I.

TITLE: “ANALYSIS OF EXHAUST AND SUPPLY AIR FOR WELDING

ROOM”
II. OBJECTIVES:
1. TO DETERMINE THE SUPPLY AIR DUCT BALANCING IN THE
WELDING ROOM.
2. TO DETERMINE THE EXHAUST AIR DUCT BALANCING IN THE
WELDING ROOM.
3. TO BE ABLE TO KNOW IF THE INSTALLED FAN BLOWER IS
OVER DESIGNED OR IT IS WELL INSTALLED IN AS THE
APPLICABLE CAPACITY IN THE WELDING ROOM.
4. TO BE ABLE TO UNDERSTAND THE BALANCING AND APPLY
IT IN REAL TIME.
III. APPARATUS:
 STEEL TAPE
A FLEXIBLE RULER USED TO MEASURE
DISTANCE IS A STEEL MEASURING
TAPE. IT IS MADE UP OF A LINEAR-
MEASURED METAL BLADE. STEEL
FIGURE 1. STEEL TAPE
TAPE IS MADE TO RESIST MORE WEAR
AND TEAR THAN FIBERGLASS TAPES, AND IT CAN
PROVIDE PRECISE RESULTS AT ANY TEMPERATURE.

 TOWER RULER
THE RULER HAS A RETRACTABLE
SCALE, WHICH CAN BE USED TO
MEASURE THE HEIGHT OF THE TOWER. 

IV. THEORY FIGURE 2. TOWER RULER

IN MANY MECHANICAL SYSTEMS, INCLUDING HVAC (HEATING,

VENTILATION, AND AIR CONDITIONING) SYSTEMS AND AUTOMOBILE
ENGINES, THE SUPPLY AND EXHAUST SYSTEM IS A CRUCIAL
COMPONENT. IT HELPS TO MAINTAIN APPROPRIATE AIR FLOW AND
CONTROL WITHIN A SPECIFIC AREA OR ENGINE.
 GENERALLY SPEAKING, THE SUPPLY SYSTEM IS IN CHARGE OF
BRINGING CLEAN AIR OR A CERTAIN GAS MIXTURE INTO THE
DEFINED REGION. INTAKES OR DUCTS THAT PULL OUTSIDE AIR AND
DIRECT IT TO THE DESIRED SPOT ARE FREQUENTLY USED. THE
SUPPLY SYSTEM IN HVAC SYSTEMS MAKES SURE THAT
CONDITIONED AIR IS DELIVERED TO VARIOUS ROOMS OR ZONES,
PRESERVING THE CORRECT TEMPERATURE AND AIR QUALITY.
THE EXHAUST SYSTEM, ON THE OTHER HAND, IS IN CHARGE OF
ELIMINATING STALE AIR, CONTAMINANTS, OR COMBUSTION
BYPRODUCTS FROM THE SPECIFIED REGION OR ENGINE. IT OFTEN
INCLUDES OF DUCTS OR TUNNELS THAT MAKE IT EASIER TO EXPEL
UNDESIRABLE AIR OR GASES INTO THE ENVIRONMENT OUTSIDE. THE
EXHAUST SYSTEM IN AUTOMOBILE ENGINES AIDS IN THE REMOVAL
OF COMBUSTION GASES PRODUCED DURING THE COMBUSTION
PROCESS.
THE SUPPLY AND EXHAUST SYSTEM'S MAJOR GOAL IS TO
MAINTAIN A BALANCED AIRFLOW AND MAKE THE SPACE COZY AND
COMFORTABLE. IT IMPROVES INDOOR AIR QUALITY, REGULATES
TEMPERATURE, AND INCREASES SYSTEM EFFECTIVENESS BY
SUPPLYING FRESH AIR AND ELIMINATING IMPURITIES OR
UNDESIRED BYPRODUCTS.
DEPENDING ON THE APPLICATION AND REQUIREMENTS,
DIFFERENT SUPPLY AND EXHAUST SYSTEM DESIGNS AND
COMBINATIONS MAY BE USED. TO ENSURE THAT THE SYSTEM
PERFORMS AS INTENDED AND COMPLIES WITH RULES OR
STANDARDS, ENGINEERS TAKE INTO ACCOUNT VARIABLES
INCLUDING AIR VOLUME, VELOCITY, FILTRATION, AND NOISE
CONTROL.
BE SURE TO PROVIDE ADEQUATE VENTILATION IN ALL SPACES
IN WHICH WELDING IS DONE TO ELIMINATE HEALTH HAZARDS SUCH
AS GASES, FUMES, AND DUST.
WHEN WELDING OR CUTTING ON LEAD-BEARING STEELS,
LEAD-COATED OR CADMIUM-COATED METALS, OR METAL COVERED
WITH PAINT CONTAINING LEAD OR CADMIUM, YOU SHOULD WEAR
AN AIRLINE MASK EVEN IF YOU ARE DOING THE WORK IN THE OPEN
AIR OR IN A WELL-VENTILATED SPACE.
 WHEN WELDING OR CUTTING IS DONE ON METALS NOT
COVERED IN 1910.252(C)(5) THROUGH(C)(12), PROVIDE MECHANICAL
VENTILATION IN:
 SPACES OF LESS THAN 10,000 CUBIC FEET (284 M (3)) PER
WELDER;
 ROOMS HAVING A CEILING HEIGHT OF LESS THAN 16 FEET
(5 M);
 CONFINED SPACES; OR
 WELDING SPACES THAT CONTAIN PARTITIONS,
BALCONIES, OR OTHER STRUCTURAL BARRIERS THAT
SIGNIFICANTLY OBSTRUCT CROSS VENTILATION.
MINIMUM RATES: VENTILATION MUST BE AT THE MINIMUM RATE OF
2,000 CUBIC FEET (57 M (3)) PER MINUTE PER WELDER. AN EXCEPTION
TO THIS REQUIREMENT IS WHEN APPROVED LOCAL EXHAUST HOODS
AND BOOTHS OR RESPIRATORS ARE PROVIDED. NATURAL
VENTILATION IS SUFFICIENT FOR WELDING OR CUTTING
OPERATIONS WHERE THE RESTRICTIONS ABOVE ARE NOT PRESENT.
FOR PROCESSES SUCH AS WELDING, BRAZING, SOLDERING, AND
TORCH CUTTING, THE PRIMARY PURPOSE OF VENTILATION IS TO
REMOVE AIR CONTAMINANTS FROM THE WORKER'S BREATHING
ZONE. WHENEVER VENTILATION IS USED AS A MEANS OF WORKER
PROTECTION, THE VENTILATION SYSTEM SHOULD BE USED AND
MAINTAINED IN ACCORDANCE WITH ACCEPTABLE PROCEDURES.

WHERE VENTILATION ALONE CANNOT ADEQUATELY PROTECT

THE WELDER, PERSONAL PROTECTIVE EQUIPMENT (RESPIRATORS)
MAY ALSO BE USED. SELECT THE APPROPRIATE RESPIRATOR
ACCORDING TO THE HAZARDS PRESENT, ANY APPLICABLE
LEGISLATION.
V. PROCEDURE
BALANCING THE SUPPLY AND EXHAUST DUCTS IN AN HVAC
SYSTEM IS ESSENTIAL TO ENSURE PROPER AIRFLOW DISTRIBUTION
AND MAINTAIN A COMFORTABLE ENVIRONMENT. THE PROCEDURE
FOR BALANCING THESE DUCTS INVOLVES THE FOLLOWING STEPS:
1. PREPARE THE NECESSARY TOOLS: YOU'LL NEED AN
ANEMOMETER, A BALANCING HOOD, AND ACCESS TO THE
AIR REGISTERS OR GRILLES.
2. IDENTIFY THE SUPPLY AND EXHAUST REGISTERS: LOCATE
ALL THE SUPPLY AIR REGISTERS AND EXHAUST AIR GRILLES
IN THE SYSTEM. MAKE SURE THEY ARE ACCESSIBLE AND
NOT BLOCKED BY FURNITURE OR OTHER OBSTRUCTIONS.
3. CLOSE ALL BUT ONE SUPPLY REGISTER: START BY CLOSING
ALL THE SUPPLY REGISTERS EXCEPT FOR ONE. THIS WILL
ALLOW YOU TO MEASURE THE AIRFLOW IN A CONTROLLED
MANNER.
4. MEASURE THE AIRFLOW AT THE OPEN SUPPLY REGISTER:
USE THE ANEMOMETER TO MEASURE THE AIRFLOW AT THE
OPEN SUPPLY REGISTER. MAKE NOTE OF THE AIR VELOCITY
OR VOLUMETRIC FLOW RATE.
5. ADJUST THE DAMPER: IF THE AIRFLOW AT THE OPEN SUPPLY
REGISTER IS TOO HIGH OR TOO LOW, ADJUST THE DAMPER
ON THAT REGISTER TO ACHIEVE THE DESIRED AIRFLOW.
DAMPERS ARE TYPICALLY LOCATED WITHIN THE
DUCTWORK NEAR THE REGISTER AND CAN BE ADJUSTED
MANUALLY OR WITH A SCREWDRIVER.
6. REPEAT THE PROCESS FOR OTHER SUPPLY REGISTERS: MOVE
ON TO THE NEXT SUPPLY REGISTER, CLOSE THE PREVIOUSLY
OPEN ONE, AND MEASURE THE AIRFLOW AT THE NEW OPEN
REGISTER. ADJUST THE DAMPER AS NEEDED TO ACHIEVE
THE DESIRED AIRFLOW. CONTINUE THIS PROCESS FOR ALL
THE SUPPLY REGISTERS IN THE SYSTEM.
7. BALANCE THE EXHAUST GRILLES: ONCE YOU HAVE
BALANCED THE SUPPLY REGISTERS, PROCEED TO BALANCE
THE EXHAUST GRILLES. START WITH ONE EXHAUST GRILLE
AND ADJUST ITS DAMPER TO ACHIEVE THE DESIRED
AIRFLOW. REPEAT THIS PROCESS FOR ALL THE EXHAUST
GRILLES IN THE SYSTEM.
8. VERIFY THE OVERALL SYSTEM BALANCE: ONCE YOU HAVE
INDIVIDUALLY BALANCED THE SUPPLY AND EXHAUST
REGISTERS, CHECK THE OVERALL SYSTEM BALANCE.
ENSURE THAT THE TOTAL SUPPLY AIRFLOW MATCHES THE
TOTAL EXHAUST AIRFLOW, ALLOWING FOR A BALANCED
AIR EXCHANGE.
 9. FINE-TUNE IF NECESSARY: IF YOU NOTICE ANY
INCONSISTENCIES OR IMBALANCES DURING THE SYSTEM
VERIFICATION, MAKE ADDITIONAL ADJUSTMENTS TO THE
DAMPERS TO ACHIEVE A BALANCED AIRFLOW
DISTRIBUTION.
IT'S IMPORTANT TO NOTE THAT BALANCING THE SUPPLY AND
EXHAUST DUCTS MAY REQUIRE EXPERTISE AND EXPERIENCE. IN
COMPLEX SYSTEMS OR LARGER COMMERCIAL SETUPS, IT'S
ADVISABLE TO CONSULT A PROFESSIONAL HVAC TECHNICIAN WHO
CAN PERFORM THE BALANCING PROCEDURE MORE ACCURATELY
AND EFFECTIVELY.
VI. DATA GATHERING
EQUATION FOR CIRCULAR EQUIVALENT OF A
RECTANGULAR DUCT
THE CIRCULAR DUCT THAT HAS THE SAME HYDRAULIC
DIAMETER AS A RECTANGULAR DUCT IS REFERRED TO AS THE
RECTANGULAR DUCT'S CIRCULAR EQUIVALENT. IN ORDER TO
DETERMINE THE CHARACTERISTICS OF FLUID FLOW IN VARIOUS
DUCT FORMS, ONE CRITERION IS THE HYDRAULIC DIAMETER.
TO FIND THE CIRCULAR EQUIVALENT OF A RECTANGULAR DUCT,
YOU CAN USE THE FOLLOWING EQUATION:

D = 1.3
[
( AB )0.625
( A+B )0.250 ] ; (SMACNA, 1990 )

WHERE;
A = LENGTH OF ONE SIDE OF RECTANGULAR DUCT, MM
B = LENGTH OF ADJACENT SIDE OF A RECTANGULAR DUCT, MM
D = CIRCULAR EQUIVALENT OF RECTANGULAR DUCT FOR
EQUAL FRICTION AND CAPACITY, MM
SUPPLY DUCT DIAMETER

[ ] [ ]
0.625 0.625
[ ( 600 )( 250 ) ] [ (300 )( 250 ) ]
DS =1.3 DS =1.3
( 600+250 )0.250 ( 300+250 )0.250
DS =413.66 MM ≈ 16.3 IN . D S =299.07 MM ≈11.77 IN .
RETURN DUCT DIAMETER

[ ]
0.625
[ ( 600 )( 250 ) ] DR =343.33 MM ≈ 13.52 IN.
DS =1.3

[ ]
( 600+250 )0.250 [ ( 300 ) ( 250 ) ]
0.625

DR =1.3
DS =413.66 MM ≈ 16.3 IN . ( 300+250 )0.250

[ ]
0.625 DR =299.07 MM ≈ 11.77 IN .
[ ( 400 )( 250 ) ]
DR =1.3
( 400+250 )0.250

TABLE 1. SUMMARY OF DUCT DIAMETER IN THE

WELDING ROOM
DESIGNATION SUPPLY AIR DUCT IN RETURN AIR DUCT IN
SAD, MM EAD, MM DIAMETER, IN. DIAMETER, IN
600 X 250 600 X 250 16.3 16.3
350 X 250 350 X 250 12.69 12.69
 400 X 250  13.52
LEGEND:
 NO

STATIC PRESSURE LOSSES AND REGAINS THROUGH ENLARGING

DUCT TRANSITIONS
IN HVAC (HEATING, VENTILATION, AND AIR CONDITIONING)
SYSTEMS, DUCTS ARE USED TO DISTRIBUTE AIR FROM THE HVAC
UNIT TO THE DIFFERENT ROOMS IN A BUILDING. SOMETIMES, THE
DUCTS NEED TO CHANGE IN SIZE OR SHAPE, AND THIS CAN LEAD TO
STATIC PRESSURE LOSSES OR GAINS. WHEN A DUCT CHANGES SIZE
OR SHAPE, THE AIR FLOW THROUGH THE DUCT WILL EITHER SPEED
UP OR SLOW DOWN. THIS CHANGE IN VELOCITY WILL RESULT IN A
CHANGE IN STATIC PRESSURE, WHICH CAN EITHER BE A LOSS OR A
GAIN IN PRESSURE. TO MINIMIZE THESE LOSSES AND GAINS, IT IS
IMPORTANT TO DESIGN THE DUCT SYSTEM CAREFULLY, TAKING
INTO ACCOUNT THE SIZE AND SHAPE OF THE DUCT TRANSITIONS.
ONE APPROACH IS TO USE GRADUAL TRANSITIONS, WHERE THE
DUCT GRADUALLY INCREASES OR DECREASES IN SIZE OVER A
LONGER LENGTH. THIS HELPS TO REDUCE THE ABRUPT CHANGE IN
VELOCITY AND THUS MINIMIZE THE STATIC PRESSURE LOSSES OR
GAINS (BHATIA, 2023).
 FIGURE 3. DUCTWORK DESIGN THROUGH ENLARGING DUCT
TRANSITION
SP2 = SP1 +R ( HV1 - H V2 ) ; INDUSTRIAL VENTILATION, 1962

WHERE;
H V IS POSITIVE

SP IS ( + ) IN DISCHARGE DUCT FROM FAN

SP IS ( - ) INLET DUCT TO FAN
Θ=TAPER ANGLE, DEGREES
D1 =INITIAL DIAMETER FROM SP1 , IN .
D2 =SECONDARY DIAMETER IN SP2 , IN.
X=DISTANCE OF ELARGE DUCT
R=REGAIN FACTOR

TABLE 2. REGAIN, TAPER ANGLE, & LOSS FACTORS CORRESPONDING VALUES THROUGH
ENLARGING DUCT TRANSITIONS

TABLE 3. MINIMUM DUCT VELOCITY

MAIN BRANCH MAIN BRANCH
WELDING SUPPLY, SUPPLY, RETURN, RETURN,
ROOM FPM FPM FPM FPM
1700 1600 1500 1200

AIR VELOCITY
 TO PREVENT NOISE, UNDESIRABLE FRICTION LOSS, AND
ENERGY CONSUMPTION, FLOW VELOCITY IN AIR DUCTS SHOULD BE
REGULATED WITHIN PRESCRIBED LIMITATIONS. FOR THE AIR
DISTRIBUTION SYSTEM TO BE AS ENERGY-EFFICIENT AS POSSIBLE,
LOW VELOCITY DESIGN IS CRUCIAL.
THIS QUANTITY IS FREQUENTLY STATED IN FEET PER MINUTE
(FPM), AND THE EQUATION BELOW CAN BE USED TO COMPUTE IT
(BHATIA, 2002).
4Q
V=
( )
2
D
3.14
12

WHERE:
Q – VOLUMETRIC FLOW RATE, FT3/MIN
D – DUCT DIAMETER, INCHES
V – AIR VELOCITY, FT/MIN

VELOCITY PRESSURE
THE PRESSURE BROUGHT ON BY MOVING AIR IS KNOWN AS
VELOCITY PRESSURE (BHATIA, 2002).
GIVEN THE COMPUTED AIR VELOCITY IN A DUCT, THE DESIGNERS
WOULD UTILIZE TABLE X TO OBTAIN THE VELOCITY PRESSURE.
TABLE 4. CONVERSION OF VELOCITY-TO-VELOCITY PRESSURES
 SOURCE: AIR POLLUTION ENGINEERING MANUAL,
1973

TOTAL EQUIVALENT LENGTH

THE AIRFLOW RESISTANCE INDUCED BY ELBOWS AND BRANCH
ENTRY IS SHOWN IN TABLE 3.5 BELOW AS EQUIVALENT FEET OF
STRAIGHT DUCT. THE EQUIVALENT LENGTHS ARE MULTIPLIED BY
THE STRAIGHT DUCT'S ACTUAL LENGTH, AND THE RESISTANCE FOR
EACH RUN IS CALCULATED USING THE RESISTANCE CHART.
TABLE 5. ELBOWS AND BRANCH ENTRIES EXPRESSED AS
EQUIVALENT FEET OF STRAIGHT DUCT
 SOURCE: AIR POLLUTION ENGINEERING MANUAL,
1973

THE EQUAL LENGTH OF FITTINGS AND BRANCH ENTRY

INCREASES THE REAL LENGTHS OF THE STRAIGHT DUCT. THE
EQUATION BELOW CAN BE USED TO EXPRESS THIS CLAIM
(ENVIRONMENTAL PROTECTION AGENCY, 1973).
LT = LSD + LE + LBE

WHERE:
LT – TOTAL EQUIVALENT LENGTH, FEET
LSD – STRAIGHT DUCT LENGTH, FEET
LE – ELBOW EQUIVALENT LENGTH, FEET
LBE – BRANCH ENTRY EQUIVALENT LENGTH, FEET
RESISTANCE PRESSURE
FRICTION LOSSES OR RESISTANCE PRESSURE ARE PRODUCED
WHENEVER MOVING AIR FLOWS IN CONTACT WITH A FIXED
BOUNDARY. WHEN AIR FLOWS THROUGH A DUCT, FRICTION IS
GENERATED BETWEEN THE FLOWING AIR AND THE STATIONARY
DUCT WALL. ENERGY MUST BE PROVIDED TO OVERCOME THIS
FRICTION, AND ANY ENERGY CONVERTED IRREVERSIBLY TO HEAT IS
KNOWN AS A FRICTION LOSS. RESISTANCE PRESSURE IS OBTAINED
USING FIGURE 3.3.
FIGURE 4. FRICTION LOSS CHART
 SOURCE: ENVIRONMENTAL PROTECTION
AGENCY, 1973
THE FOLLOWING EQUATION IS USED TO DETERMINE THE
RESISTANCE PRESSURE IN A STRAIGHT DUCT (ENVIRONMENTAL
PROTECTION AGENCY, 1973).

HR =TL ( H100 FT )
F

WHERE:
HR – RESISTANCE PRESSURE, IN. WC
LT – TOTAL EQUIVALENT LENGTH. FEET
HF – FRICTION LOSS PER 100 FEET, IN. WC
TOTAL STATIC PRESSURE
 THE PRESSURE THAT CAUSES THE AIR IN THE DUCT TO FLOW IS
KNOWN AS STATIC PRESSURE. STATIC PRESSURE IS A
MEASUREMENT OF RESISTANCE WHEN AIR PASSES THROUGH AN
OBJECT LIKE DUCT WORK AND IS THE OUTWARD PUSH OF AIR
AGAINST DUCT SURFACES (BHATIA, 2002).
SP= H R + HV + HD

WHERE:
SP – TOTAL STATIC PRESSURE, IN. WC
HR – RESISTANCE PRESSURE, IN. WC
HV – VELOCITY PRESSURE, IN. WC
HD – DIFFUSER LOSS, IN. WC
WHEN BUILDING A DUCTWORK SYSTEM WITH MANY
BRANCHES, IT IS NECESSARY TO ADJUST EACH BRANCH'S
RESISTANCE SO THAT THE STATIC PRESSURE BALANCE AT THE
INTERSECTION OF TWO BRANCHES WILL RESULT IN THE BRANCH'S
APPROPRIATE VOLUME. A BALANCED-DUCT SYSTEM'S
CALCULATIONS BEGIN AT THE BRANCH WITH THE HIGHEST
RESISTANCE. CALCULATE THE STATIC PRESSURE UP TO THE
JUNCTION WITH THE NEXT BRANCH USING THE SIZE OF THE DUCT
THAT WILL PROVIDE THE NEEDED VOLUME AT THE SMALLEST
CONVEYING VELOCITY. AFTER THAT, ALONG THIS SUBSEQUENT
BRANCH TO THE SAME JUNCTION, THE STATIC PRESSURE IS
DETERMINED. TO VERIFY THAT THE BALANCED DUCT, WE REFER TO
THE EQUATION BELOW (ENVIRONMENTAL PROTECTION AGENCY,
1973).

PERCENT INCREASE= ( H S HIGHER )

H S HIGHER - HS LOWER
X100

WHERE:
HS – STATIC PRESSURE, IN. WC
THE BRANCHES MAY BE REGARDED AS BALANCED IF TWO
CALCULATIONS AGREE WITHIN 5%. BALANCE CAN BE ATTAINED BY
INCREASING THE FLOW IN THE BRANCH WITH THE LOWEST LOSS IF
THE DIFFERENCE IN PRESSURE LOSS IS BETWEEN 5-20%. THE
EQUATION BELOW IS USED FOR THE CORRECTION OF VOLUMETRIC
FLOW RATE (ENVIRONMENTAL PROTECTION AGENCY, 1973).

CORRECTED CFM=
√ HS (LARGER )
HS (LOWER )
× ORIGINAL CFM
WELDING ROOM BALANCING
THE WELDING ROOM IS EQUIPPED WITH VARIOUS WELDING MACHINES AND POWER
SOURCES BASED ON THE SPECIFIC WELDING PROCESSES PERFORMED. COMMON WELDING
METHODS INCLUDE SHIELDED METAL ARC WELDING (SMAW), GAS METAL ARC WELDING
(GMAW/MIG), GAS TUNGSTEN ARC WELDING (GTAW/TIG), AND FLUX-CORED ARC WELDING
(FCAW). DUE TO THE GENERATION OF FUMES, GASES, AND SMOKE DURING WELDING, A
WELL-VENTILATED AREA OR AN EXHAUST SYSTEM IS CRUCIAL. PROPER VENTILATION
HELPS REMOVE HARMFUL AIRBORNE PARTICLES, GASES, AND SMOKE, PROVIDING A SAFER
AND HEALTHIER WORKING ENVIRONMENT. SAFETY IS OF UTMOST IMPORTANCE IN THE
WELDING ROOM. YOU'LL FIND A RANGE OF SAFETY EQUIPMENT SUCH AS WELDING
HELMETS, FACE SHIELDS, SAFETY GLASSES, GLOVES, WELDING APRONS, AND FLAME-
RESISTANT CLOTHING. THESE ITEMS PROTECT AGAINST SPARKS, INTENSE LIGHT, HEAT,
AND POTENTIAL HAZARDS ASSOCIATED WITH WELDING.
 FIGURE 5. WELDING ROOM LAYOUT

ANALYSIS OF THE EXHAUST AND SUPPLY AIR FOR WELDING ROOM

THE TABLE BELOW SHOWS THE BALANCING RESULT OF THE SUPPLY AND EXHAUST DUCT
AT THE WELDING ROOM WHICH RESIDES IN THE GROUND FLOOR OF THE LUALHATI BUILDING.
TABLE 6. SUPPLY AIR DUCT STATIC PRESSURE
DIFFERENCE

TABLE 7. EXHAUST AIR DUCT STATIC PRESSURE DIFFERENCE

 IT IS CONCLUDED THAT THE STATIC PRESSURE DIFFERENCE IN THE EXHAUST AND SUPPLY
AIR DUCT HAS THE SAME STATIC PRESSURE DIFFERENCE IN THEIR BALANCING WHICH IS
ROUGHLY 38%. THIS SHOWS THAT THE DESIGN OF SUPPLY AND AIR DUCT IN THE WELDING
ROOM IS NOT BALANCE AND IS NOT WELL TAKEN CARE OF CONSIDERATION IN THE REMAINING
33% TO BALANCE.
VOLUMETRIC FLOW RATE
THE VOLUMETRIC AIRFLOW RATE IS ADVISED AS THE
VENTILATION RATE TO KEEP THE OCCUPANTS' INDOOR AIR QUALITY
WITHIN ACCEPTABLE LIMITS. DESIGNERS AND OPERATORS USUALLY
USE THE LEAST AMOUNT OF CFM REQUIRED TO CONSERVE ENERGY.
(PITA, 1981).
TABLE 8. MINIMUM VENTILATION RATES IN BREATHING ZONE

THE MINIMAL VENTILATION RATES ARE SHOWN IN TABLE 8. IT

IS PRESUMED THAT THE DESIGNERS TOOK AN ACCOUNT OF 20%
REDUCTION IN THE ROOMS. THIS TAKES INTO ACCOUNT THE SPACE
THAT IS UNOCCUPIED BY PEOPLE AND MACHINERY.
TABLE 9. VENTILATION RATE PARAMETERS IN THE WELDING
ROOM
ROOM AREA, m2 REDUCED AREA, m2
WELDING ROOM 61 48.8

FOR THE WELDING ROOM;

Q = (VENTILATION RATE) (ROOM AREA)

( ) ( )
2
CFM ( 2 3.28 FT
)
Q= 1 48.8 M (0.8)
FT2 1M

Q = 420 CFM
WELDING ROOM
 THE MINIMUM FLOW RATE SHALL BE 2,000 CFM PER WELDER,
EXCEPT WHERE LOCAL EXHAUST HOODS AND BOOTHS OR AIRLINE
RESPIRATORS ARE PROVIDED AND USED. ACCORDING TO OSHA 29
CFR 1910.252(C), THE FOLLOWING SPACES REQUIRE MECHANICAL
VENTILATION IN A SPACE OF LESS THAN 10,000 CUBIC FEET PER
WELDER.
THEREFORE, THE REQUIRED VOLUME FLOW RATE OF THE WELDING
ROOM IS SHOWN BELOW;

EXHAUST VENTILATION=
2000CFM
WELDER (10000F
WELDER
T )
3
( VOLUME OF WELDING ROOM )

TABLE 10. AREA OF WELDING ROOM

ROOM AREA (FT2)
WELDING ROOM 667 FT2

USING THE VENTILATION RATE CONSIDERED ABOVE, THE

COMPUTED CFM CAPACITY OF THE WELDING ROOM CAN BE
COMPUTED AS THE FORMULA SHOWN BELOW.

EXHAUST VENTILATION=
2000CFM
WELDER (10000F
WELDER
T )
3
( 667F T ) ( 17.5FT )
2

EXHAUST VENTILATION=2335 CFM

THE WELDING ROOM WHICH HAS A UNIT OF NIAGARA EXHAUST FAN

(TUBULAR INLINE FAN) WITH A CAPACITY OF 6,270 CFM. THE TABLE
BELOW SHOWS THE COMPARISON BETWEEN THE COMPARISON CFM
BETWEEN THE DESIGN AND ACTUAL.
TABLE 11. COMPARISON OF REQUIRED CFM AND INSTALLED UNIT
COMPUTED INSTALLED UNIT
ROOM VENTILATION RATE CAPACITY
(CFM) (CFM)
WELDING ROOM 2335 6270
 THE FACT THAT THE DESIGN AND COMPUTED VENTILATION
RATES DIFFER IN THE TABLE ABOVE INDICATES THAT IT IS
OVERDESIGNED. THE CALCULATED VENTILATION AND THE ROOM'S
INSTALLED VENTILATION DIFFER BY 62.75%.
Q- Q
'
( 6270-2335 ) CFM
% DIFFERENCE= X 100%= X 100 %=62.75 %
Q 6270CFM
VII. DISCUSSION
THE DESIGN OF A HEATING, VENTILATION, AND AIR
CONDITIONING (HVAC) SYSTEM, INCLUDING THE EXHAUST AND
SUPPLY AIR DUCTS, IS VITAL FOR GETTING ENOUGH VENTILATION
AND KEEPING THE PROPER AIR BALANCE IN A ROOM. HOWEVER, IF
THESE DUCTS ARE MADE TOO BIG, THEY CAN HAVE UNINTENDED
EFFECTS LIKE TOO MUCH STATIC PRESSURE AND A BIG DIFFERENCE
FROM THE IDEAL STATIC PRESSURE DIFFERENCE.
IN THIS DESIGN, THE CAPACITY OF THE TUBE INLINE FAN,
WHICH IS 6270 CFM, IS USED TO FIGURE OUT THE TOTAL
VOLUMETRIC FLOW RATE. IT ENSURES THE WELDING ROOM HAS
THE PROPER AIR COMING IN AND OUT. THE TOTAL VOLUMETRIC
FLOW RATE IN EACH DIFFUSER CAN BE FOUND BY DIVIDING THE
TOTAL CFM CAPACITY BY THE NUMBER OF DIFFUSERS. THIS IS THE
FIRST STEP IN BALANCING THE WELDING ROOM'S SUPPLY AND
OUTPUT.

FIGURE 6. TUBULAR INLINE FAN CAPACITY

TABLE 12. COMPARISON OF REQUIRED CFM AND INSTALLED UNIT
COMPUTED VENTILATION INSTALLED UNIT
ROOM RATE CAPACITY
(CFM) (CFM)
WELDING
2335 6270
ROOM

THE TABLE ABOVE SHOWS THAT IT IS OVERDESIGNED

BECAUSE THE DESIGN AND COMPUTED VENTILATION RATES ARE
DIFFERENT. THE DIFFERENCE BETWEEN THE ROOM'S INSTALLED
VENTILATION AND THE CALCULATED VENTILATION IS 62.75%.
Q- Q
'
( 6270-2335 ) CFM
% DIFFERENCE= X 100%= X 100 %=62.75 %
Q 6270CFM
IN THIS CASE, THE FACT THAT THERE IS TOO MUCH STATIC
PRESSURE MEANS THAT THE DEVICE IS BLOCKING AIRFLOW MORE
THAN IT SHOULD. THIS CAN HAPPEN IF THE PIPES ARE TOO BIG, TOO
LONG, HAVE TOO MANY FITTINGS, OR ARE BLOCKED BY
SOMETHING. DIFFERENT THINGS CAN HAPPEN BECAUSE OF THE
HIGHER STANDING PRESSURE:
1. REDUCED AIRFLOW: MORE STATIC PRESSURE CAN STOP THE AIR
FROM MOVING THROUGH THE DUCTS, SO THE AIRFLOW RATE IS
LOWER THAN PLANNED. THIS CAN MAKE THE AREA NOT HAVE
ENOUGH AIRFLOW AND WORSEN AIR QUALITY.
2. INCREASED ENERGY CONSUMPTION: MORE ENERGY IS USED.
BECAUSE OF THE HIGHER STATIC PRESSURE, THE EXHAUST AND
SUPPLY FANS MUST WORK HARDER TO BEAT THE RESISTANCE,
WHICH USES MORE ENERGY. THE FANS NEED TO RUN AT HIGHER
SPEEDS, WHICH WOULD USE MORE POWER AND COULD LEAD TO
HIGHER OPERATING COSTS.
3. NOISE AND VIBRATION: HIGHER STATIC PRESSURE LEVELS CAN
MAKE THE DUCT SYSTEM NOISIER AND SHAKIER, WHICH CAN BE
UNCOMFORTABLE FOR PEOPLE IN THE BUILDING AND COULD
DAMAGE THE EQUIPMENT.
IN THIS SCENARIO, THE ACTUAL DIFFERENCE IN STATIC
PRESSURE IS FAR FROM THE 5% DESIRED DIFFERENCE. THIS
DIFFERENCE SHOWS THAT THE AIRFLOW BETWEEN THE EXHAUST
AND SUPPLY CIRCUITS IS OUT OF BALANCE IN A BIG WAY. SEVERAL
THINGS CAN CAUSE THIS KIND OF DIFFERENCE:
1. INACCURATE SYSTEM DESIGN: THE INITIAL DUCTWORK DESIGN
MAY NOT HAVE CONSIDERED THE ROOM'S SPECIFIC NEEDS. THIS LED
TO AN IMBALANCE BETWEEN THE AIRFLOW RATES OF THE EXHAUST
AND SUPPLY SYSTEMS.
2. IMPROPER DAMPER SETTINGS: THE DAMPERS, WHICH CONTROL
AIRFLOW IN THE DUCTS, MAY NEED TO BE CHANGED TO GET THE
RIGHT STATIC PRESSURE DIFFERENCE. THE AIRFLOW CAN BE
SPREAD OUT EVENLY IF THE DAMPERS ARE SET RIGHT.
3. DUCT LEAKAGE OR OBSTRUCTIONS: LEAKS OR UNDETECTED
BLOCKAGES IN THE DUCTWORK CAN THROW OFF THE AIRFLOW
BALANCE AND CAUSE A BIG DIFFERENCE IN STATIC PRESSURE
BETWEEN THE EXIT AND SUPPLY AIR SYSTEMS.
SEVERAL STEPS CAN BE TAKEN TO FIX THE FACT THAT THE
EXHAUST AND SUPPLY AIR PIPES ARE TOO BIG AND GET THE
DESIRED STATIC PRESSURE DIFFERENCE:
1. DUCT SIZING AND DESIGN REVIEW: CHECK THE DUCTS' SIZE AND
LAYOUT AGAIN TO ENSURE THEY MEET THE NEEDS OF THE AREA.
STATIC PRESSURE CAN BE REDUCED BY ENSURING THAT DUCTS ARE
THE RIGHT SIZE BASED ON HOW FAST AIR MOVES THROUGH THEM
AND BY REMOVING ANY EXTRA FITTINGS.
2. DAMPER ADJUSTMENT: ADJUST THE DAMPERS IN THE SUPPLY AND
EXIT DUCTS CAREFULLY TO GET THE DESIRED STATIC PRESSURE
DIFFERENCE. THIS IS DONE BY CHECKING THE DAMPNESS AND FINE-
TUNING IT REGULARLY.
AFTER COMPARING THE ACTUAL AND INSTALLED CAPACITY OF
AN INLINE FAN IN THE WELDING ROOM, IT IS SUGGESTED TO USE AN
INLINE FAN WITH A CAPACITY OF 2335 CFM IN THE WELDING ROOM.
BECAUSE OF THIS, IT IS RECOMMENDED TO USE A FAN WITH A
RANGE OF 2300 TO 2400 CFM. THE FG 10XL CENTRIFUGAL INLINE FAN
CAN MOVE 2340 CFM, WHICH IS IN THE ACCEPTABLE RANGE FOR THE
FAN NEEDED IN THE WELDING ROOM. THE PICTURE BELOW SHOWS
WHAT THE FAN LOOKS LIKE.

FIGURE 7. FG 10XL CENTRIFUGAL INLINE FAN

TABLE 13. DESIGN CAPACITY OF THE FG 10XL CENTRIFUGAL
INLINE FAN
NOMINAL DATA
 MODEL FG 10XL
AIR FLOW 2340 CFM
PHASE(S) 3
POWER 1.27 HP
IN THE SUPPLY OR EXHAUST BRANCH, THE TOTAL STATIC
PRESSURE IS FOUND BY ADDING THE VELOCITY PRESSURE, THE
RESISTANCE PRESSURE, AND THE DIFFUSER LOSS. IN THE MAIN
SUPPLY OR EXHAUST, THE TOTAL STATIC PRESSURE IN THE BRANCH
IS ADDED TO THE RESISTANCE PRESSURE AND THE VELOCITY
PRESSURE IN THE CENTRAL DUCT OF THE SUPPLY OR EXHAUST.
ALSO, BY GETTING THE TOTAL EQUAL LENGTH OF THE DUCT
AND ITS DIAMETER SIMULTANEOUSLY, THE CFM IS ADDED TO THE
TOTAL TO GET THE RESISTANCE PRESSURE PER 100 FEET AND THEN
THE RESISTANCE PRESSURE IN INCHES OF WATER. FOLLOW WHAT
THE INDUSTRIAL REVOLUTION GUIDEBOOK SAYS FOR EACH
BRANCH AND SUPPLY TO DETERMINE THE DUCT SIZE. ONCE THE
VOLUMETRIC FLOW RATE IS KNOWN, THE DUCT'S WIDTH AND SPEED
CAN BE FOUND. LASTLY, THE EQUATION FOR STATIC PRESSURE
NEEDS THE VELOCITY PRESSURE. THIS CAN BE FOUND BY LOOKING
AT THE CORRESPONDING NUMBERS IN THE INDUSTRIAL
REVOLUTION AND INTERPOLATING IF THE VELOCITY IS NOT
EXACTLY IN THE VALUE.
A CRITICAL STEP IN FIGURING OUT HOW WELL AN HVAC
SYSTEM WORKS IS TO COMPARE THE INSTALLED AND ACTUAL
VOLUMETRIC FLOW RATES IN THE SUPPLY AND EXHAUST DUCTS.
THIS COMPARISON LETS CHANGES BE MADE SO THAT THE SYSTEM
WORKS AS PLANNED AND AIRFLOW IS SPREAD IN THE BEST WAY.
THE FIXED VOLUMETRIC FLOW RATE IS THE AMOUNT OF AIR
THE SYSTEM IS SUPPOSED TO MOVE THROUGH EACH SUPPLY AND
EXHAUST DUCT BASED ON HOW IT WAS DESIGNED. DURING THE
PLANNING AND INSTALLATION OF THE SYSTEM, FACTORS LIKE
ROOM SIZE, NUMBER OF PEOPLE IN THE ROOM, AND VENTILATION
NEEDS ARE CONSIDERED TO COME UP WITH THESE NUMBERS.
ON THE OTHER HAND, THE REAL VOLUMETRIC FLOW RATE
SHOWS HOW MUCH AIR IS MOVING THROUGH EACH SUPPLY AND
EXHAUST DUCT. USUALLY, UNIQUE TOOLS LIKE ANEMOMETERS OR
AIRFLOW HOODS ARE USED TO MEASURE THIS. BY COMPARING THE
TWO SETS OF VALUES, ANY DIFFERENCES BETWEEN THE INSTALLED
AND FUNDAMENTAL VALUES CAN BE FOUND AND FIXED.
INSTALLATION AND ACTUAL VOLUMETRIC FLOW RATES MAY
BE DIFFERENT FOR SEVERAL REASONS. THESE INCLUDE THE WRONG
SIZE OF THE DUCTS, LOUSY INSTALLATION, OBSTACLES IN THE
DUCTWORK, DIFFERENCES IN HOW WELL THE EQUIPMENT WORKS,
AND THE WRONG SIDE OF THE DUCTS. A DIFFERENCE BETWEEN HOW
MUCH AIR COMES IN AND HOW MUCH GOES OUT CAN CAUSE
PROBLEMS, SUCH AS NOT ENOUGH VENTILATION, UNEVEN
TEMPERATURE SPREAD, OR BAD AIR QUALITY INSIDE.
BY MAKING A THOROUGH COMPARISON, CHANGES CAN BE
MADE TO GET THE RIGHT MIX OF AIRFLOW. THIS CAN MEAN
CHANGING HOW THE DAMPERS ARE SET, THE SIZE OF THE PIPES, OR
GETTING RID OF ANY BLOCKAGES. THE METHOD CAN BE CHANGED
TO WORK BEST, IS MOST COMFORTABLE, AND USES THE LEAST
ENERGY.
IT IS IMPORTANT TO REMEMBER THAT LICENSED HVAC
TECHNICIANS OR OTHER EXPERTS WITH THE RIGHT MEASURING
TOOLS AND INFORMATION SHOULD BE THE ONLY ONES TO
COMPARE THE ACTUAL VOLUMETRIC FLOW RATES TO THOSE
SETUPS. THE AIRFLOW IN THE SUPPLY AND EXHAUST DUCTS
SHOULD BE CHECKED AND CHANGED REGULARLY TO MAKE SURE
THE INDOOR TEMPERATURE IS COSY AND HEALTHY.
VIII. CONCLUSION
A CRUCIAL PART OF A GOOD HVAC SYSTEM IS ENSURING THE
SUPPLY AND EXHAUST AIR PIPES ARE BALANCED. BUT IF THE
BALANCE ISN'T DONE WELL AND THERE ARE BIG DIFFERENCES IN
STATIC PRESSURE AND THE SYSTEM IS OVER-DESIGNED, IT COULD
CAUSE PROBLEMS IN THE FUTURE. THE FACT THAT THERE IS A 33%
EXCESS OF STATIC PRESSURE AND A 38% DIFFERENCE BETWEEN THE
REAL STATIC PRESSURE AND THE DESIRED STATIC PRESSURE
DIFFERENCE SHOWS THAT THE AIRFLOW DISTRIBUTION IS NOT
BALANCED. THIS RESULT SHOWS HOW IMPORTANT IT IS TO FIX
THESE PROBLEMS TO AVOID FUTURE PROBLEMS AND MAKE SURE
THE HVAC SYSTEM WORKS WELL.
ONE OF THE BIGGEST PROBLEMS CAUSED BY THE IMBALANCE IS
THAT THE ROOM DOESN'T HAVE ENOUGH AIR FLOW. WHEN THE
AIRFLOW ISN'T BALANCED, SOME PLACES MAY NOT GET ENOUGH
FRESH AIR OR GET RID OF ENOUGH STALE AIR. THIS CAN LEAD TO
POOR INDOOR AIR QUALITY AND HEALTH PROBLEMS FOR THE
PEOPLE WHO LIVE THERE. ALSO, THE HIGH STATIC PRESSURE MAKES
THE FANS WORK HARDER, WHICH USES MORE ENERGY AND RAISES
THE COST OF UTILITIES. THIS WASTEFUL USE OF ENERGY CAN ALSO
AFFECT HOW WELL THE SYSTEM USES ENERGY AS A WHOLE.
IF THE AIRFLOW ISN'T EVEN, THERE MAY BE DIFFERENT
TEMPERATURES IN DIFFERENT PARTS OF THE ROOM, WHICH IS
ANOTHER BIG PROBLEM. SOME PLACES MAY HAVE DIFFERENT
TEMPERATURES, WHICH CAN MAKE PEOPLE UNCOMFORTABLE AND
CREATE HOTSPOTS OR COLDSPOTS. ALSO, THE HIGHER STATIC
PRESSURE LEVELS CAN MAKE THE DUCT SYSTEM NOISIER AND
SHAKIER, WHICH CAN BE UNCOMFORTABLE FOR THE PEOPLE LIVING
THERE AND COULD DAMAGE THE PIPES OR EQUIPMENT OVER TIME.
IF THE SUPPLY AND EXHAUST AIR PIPES AREN'T BALANCED, IT
CAN CAUSE PROBLEMS THAT CAN SHORTEN THE LIFE OF THE
SYSTEM AS A WHOLE. THE EXTRA STRESS PUT ON THE HVAC
SYSTEM'S FANS, FILTERS, AND OTHER PARTS CAN SPEED UP THEIR
WEAR AND TEAR, MAKING IT MORE LIKELY THAT THEY WILL BREAK
DOWN AND NEED EXPENSIVE REPAIRS OR REPLACEMENTS.
QUICK ACTION IS NEEDED TO AVOID THESE POSSIBLE PROBLEMS
AND ENSURE LONG-TERM USEFULNESS AND EFFICIENCY. THIS
INCLUDES ADJUSTING THE DAMPERS, REEVALUATING THE SIZE AND
DESIGN OF THE DUCTS, AND FINE-TUNING THE SYSTEM TO GET THE
RIGHT MIX OF AIRFLOW. TO FIX THE PROBLEM, IT IS BEST TO GET
HELP FROM HVAC EXPERTS OR PEOPLE WHO KNOW HOW TO DESIGN
AND BALANCE DUCTWORK.
MONITORING AND MAINTAINING THE DUCTWORK SYSTEM ON A
REGULAR BASIS IS THE BEST WAY TO FIND AND FIX ANY FLAWS OR
PERFORMANCE PROBLEMS AS SOON AS POSSIBLE. BY KEEPING A
WELL-BALANCED SUPPLY AND EXHAUST AIR DUCT SYSTEM, YOU
CAN MAKE SURE THAT THERE IS ENOUGH AIRFLOW, THAT THE AIR
QUALITY INSIDE IS BETTER, THAT THE BUILDING USES LESS ENERGY,
AND THAT THE PEOPLE INSIDE ARE COMFORTABLE. THIS WILL MAKE
IT LESS LIKELY THAT PROBLEMS WILL COME UP IN THE FUTURE.
 IN CONCLUSION, IT IS IMPORTANT TO KNOW HOW IMPORTANT IT
IS TO BALANCE THE SUPPLY AND EXHAUST AIR PIPES TO AVOID
PROBLEMS IN THE FUTURE. BY BEING PROACTIVE AND FIXING THE
IMBALANCE QUICKLY, THE RISKS OF POOR VENTILATION,
WASTEFUL ENERGY USE, UNEVEN TEMPERATURE DISTRIBUTION,
MORE NOISE AND VIBRATION, AND A SHORTER SYSTEM LIFE CAN BE
AVOIDED. A WELL-BALANCED HVAC SYSTEM WILL WORK WELL,
KEEP PEOPLE COMFORTABLE, AND BE RELIABLE FOR A LONG TIME.

IX. REFERENCES

FG 10XL CENTRIFUGAL INLINE FAN -

PACKARD.BLOB.CORE.WINDOWS.NET. (N.D.-A).
HTTPS://PACKARD.BLOB.CORE.WINDOWS.NET/DOCUMENTS/FANT
ECH_FG_10XL_CENTRIFUGAL_INLINE_FAN.PDF

HVAC DUCTING – PRINCIPLES AND FUNDAMENTALS -

PDHONLINE.COM. (N.D.-B).
HTTPS://PDHONLINE.COM/COURSES/M246/M246CONTENT.PDF

LIBRARY.NAVOIY-UNI.UZ. (N.D.-C).
HTTP://LIBRARY.NAVOIY-UNI.UZ/FILES/HVAC%20SYSTEMS
%20DUCT%20DESIGN%20(3D%20EDINION)(1990)(335S).PDF

VENTILATION. WELDING, CUTTING, BRAZING, SOLDERING

| ENVIRONMENTAL, HEALTH AND SAFETY SERVICES | VIRGINIA
TECH. (N.D.).
HTTPS://WWW.EHSS.VT.EDU/PROGRAMS/WEL_VENTILATION.PHP