pressure drop per unit length of the duct is
maintained constant throughout the duct system.
Used for sizing the supply, exhaust and return air duct systems
Superior than velocity reduction since it requires less
balancing.
Generally recommended because of simplicity and is used in
`ductulator’.
The shortest duct needs considerable amount of dampering
(high velocity)
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Air Duct Design
DUCT DESIGN METHODS
Procedures of EFM
Select a suitable initial velocity in the main duct from Table 1.
Knowing the air flow rate and the velocity in the main duct, the
size and friction loss of the main duct are determined from the
friction chart.
The same friction rate is used throughout the system.
This will reduce the air velocity in the direction of flow.
To determine the total friction loss, it is necessary to calculate
the loss in the duct run has the highest resistance (normally
the longest duct run)
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Air Duct Design
DUCT DESIGN METHODS

Equal Friction method (EFM)
EXAMPLE 1
Size the duct system below and determine the total friction loss using
the equal friction method. Initial velocity can be taken as 360 mpm.
F
100 L/s
60 m
A
D
B C
20 m 10 m
20 m
300 L/s
G
400 L/s
E
40
Air Duct Design
DUCT DESIGN METHODS

Solution for example 1
Step 1 : Calculate the total air quantity at each duct section

Step 2 : Using the air quantity (800 L/s) at the main duct and the initial
velocity (360 m/min = 6 m/s), determine the friction loss from
the friction chart
F
100 L/s
A 700 L/s 400 L/s

C D
800 B
L/s
300 L/s
G
400 L/s
E
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Air Duct Design
DUCT DESIGN METHODS
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Air Duct Design
DUCT DESIGN METHODS

Solution for example 1
Step 3 : Using the same friction loss, we can determine the velocity and the
diameter of each section.
Step 4 : Calculate the friction loss for the elbow D
Step 5 : Taking the max high of the duct as 30 mm, the size of each duct section
is determined using Table 21.
2 2
Elbow D, friction loss, po = Co ⎛⎜
C ⎞ ⎛ 5.2 ⎞
⎟ = 0.26 x ⎜ ⎟ = 4.22
⎝1.29 ⎠ ⎝ 1.29 ⎠
Section Q Vel Dia Size (mm) L Le F/L Total F/L
(l/s) (m/s) (mm) (W X D) (m) (m) Pa/m Pa
A
A-B 800 6 420 300 x 500 20 0.98 x 20 19.6
B-C 700 5.8 380 300 x 420 10 0.98 x 10 9.8
C-D-E 400 5.2 315 300 x 280 80 0.98 x 80 78.4
Elbow D 400 5.2 315 300 x 280 - 4.22 4.22
Total F/L = 112.02

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Air Duct Design
DUCT DESIGN METHODS

EXAMPLE 2
Determine the velocity and size for each section of the duct layout as
shown below and the total pressure loss. Initial velocity and the
maximum duct high can be taken as 6 m/s and 22 cm respectively.
I 500 l/s
5m
H 500 l/s
5m
A
15 m 12 m C 10 m D 20 m E
B
5m
750 l/s 750 l/s F 750 l/s

J K
8m
G 750 l/s
44
Air Duct Design
DUCT DESIGN METHODS

Solution for Example 2
I 100 l/s
5m 100 l/s
H 100 l/s
5m 200 l/s
A C
15 m 12 m 10 m D 20 m E
650 l/s B 350 l/s 250 l/s 150 l/s
5m
100 l/s F 75 l/s

J 100 l/s K
8 m 75 l/s
Note : G 75 l/s
1. Initial velocity = 6 m/s
2. Total air quantity at main duct = 650 L/s
3. The longest duct run should be considered to determine the total friction loss
45
Air Duct Design
DUCT DESIGN METHODS

Solution
0.36
46
Air Duct Design
DUCT DESIGN METHODS

Solution
47
Air Duct Design
DUCT DESIGN METHODS

Solution for Example 2
2 2
Elbow D, friction loss, p = C ⎛ C ⎞ = 0.34 x ⎛ 4.2 ⎞ = 3.60
o o⎜ ⎟ ⎜ ⎟
⎝1.29 ⎠ ⎝ 1.29 ⎠
Section Q Vel Dia Size (mm) L F/L Total F/L
(l/s) (m/s) (mm) (W X D) (m) Pa/m Pa
A
A-B 650 6.0 365 240 x 480 15 1.1 x 15 16.5
B-C 350 5.2 295 240 x 300 12 1.1 x 12 13.2
C-D 250 4.7 255 240 x 240 10 1.1 x 10 11
D-E-F 150 4.2 205 200 x 180 25 1.1 x 25 27.5
Elbow E 150 4.2 205 200 x 180 0.34 x (4.2/1.29)2 3.60
F-G 75 3.5 165 200 x 120 8 1.1 x 8 8.8
B-H 200 4.5 235 240 x 300
H-I 100 3.8 185 200 x 150
C-J 100 3.8 185 200 x 150
D-K 100 3.8 185 200 x 150
Total Friction loss = 80.6 Pa
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Air Duct Design
DUCT DESIGN METHODS

EXAMPLE 3
Determine the velocity and size for each section of the duct and the total pressure
loss. Take the initial velocity and the maximum duct high as 360 m/min and 30
cm respectively. Take appropriate max duct height.
50 l/s
5m
50 l/s 50 l/s
5m 5m
50 l/s 50 l/s
5m 5m
15 m 10 m 10 m 20 m
8m 3m
80 l/s 75 l/s
8m 8m
80 l/s 75 l/s
8m
80 l/s
8m
80 l/s 49
Air Duct Design
DUCT DESIGN METHODS

Solution Ex3
50 l/s D3
50 l/s
B2 500 l/s 50 l/s D2
50 l/s 100 l/s
B1 500 l/s 50 l/s D1
A 100 l/s 150 l/s
620 l/s C 300 l/s E
720 l/s B D 150 l/s
320 l/s
800 l/s C1 F 75 l/s
240 l/s 75 l/s
800 l/s C2 G 75 l/s
160 l/s
800 l/s C3
80 l/s
800 l/s C4
50
Air Duct Design
DUCT DESIGN METHODS

Solution Ex3
AB
BC
CD
DEF
Elbow E
FG
51
Air Duct Design
DUCT DESIGN METHODS
STATIC REGAIN METHOD (SRM)

The basic principle is to size a duct run so that the increase in
static pressure (regain due to reduction in velocity) at each
branch just offsets the friction loss in the succeeding section.
The static pressure is the same before and at each branch.
This will maintain a uniform static pressure at all branches and
outlets.
Provide a balanced duct system and does not require the use
of dampers.
52
Air Duct Design
DUCT DESIGN METHODS
Procedures of SRM
Select an initial velocity in the main duct from Table 1
Determine the friction rate and duct size from the frictionn
chart using the initial velocity and air quantity
Reduce the velocity of the next branch and calculate the static
pressure regain, SPR using
⎡⎛ C ⎞2 ⎛ C ⎞2 ⎤
SPR = 0.75 ⎢⎜ 1 ⎟ − ⎜ 2 ⎟ ⎥ Pa
⎢⎣⎝1.29 ⎠ ⎝1.29 ⎠ ⎥⎦
Compare this static pressure with the friction loss taken from
the chart. Trial and error should be done until both static
pressure and friction loss almost similar
53
Air Duct Design
DUCT DESIGN METHODS
Advantages of SRM
Uniform static pressure along the duct runs
Duct system will stay in balance because the losses (friction
loss) and static regain are proportional to a function of
velocities.
Excellent method for designing VAV system.
Disadvantages of SRM
More complex to use
Oversized ducts can occur at the end of long duct branches.
This results in very low velocity, so very good thermal
insulation is necessary to prevent heat gains.
54
Air Duct Design
DUCT DESIGN METHODS

Static Regain Method (SRM)
EXAMPLE 4
the static regain method. Initial velocity can be taken as 360 mpm.
F
100 L/s
60 m
A
D
B C
20 m 10 m
20 m
300 L/s
G
400 L/s
E
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Air Duct Design
DUCT DESIGN METHODS

F
100 L/s
Solution EX4 A 700 L/s 400 L/s
C D
B
800 L/s
300 L/s
G
400L/s
E
1. Determine the friction loss and the size of the main duct by using the initial
velocity (6 m/s) and air quantity (800 L/s)
2. Estimate the velocity at section BC and calculate the SPR, then compare with
the friction loss.
1st trial, let say CBC =5.5 m/s, from the chart F/L = 0.82 Pa
[
SPR = 0.75 (6 1.29 )2 − (5.5 1.29 )2 = 2.59 ] Too large
2nd trial, let say CBC =5.8 m/s, from the chart F/L = 0.96 Pa
[
SPR = 0.75 (6 1.29 )2 − (5.5 1.29 )2 = 1.06 ] Acceptable
56
Air Duct Design
DUCT DESIGN METHODS

Solution EX4
Section CDE
1st trial, let say CCDE =5.5 m/s, from the chart F/L = 1.20 Pa
[
SPR = 0.75 (5.8 1.29 )2 − (5.5 1.29 )2 = 1.53 ] Can be refined
2nd trial, let say CCDE =5.8 m/s, from the chart F/L = 1.25 Pa
[
SPR = 0.75 (5.8 1.29 )2 − (5.55 1.29 )2 = 1.28 ] O.K
Elbow D
2 2
⎛ C ⎞ ⎛ 5.55 ⎞
po = Co ⎜ ⎟ = 0.26 x ⎜ ⎟ = 4.81 Pa
⎝ 1.29 ⎠ ⎝ 1.29 ⎠
57
Air Duct Design
DUCT DESIGN METHODS

F
100 L/s
Solution EX4
A 700 L/s 400 L/s
C D
B
800 L/s
300 L/s
G
Taking the max H of the duct as 240 mm 400L/s
E
Sect Q Vel Dia Size (mm) L F/L Total F/L
(l/s) (m/s) (mm) (W X D) (m) Pa/m Pa
A
A-B 800 6 420 240 x 660 20 0.92 18.4
B-C 700 5.8 390 240 x 560 10 0.96 9.6
C-D-E 400 5.55 300 240 x 320 80 1.25 100
Elbow D 400 5.55 300 240 x 320 - 4.81 4.81
Total F/L = 132.81 Pa
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Air Duct Design
DUCT DESIGN METHODS

EXAMPLE 5
the static regain method. Initial velocity can be taken as 360 mpm.
100 l/s 150 l/s
A C 10 m 20 m
15 m 10 m E
B D
300 l/s
20 m
150 l/s
F
59
Air Duct Design
DUCT DESIGN METHODS

Solution Ex5
100 l/s 150 l/s
A C 10 m 20 m
15 m 10 m E
700 l/s B 600 l/s 300 l/s D
300 l/s
150 l/s 20 m
150 l/s
F
60
Air Duct Design
DUCT DESIGN METHODS

Solution Ex5
61
Air Duct Design
THE END
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AIR

Air Duct Design

TOTAL, STATIC AND VELOCITY

 Static pressure is the pressure that is exerted by a liquid or gas,

TOTAL, STATIC AND VELOCITY

Air Duct Design

TOTAL, STATIC AND VELOCITY

 Neglecting the pZ, then pS + pV = pT = constant

STATIC PRESSURE REGAIN, SPR

 Static pressure increases in the direction of flow if the velocity decreases.

Air Duct Design

FRICTION LOSS IN DUCTS

 Where ∆pf - frictional pressure drop

 For circular duct, A = πD2/4 and P = πD, then Dm = D/4

Air Duct Design

Friction Loss (Pa/m)

 Air ducts are usually sized first for round sections.

Air Duct Design

Air Duct Design

Air Duct Design

PRESSURE LOSSES IN FITTING

PRESSURE LOSSES IN FITTING

Air Duct Design

PRESSURE LOSSES IN FITTING

PRESSURE LOSSES IN FITTING

Air Duct Design

INTRODUCTION DUCT SYSTEM

The air handling system consists of :

COMPONENT OF DUCT SYSTEM

Air Duct Design

COMPONENT OF DUCT SYSTEM

COMPONENT OF DUCT SYSTEM

Air Duct Design

COMPONENT OF DUCT SYSTEM

AHU RETURN AIR

COMPONENT OF DUCT SYSTEM

Air Duct Design

COMPONENT OF DUCT SYSTEM

COMPONENT OF DUCT SYSTEM

Air Duct Design

COMPONENT OF DUCT SYSTEM

COMPONENT OF DUCT SYSTEM

RETURN AIR GRILL/OPENING

Air Duct Design

DUCT SHAPE CONSIDERATIONS

DUCT SHAPE CONSIDERATIONS

Air Duct Design

DUCT SHAPE CONSIDERATIONS

DUCT SHAPE CONSIDERATIONS

Air Duct Design

• Low pressure system :

• Medium pressure system :

• High pressure system

MAXIMUM AIR VELOCITY

Table 1 : RECOMMENDED MAXIMUM DUCT VELOCITY (LOW

Air Duct Design

The following items directly influence the

Heat gain or loss :

Air Duct Design

 Lowest operating cost occurs

DUCT DESIGN METHODS

VELOCITY REDUCTION METHOD (VRM)

Air Duct Design

DUCT DESIGN METHODS

Static pressure is the pressure that is exerted by a liquid or gas,

Neglecting the pZ, then pS + pV = pT = constant

Static pressure increases in the direction of flow if the velocity decreases.

Where ∆pf - frictional pressure drop

For circular duct, A = πD2/4 and P = πD, then Dm = D/4

Air ducts are usually sized first for round sections.

Lowest operating cost occurs