“TAB” Testing Adjusting and

Balancing “Technical Basics

Presentation

2021
Ross D. Montgomery, PE., TBE, CCE
ASHRAE: BEAP, HBDP,
AABC-ACG: CxA.
AEE: CEM,GBE,CSDP,CIAQP
1 LU/HSW Credit by AIA ;course # MONTGOMERY07 (TAB)

1- GBCI (US Green Building Council) credit (TAB)

# 0920020165
Testing Adjusting and Balancing
A i r + Wate r S e r i e s
Agenda – Air Side TAB

Air Balancing

Fan Laws,
Fans, Ducts,
Dampers, flow
monitors, etc.
Basic
Measurements

Instruments,
Publications,
Rules and
Procedures
Calculations

Air
calculations
for an
assorted list
of typical
tasks
A B C
A+B+C Basic Air
Balancing Calculations
Measurements
Instruments, Fan Laws, Fans, Air calculations
Publications, Ducts, for an assorted
Dampers, flow list of typical
Rules and monitors, etc. tasks
Procedures

Main subjects of the Talk

 Agenda- Water Side TAB

Pumps, Pump
calculations, Series and Psychrometrics, Moisture
Parallel, Pump curves, and Latent heat
PRV’s, Expansion Tanks, calculations, Controls and
TD valves and VFD’s
BAS systems.

Water Balancing Prep +

Process;
Dead head pumps, clear
strainers, set flows at Pump Laws, Instruments,
central plant, Balance Flow Calculations
Mains, Headers,
Branches, units, etc.
 Testing Adjusting
and Balancing (Engineering and Office Support)

Testing Adjusting Mechanical Contractor

and Balancing (Field Technician)

2
1

3
TEAM
6
BAS/Controls
4
5

Specialty Start Up
and Tuning Crew
Major Equipment and
Manufacturer Reps
 Testing Adjusting Balancing……” It’s all about the numbers and calculations” !!

GPM (gallons
per minute)
6
4 RPM
(revolutions
Head Pressure 5 per minute)
2
Static Pressure

CFM 3
(cubic feet
per minute) BHP (brake
1 horsepower)
 AABC (Associated Air
Who are the Balance Council)

Major
Certifying NEBB (National
Organizations Environmental Balancing
Bureau)
? For (TAB)
Testing
Adjusting and TABB (aka SMACNA) (Test
and Balancing Bureau)
Balancing in
the United
States? ?Other
TAB Icons in the Industry
 Application

Education

Certification Testing

Process Interviews

Background checks
(AABC/
NEBB) Annual meeting attendance

Continuing Education

Annual membership dues

 Testing Adjusting and
Balancing (in the USA)
requires Certification
• In most US states and jurisdictions,
TAB is required on most projects by
CODE.
• Subsequently, legislative
requirements also comes with
mandated credentialed certification.
• Certification has continuing
education required.
• ANSI compliance is becoming
desired and necessary for future
government work
Basics of Why we Perform
TAB
What are the ultimate goals
 Has a “Close” and
“Special” Relationship
with Commissioning
 TESTING ADJUSTING BALANCING

Air + EOR
Water Design

The “air” and “water” side components, devices, TAB - verifies the ENGINEER’s
equipment, and systems, try to meet the design Design and reports any
requirements. (within 5-10%), as shown in the deficiencies/problems
Design Documents
WHAT TYPE OF “AIR” SYSTEMS DO
WE PERFORM TAB SERVICES FOR?
Zoned Chilled Water AHU Systems
AHU’s HVAC
FCU-Unit ventilators
Split DX
Systems
Variable Air Volume Boxes
Exhaust fan systems
VRF
Mini
Splits
TAB PUBLICATIONS
ANSI-ASHRAE
Standards for
(TAB) Testing
Adjusting and
Balancing
 ASHRAE
Performance
Measurement
Protocols
(PMP)
Fundamentals
of HVAC
Control
Systems,
I-P & SI
(2nd edition)
AABC Standards and Technician Training Manual for
(TAB) Testing Adjusting and Balancing
NEBB Testing Protocols
 NEBB Cleanroom
Process/Procedures/Protocols
 BASIC
Measurements
Temperature
Probes and
Instruments
Relative Humidity
Probes and Instruments
Air flow instruments / Flow Hoods
Flow Hood ( Using a Pole)
Air pressure instruments
Voltage and Amperage ++ Meters
Illuminance and Light Level Meters
Kilowatt-hour (Energy) meters
Particle Counters
CO2 measuring Instruments
Sound Meters (dBA)
 Equations…
Brake Horsepower…
Electrical Measurements/
Variable Speed
Calculations Drives (VFD’s)….
 • Single Phase • Voltage (V)
Alternating 110-120 • Amps (A)
volt
• Watts = (W)
• Single Phase
Alternating 220-240 • Impedance (Z)
volt
Basic Electrical • Direct Current (DC)
• Three-wire Delta 3- • Alternating Current
Measurements phase 220-240 volt (AC)
• 220-240 volt 3-wire • Frequency (Hz)
Delta 3-phase
circuit with 110-120 • Phase (ph)
volt single phase • Kilowatt-hour (KwHr)
supply
• Power factor (pf)
• Four-wire WYE
circuit 120/208 volt
3-phase
• 480/277 volt 3-
phase
 • % Imbalance =
Maximum deviation from
avg. voltage x 100/Avg.
Voltage
• Solution:
Electrical * A 2% limit for a 3-phase
Measurements motor circuit is
prescribed. 1. Average voltage imbalance:
“Voltage
240 + 238 + 226 / 3 = 235 v
Imbalance”
Example: Find the voltage
imbalance of a 230 volt 3- 2. Find the maximum deviation
from the average voltage:
phase motor with phase-
to-phase readings of: L1-L2=240-235=5v

L1 to L2 = 240 v L1-L3=238-235=3v
L2-L3=235-226=9v
L1 to L3 = 238 v
From the % imbalance equation:
L2 to L3 = 226 v
% Imbalance= 9 x 100 / 235 =
3.8
• Since 3.8% is larger than 2%,-
-----IT DOES NOT PASS ---
• The AHJ/Engineer should be
notified
 • Brake Horsepower (BHP) =
1.732 x RA x RV x L factor (pf
Electrical x eff) / 746
Measurements,
continued’- Example: Find the brake
“BHP (Brake horsepower for 3-phase
Horsepower)”
motor with the following
conditions:
Average amps: 54
Average volts: 235
Average power factor: 0.87
Motor efficiency: 0.83
• Answer…..
• 1.732 x 54 x 235
(.87x.83)/746= 21.25 BHP
Variable Frequency Drives
offer a great potential for
energy savings. Fan and
pump applications follow
the affinity laws, which
means that flow is
proportional to speed,
pressure is proportional to
the square of
speed, and horsepower is
proportional to the cube of
speed.

That means if an application only

needs 80 percent flow, the fan or
pump will run at 80 percent of
rated speed and only requires 51
percent of rated power. In other
words, reducing speed by 20
percent requires only 51 percent
of the power.
 How do VFD’s save energy?

Example:
• From 100% to 80% speed; resultant
speed is .8x.8x.8
Motor Speed Hertz Savings (cube root of speed)
100% 60 0% • = .51
90% 54 27%
80% 48 49% • = 49% energy savings
70% 42 66%
60% 36 78%
Measuring Duct Air
Velocity and Flows
 Rectangular + Round
+ Oval Ducts

Measuring Duct • Step-1 Locating - Where to

Get the Velocity
Air Velocity and measurements
Flows • Step-2: Measuring Duct Air
Velocity -Getting the Velocity
measurements
• Step-3: Measuring Duct Air
Flows - Calculating the Air
flow measurements
 Measuring Duct Air Flows
(Step-1 Locating Where to Get
the Velocity measurements)
Duct Traverses for Air flow measurements
(velocity)
• There are standards and criteria for
determining where to locate accurate
traverse readings;
• Traverses shall be made 8 diameters
downstream and 2 diameters
upstream from obstructions such as
elbows, transitions, take-offs, etc.
• Use the formula for “Equivalent duct
diameters” d=√4hw/π, where h=height,
w=width, π=3.14
For example using a duct that is 18” wide x
12” high, d=√4(12)(18)/ 3.14 =16.6”
• 8 x 16.6”=132.8” downstream
• 2 x 16.6” = 33.2” upstream
• These are the points where the traverse
points should be taken
Measuring Duct
Pressures
Total Pressure =
Static Pressure (SP) + Velocity
Pressure (VP)
(TP= SP + VP)
Instruments we use are:
• Pitot tubes
• Manometers (U-tube,
micro-, or inclined
manometers)
• Magnehelic gauges
 Equation:
from raw
readings of
pitot tube;
• Velocity
(fpm) =
4005 *
How the Pitot Tube SQRT(VP)
is used in the Duct
Round and Rectangular Duct Pitot tube hole locations
Drilling holes in duct for Traverse
Taking Duct
Traverse
measurements
RECTANGULAR
Duct Example
Measuring Duct Air Flows
[Rectangular Duct (Step-2 Getting
the Velocity measurements)

• Duct Traverses for Air flow measurements (velocity)

• There are standards and criteria for a minimum #
of measurements based on size of the rectangular
ducts
• For example; Rectangular duct: Typical 36”x 24” ;
• If you use the 36” side: divide 36” by 6=6; use 6”
centers (Minimum=6)
• If you traverse the 24” side: divide 24” by 4=6; use
6” centers (Minimum=4)

❖ Note: if internal insulation is used; for example 1”

internal insulation, then subtract the thickness of
the duct inside liner and the inside duct area open
to airflow would be 34” x 22”-adjust calculations
and pitot tube placement accordingly
Sample Calculation of
Velocity and Flow
[Rectangular Duct] (1/5)
• Insert pitot tube into duct holes and take six (6)
readings;
Duct 36” x 24”; 36x24/144
• VP (a) readings = 0.074, 0.288, 0.405, 0.511, 0.715,
0.926 Area = 6 SF
• Use equation Velocity (V) = 4005 * SQRT (VP)
• V(a1) = 4005*SQRT(0.074)=1089
• V(a2) = 4005*SQRT(0.288)=2149
• V(a3) = 4005*SQRT(0.405)=2548
• V(a4) = 4005*SQRT(0.511)=2862
• V(a5) = 4005*SQRT(0.715)=3386
• V(a6) = 4005*SQRT(0.926)=3853
Making traverse measurements using a pitot tube
Sample Calculation of
Velocity and Flow
[Rectangular Duct] 2/5)
• Insert pitot tube into duct holes and take six (6)
more readings; Duct 36” x 24”; Area = 6 SF
• VP (b) readings = 0.064, 0.388, 0.305, 0.411, 0.615,
0.826
• Use equation Velocity (V) = 4005 * SQRT (VP)
• V(b1) = 4005*SQRT(0.064)=1013
• V(b2) = 4005*SQRT(0.388)=2494
• V(b3) = 4005*SQRT(0.305)=2211
• V(b4) = 4005*SQRT(0.411)=2567
• V(b5) = 4005*SQRT(0.615)=3140
• V(b6) = 4005*SQRT(0.826)=3639
Sample Calculation of
Velocity and
Flow[Rectangular Duct] 3/5)
• Continue to do the same for duct holes
c, d, e, f.
Duct 36” x 24”; Area = 6 SF
• VP (c, d, e, f) readings = see next slide
for summary
• Use equation Velocity (V) = 4005 *
SQRT (VP)
• Solve for Velocity (V) for each reading.
 Sample Calculation of
Velocity and Flow;4/5)
• Take all velocity readings and take
average of all readings. (36 readings) Duct 36” x 24”; Area = 6 SF
• 1089+2149+2548+2862+3386+3853+1
013+2494+2211+2567+3140+3639+10
11+2100+2500+2777+3300+3500+999
+2289+2109+2666+3111+3649+2245+
2956+3232+3765+1113+2333+2967+2
688+1299+2533+2422+2169
• 90,664/36=2,518 fpm
Step-3: Measuring Duct
Air Flows [Rectangular
Duct] Calculating the
Air flow measurements)-
5/5

Calculations: cfm= area x velocity

Rectangular ducts: area calculation: (Height x
width )

• Sample: Rectangular Duct = 36” x 24” Area

= 36 x 24 / 144 = 6 SF
• Average velocity = 90,664/36
measurements=2,518 fpm

• Flow = 6 SF x 2,518 fpm = 15,111 CFM

 ROUND
Duct
Example
Measuring Duct Air Flows [Round
Ducts] (Step-2 Getting the
Velocity measurements)

• Duct Traverses for Air flow

measurements (velocity)
• There are standards and criteria for
a minimum # of measurements
based on size of the round ducts
• If the round duct is LARGER
than 10 “, it requires 20
velocity readings
• If the round duct is 10” or
SMALLER, it requires 12
velocity readings
• A sample diagram is shown here for
visualization
 • Example is a 20” Round Duct
• Insert pitot tube into duct holes and
take twenty (20) readings; (10
readings at each hole since the duct is
20” round)

• VP (1) readings (at hole-1) = 0.074,

0.288, 0.405, 0.511, 0.715, 0.926,
0.074, 0.288, 0.405, 0.511
• Use equation Velocity (V) = 4005 *
SQRT (VP)

• V(1) = 4005*SQRT(0.074)=1089
• V(1) = 4005*SQRT(0.288)=2149
• V(1) = 4005*SQRT(0.405)=2548
• V(1) = 4005*SQRT(0.511)=2862
• V(1) = 4005*SQRT(0.715)=3386
• V(1) = 4005*SQRT(0.926)=3853
• V(1) = 4005*SQRT(0.405)=2548

• V(1) = 4005*SQRT(0.511)=2862

Sample Calculation of •
•
V(1) = 4005*SQRT(0.715)=3386
V(1) = 4005*SQRT(0.926)=3853

Velocity and Flow (Round

Duct) 1/4
 • Example is a 20” Round Duct
• Insert pitot tube into duct holes and
take twenty (20) readings; (10
readings at each hole since the duct is
20” round)

• VP (2) readings (at hole-2) = 0.064,

0.388, 0.305, 0.411, 0.615, 0.826
0.064, 0.388, 0.305, 0.411
• Use equation Velocity (V) = 4005 *
SQRT (VP)

• V(2) = 4005*SQRT(0.064)=1013
• V(2) = 4005*SQRT(0.388)=2494

• V(2) = 4005*SQRT(0.305)=2211
• V(2) = 4005*SQRT(0.411)=2567
• V(2) = 4005*SQRT(0.615)=3140

• V(2) = 4005*SQRT(0.826)=3639
• V(2) = 4005*SQRT(0.305)=2211
• V(2) = 4005*SQRT(0.411)=2567
• V(2) = 4005*SQRT(0.615)=3140
Sample Calculation of • V(2) = 4005*SQRT(0.826)=3639

Velocity and Flow (Round

Duct) 2/4
 • Example is a 20” Round
Duct
• Take all velocity
readings and take
average of all readings.
(20 concentric areas x
10 readings/each
direction = 20 readings)
• 1089+2149+2548+2862
+3386+3853+2548,2862
,3386,3853,1013+2494+
2211+2567+3140+3639
+2211,2567,3140,3639
• 67,806/20
readings=3390 fpm

Sample Calculation of
Velocity and Flow (Round
Duct) 3/4
 Step-3 : Measuring Duct Air
Flows [Round Duct] Calculating
the Air flow measurements)-4/4

• calculations: cfm= area x velocity

• Round ducts: area calculation: (π 𝑟 2 )

• Sample: Round Duct diameter = 20”

(radius = 10”)
• Area = (π 𝑟 2 ) = 3.1416 x (.833 ft)(.833
ft)= 2.18 SF
• Average velocity = 67,806/20
measurements=3,390 fpm

• Flow = 3,390 fpm x 2.18 SF = 7,390

CFM
OVAL Duct Treatment Variations;
Next two (2) examples:
Sample Calculation
of Velocity and
Flow [OVAL Duct]
(1/8)

• Insert pitot tube into duct holes

and take six (6) readings; “traverse as rectangle”
• VP (a) readings = 0.074, 0.288,
0.405, 0.511, 0.715, 0.926
• Use equation Velocity (V) = 4005
* SQRT (VP)
• V(a1) = 4005*SQRT(0.074)=1089
• V(a2) = 4005*SQRT(0.288)=2149
• V(a3) = 4005*SQRT(0.405)=2548
• V(a4) = 4005*SQRT(0.511)=2862
• V(a5) = 4005*SQRT(0.715)=3386
• V(a6) = 4005*SQRT(0.926)=3853

Duct 36” x 24”; 2 x 12” semi-rounds

(OVAL)
Area = (36x24/144=6 SF) + (π 𝑟^2)=
(3.1416 x1ftx1ft=3.1416ft)=[6+3.1416 ]
=9.1 SF
Sample Calculation of Velocity and
Flow [OVAL] 2/8)
• Insert pitot tube into duct holes and
take six (6) more readings;
• VP (b) readings = 0.064, 0.388, 0.305,
0.411, 0.615, 0.826
• Use equation Velocity (V) = 4005 *
SQRT (VP)
• V(b1) = 4005*SQRT(0.064)=1013
• V(b2) = 4005*SQRT(0.388)=2494
• V(b3) = 4005*SQRT(0.305)=2211
• V(b4) = 4005*SQRT(0.411)=2567
• V(b5) = 4005*SQRT(0.615)=3140
• V(b6) = 4005*SQRT(0.826)=3639
Sample Calculation of Velocity and
Flow[OVAL] 3/8)
• Continue to do the same for duct
holes c, d, e, f.
• VP (c, d, e, f) readings = see next slide
for summary
• Use equation Velocity (V) = 4005 *
SQRT (VP)
• Solve for Velocity (V) for each reading.
• Duct 36” x 24”; 2 x 12” semi-rounds
(OVAL)
• Area = (36x24/144=6 SF) + (π 𝑟^2)=
(3.1416 x 1ftx1ft=3.1416ft)=[6+3.1416
]=9.1 SF
 Sample Calculation of Velocity and
Flow [OVAL] 4/8)
• Take all velocity readings and take average
of all readings. (36 readings)
• 1089+2149+2548+2862+3386+3853+1013
+2494+2211+2567+3140+3639+1011+210
0+2500+2777+3300+3500+999+2289+210
9+2666+3111+3649+2245+2956+3232+37
65+1113+2333+2967+2688+1299+2533+2
422+2169
• 90,664/36=2,518 fpm (rectangle)

Duct 36” x 24”; 2 x 12” semi-rounds (OVAL)

Area = (36x24/144=6 SF) + (π 𝑟^2)= (3.1416
x 1ftx1ft=3.1416ft)=[6+3.1416 ]=9.1 SF
Sample Calculation of
Velocity and Flow (OVAL
Duct) 5/8
Example is two- 12” semi-circle sections (treat like a 24” round duct)
• Since the width of the rectangle (36”) is greater than the diameter of the
semi-circle (12”), traverse as a rectangle.
• Because the diameter is bigger than 10”, Drill 5 holes at each semi-circle
duct. (required at diameter x .019, .077, .153, .217, and .361 from duct wall)
• Traverse and take 10 readings at each hole
• VP (1) readings (at hole-1) = 0.074, 0.288, 0.405, 0.511, 0.715, 0.926, 0.074,
0.288, 0.405, 0.511
• Use equation Velocity (V) = 4005 * SQRT (VP) fpm
• V(1) = 4005*SQRT(0.074)=1089
• V(1) = 4005*SQRT(0.288)=2149
• V(1) = 4005*SQRT(0.405)=2548
• V(1) = 4005*SQRT(0.511)=2862
• V(1) = 4005*SQRT(0.715)=3386
• V(1) = 4005*SQRT(0.926)=3853
• V(1) = 4005*SQRT(0.405)=2548
• V(1) = 4005*SQRT(0.511)=2862
• V(1) = 4005*SQRT(0.715)=3386
• V(1) = 4005*SQRT(0.926)=3853

“traverse as rectangle”
Sample Calculation of Velocity and
Flow (OVAL Duct) 6/8
• VP (2) readings (at hole-2) = 0.064, 0.388, 0.305,
0.411, 0.615, 0.826 0.064, 0.388, 0.305, 0.411
• Use equation Velocity (V) = 4005 * SQRT (VP)
• V(2) = 4005*SQRT(0.064)=1013
• V(2) = 4005*SQRT(0.388)=2494
• V(2) = 4005*SQRT(0.305)=2211
• V(2) = 4005*SQRT(0.411)=2567
• V(2) = 4005*SQRT(0.615)=3140
• V(2) = 4005*SQRT(0.826)=3639
• V(2) = 4005*SQRT(0.305)=2211
• V(2) = 4005*SQRT(0.411)=2567
• V(2) = 4005*SQRT(0.615)=3140
• V(2) = 4005*SQRT(0.826)=3639
Sample Calculation of Velocity and
Flow (OVAL Duct) 7/8
• Take all velocity readings and take
average of all readings. (5 holes on
each side; 10 holes total= 10 readings
each= 100 readings total
• 312,000/100=3,120 fpm (OVAL)
• 2,518 fpm (Rectangular)
• Average Velocity = 3,120 + 2,518 / 2 =
2,819 fpm
 Step-3 ; Measuring Duct Air Flows [OVAL Duct]
Calculating the Air flow measurements) 8/8

• calculations: cfm= area x velocity (both

rectangular and round)
• Rectangular ducts: area calculation:
(Height x width ); 36” x 24”
• Round ducts: area calculation: (π 𝑟 2 )

• Sample: Round Duct diameter = 24”

(radius = 12”)
• Area = (36”x24”/144=6 SF) + (π 𝑟 2 ) =
3.1416 x (1 ft)(1 ft)= 3.1416 SF=[6 +
3.1416]= 9.1 SF
• Average velocity = 2,819 fpm
• Flow = 2,819 fpm x 9.1 SF = 25,652 CFM
Another
Oval Duct
Example
Sample Calculation of Velocity and Flow [OVAL Duct] (1/3) Duct 12” x 20”; 2 x 10”
semi-rounds (OVAL)

• Because the rectangle width is less than the diameter of the diameter of
the semi-circle, we are going to traverse this OVAL duct as a circle using
the Log Linear method across A-B and C-D in Figure 1.22a

• Insert pitot tube into duct holes and take ten (10) readings; A-B

• VP (A-B) readings = 0.074, 0.099, 0.288, 0.35, 0.405, 0.511, 0.65, 0.715,
0.88, 0.926

• Use equation Velocity (V) = 4005 * SQRT (VP)

• V(ab) = 4005*SQRT(0.074)=1089

• V(ab) = 4005*SQRT(0.099)=1260

• V(ab) = 4005*SQRT(0.288)=2149

• V(ab) = 4005*SQRT(0.35)=2369

• V(ab) = 4005*SQRT(0.405)=2548

• V(ab) = 4005*SQRT(0.511)=2862

• V(ab) = 4005*SQRT(0.65)=3228

• V(ab) = 4005*SQRT(0.715)=3386

• V(ab) = 4005*SQRT(0.88)=3757

• V(ab) = 4005*SQRT(0.926)=3853

Area = (12x20/144=1.66 SF) + (π 𝑟^2)= (3.1416 x.833

“Traverse as “circle” ftx.833ft=2.18ft)=[1.66+2.18]
=3.84 SF
Sample Calculation of Velocity and
Flow [OVAL Duct] (2/3)
• Pitot Tube Readings for C-D of duct
• Insert pitot tube into duct holes and take ten (10) readings;

• VP (C-D) readings = 0.066, 0.087, 0.199, 0.32, 0.41, 0.55,

0.60, 0.75, 0.80, 0.85
• Use equation Velocity (V) = 4005 * SQRT (VP)
• V(cd) = 4005*SQRT(0.066)=1028
• V(cd) = 4005*SQRT(0.087)=1181

• V(cd) = 4005*SQRT(0.199)=1786
• V(cd) = 4005*SQRT(0.32)=2265
• V(cd) = 4005*SQRT(0.41)=2564

• V(cd) = 4005*SQRT(0.55)=2970
• V(cd) = 4005*SQRT(0.60)=3102

• V(cd) = 4005*SQRT(0.75)=3468
• V(cd) = 4005*SQRT(0.80)=3582
• V(cd) = 4005*SQRT(0.85)=3692

Duct 12” x 20”; 2 x 10” semi-rounds (OVAL)

Area = (12x20/144=1.66 SF) + (π 𝑟^2)= (3.1416 x.833
ftx.833ft=2.18ft)=[1.66+2.18]
=3.84 SF
Step-3 ; Measuring Duct Air Flows [OVAL Duct]
(3/3) Calculating the Air flow measurements)

• calculations: cfm= area x velocity

• Rectangular ducts: area calculation: (Height x
width )
• Round ducts: area calculation: (π 𝑟 2 )

• Sample: Round Duct diameter = 20” (radius =

10”)
• Area Duct 12” x 20”; 2 x 10” semi-rounds
(OVAL)
• Area = (12x20/144=1.66 SF) + (π 𝑟 2 )= (3.1416
x.833 ft x .833ft=2.18ft)=[1.66+2.18]
• =3.84 SF
• Average velocity = 2,609 fpm
• Flow = 2,609 fpm x 3.84 SF = 10,018 CFM
 Density Correction for
Altitude and Temperature
*Density Correction*
If the air is different than standard conditions (70 DegF,
altitude at sea level), then a correction for Density can
be made
• Example; Rectangular Duct = 18” x 12” ; Average
velocity = 950 fpm; CFM= [18x12/144] ft2 [950] f/min;
= 1,425 CFM
• Standard Air Density Calculations are based on 14.7 psi
(sea level) and 70 DegF.
If we change those conditions to 7000 feet above sea
level (barometric pressure 23.1 in. Hg and 100 DegF)
• d= 1.325 x 23.1 / 100 + 460 = 0.055
• cf (correction factor)=√0.075/0.055=1.17
• 1425 CFM x 1.17 = 1524 CFM

[Rule of Thumb:]
+ 2% correction for each 1000 feet above sea level
+/- 1% correction for each 10 DegF above/below 70 DegF]
 Question? (Fan Law-3 (BHP-
Density)
• A fan is operating at 5,000
CFM and 4.2 BHP. The density
of the air is 0.062 lbs. per cubic
So, How do we use the foot. FIND the new BHP at
FAN LAWS? In practice? standard conditions (0.075)?
(BHP-Density)

Answer: BHP2=BHP1 ( d2/d1)

• = 4.2 (0.075/0.062)
• = 5.1 BHP
• Density increased….BHP
increased…..
Duct Leakage Ducts and Whole
Building
 The purpose of the standard – Method of Test to
Determine Leakage of Operating HVAC Air
Distribution Systems – is to specify a method of
test to determine leakage airflow and
fractional leakage of operating HVAC air
distribution systems and determine the
uncertainty of the test results.
ASHRAE SPC
215 - 2018
Available Now

ASHRAE SPC-215-2018 takes duct

testing to a new level by specifying
the methods of duct testing to be
used to determine leakage.
 Measuring Duct
Leakage
• Duct Leakage Testing;
• Excessive Duct leakage reduces the air
quantities available at the terminals and
ultimately for the conditioning of the
spaces, therefore should be reduced or
eliminated.
• Typically, the Engineer specifies a “maximum
allowable duct leakage rate”.
• There is a recommended table: (next 4th ppt Slide)
• Duct leakage is affected (caused) by static
pressure, openings in the duct by joints, seams,
access doors, rod penetrations, etc. and
“workmanship”.
• Can be tested on the entire installed duct
system , or,
• Can be tested on a section of installed duct
(before external insulation is installed)
Examples of Duct
pressurization
machines
• For example, using a
blower fan assembly,
air flow measurement
device, and duct static
pressure duct test
device,
• The duct is pressured to
the appropriate
pressure setting per the
table, and the
maximum leakage rate
is observed to make
sure it is within
tolerance
Setting up for Duct Pressure Testing
 Air Duct Leakage Test Summary Sheet

Design Data Field Test Data Record

Surface Allowable Leakage Diameter Static Pressure
Actual
Subject Data Area In Sq. Factor CFM / Across Date Performed By Witnessed By
CFM Orifice Tube Duct CFM
Ft. 100 Sq. Ft. Orifice
 Maximum Allowable Duct Leakage Rates
Figure 24.1 AABC Technician Training Manual

Maximum
Minimum Test
Type of System Allowable
Pressure “(w.g)
Leakage (%)
1. Fractional HP, fan systems; fan
0.50" 2%
coils, small EF’s, SF’s
2. Small Systems ; Split DX- usually
1.00” 2%
under 2000 cfm
3. VAV and CAV boxes and associated
1.00” 2%
downstream ductwork
4. Single zone, multi-zone, low
pressure VAV and CAV systems,
2.00” 2%
return ducts, and exhaust duct
systems
5. All Constant volume ducts in chases
and concealed spaces, main return 3.00” 1%
ducts on supply and supply systems.
6. Supply ducts for VAV and CAV
4.00” 1%
systems
7. High Pressure Induction Systems 6.00” 0.50%

Note; Supply ducts should be tested with positive pressure; return and exhaust ducts
should be tested with negative pressure.
“Whole Building” Ducts and Whole
Building
Leakage
 ASTM Standard E799-87, “Test Method for Determining Air
Leakage by Fan Pressurization.”

To determine if the air barrier functions of the envelope are

constructed properly, air infiltration testing is conducted on a
random sample of rooms using a blower door assembly
following the protocols detailed in ASTM Standard E799-87,
“Test Method for Determining Air Leakage by Fan
Pressurization.”
The blower door testing and subsequent relative pressure testing
are preformed to assure the envelope construction is tight, and
that the HVAC systems is the building have no trouble meeting
the positive pressurization design developed for the HVAC
system.
Functional Performance Testing
(Air pressurization)
 Blower
Doors and
Assemblies
Standards and Methods for Building Enclosure
Commissioning and Testing
• ASTM E1827 ; Standard
Test Methods for
Determining
Airtightness of Building
using an Orifice Blower
Door
• “x” cfm/sq ft @ 50-75
Pa
Blower Doors
Sealing of Windows, Fenestrations, Vents, intake and exhaust louvers,
Bathroom exhaust vent openings, Combustion air intakes, Outdoor air
intakes of air handlers, and indoor grilles.
Sample IgCC Code Mandated
Commissioning Test

606.1.2.2 Testing requirement. The building

envelope air tightness shall be considered to be
acceptable where the tested air leakage is less
than 0.25 cfm/ft2 (4.57 m3/hr/m2) when tested at a
pressure of .30 in w.c. (75 Pa). Testing shall occur
after rough in and after installation of penetrations
of the building envelope, including penetrations for
utilities, HVAC, plumbing, and electrical equipment
and appliances. Testing shall be done in
accordance with ASTM E779.
 Measuring and Changing
Rotational Speeds on Fans
Laser and Strobe tachometers to measure Rotational
Speeds
 Fan/Motor Sheaves

Measuring
and The fan laws will help you make
Changing changes to RPM, CFM, static
pressure, and Horsepower, etc.
Rotational “up and down” as you need it.
Speeds on
Fans
We can change the FAN or
MOTOR sheaves to change
those characteristics
Changing Drive components “Sheaves” to change the
RPM of the Fan
 cfm2= cfm 1
(rpm2/ rpm1)
Fan Law SP2=SP1
Relationships
(rpm2/rpm1)2

BHP2=BHP1
(rpm2/rpm1)3
 Measuring Rotational
Speed and its
Resultant Flows
• Motors drive the fans and pumps that produce
the air and fluid flow in HVAC systems.
• TAB professionals test, adjust, and balance the
rotational equipment.
• The “1st Fan Law” states that that the output
of the fan in cfm varies in direct proportion to
the fans rpm.

Example: A fan running at 750 rpm, and 10,000

cfm is changed to 795 rpm; what is the new flow
rate (cfm)?
Cfm2=cfm1 x rpm2/rpm1=10,000 x
795/750=10,600 cfm
Fan
motor
and
pulley
 • A fan is delivering 1,500
cfm and has a fan sheave
of 13.6” pitch diameter
(Pd).
• We need to reduce the
Example: output of the fan flow to
Changing the 1350 cfm by reducing the
fan speed to 540 rpm.
Pitch diameter
• The motor speed is 1725
(Pd) of the rpm with a pitch diameter
MOTOR sheave (Pd) of 4.75”. What is the
• Rule of Thumb:
new Pd of the motor
sheave to reduce the • Increasing the size of
speed of the fan to 540 fixed pitch MOTOR
rpm and flow to 1350 sheave INCREASES fan
cfm? speed.
• D(m)= rpm(f) x D(f) = • Decreasing the size
540 x 13.6 rpm(m) of fixed pitch MOTOR
/ 1.725 = sheave DECREASES fan
= 4.25 “ speed.
• (Opposite is true
when working with FAN
sheaves)
Example: Changing the Pitch
diameter (Pd) of the FAN
sheave
• A motor and fan sheave have fixed sheaves. The
motor sheave is 6.0” Pd. And the fan sheave is
11.0” Pd.
• The motor speed is 1725 rpm and the fan speed is
940 rpm.
• We need to INCREASE the air flow from 18,000 cfm
to 21,050 cfm by changing the fan sheave diameter
(Pd).
• Answer: First solve for the new rpm (2); rpm (2)=
940 x 21,050/18000= 1100 rpm

• D(f)= rpm(m) x D(m) = 1,725 x 6

rpm(f) / 1,100 =
= 9.4 “
After you change the “sheaves”
you may have to change the
“belts”
• A motor sheave has a pitch
diameter of 3” and a fan sheave
diameter of 7”.The distance
between the shaft centers is
14”Find the new belt length?
• Answer: L= 2(14) + 3.14(7+3)/2
+ (7-3)2 /56
• =28+15.7+0.28=43.9 in.
FANS
 cfm2= cfm 1
(rpm2/ rpm1)
Fan Law SP2=SP1
Relationships
(rpm2/rpm1)2

BHP2=BHP1
(rpm2/rpm1)3
 • Question? (Fan • Question? (Fan
Law-1 (RPM)) Law-1(CFM))
• A fan is operating • A fan is operating
So, How do at a speed of 835 at 655 RPM and
we use the RPM. The volume delivering 12,250
of air out of the CFM. FIND the
FAN LAWS? fan is 6,000 cfm. new CFM
In practice? FIND the new fan delivered by the
(RPM-CFM) speed (RPM) fan if the fan
required to speed is
deliver 6,600 decreased to 625
cfm? RPM?
Answer: Rpm2= Answer: cfm2= cfm
Rpm 1 (cfm2/ 1 (rpm2/ rpm1)
cfm1) • = 12,250
• =835(6600/6000) (625/655)=11,690
=919 rpm cfm
 • Question? (Fan Law-2 • Question? (Fan Law-
(SP-RPM)) 2(SP-CFM))
• A fan is operating at a • A fan is operating at
speed of 835 RPM. 25,000 CFM with a
So, How do we The fan discharge discharge static
static pressure is 2.25 pressure of 4.1 in.
use the FAN in. WC. Find the new WC. The air volume
LAWS? In static pressure if the is reduced to 21,250
practice? (Static fan speed is CFM. FIND the new
Pressure) increased to 920 static pressure.?
RPM?
Answer: SP2=SP1
(rpm2/rpm1)2
Answer:
SP2=SP1(rpm2/rpm1)2 • =SP2=4.1
(21,250/25,000)2
• =SP2=2.25 (920/835)2

• =2.73 in. WC • =2.96 in. WC

 • Question? (Fan Law-2 (SP-
Density)
• A fan is operating at 5,000
So, How do we CFM and at a static pressure of
use the FAN 1.1 in. WC. Air density is at
LAWS? In
practice? (Static standard condition. [0.075]
Pressure-Density) • Find the new static pressure if
the density is increased to
0.15?

• Answer: SP2=SP1 ( d2/d1)

• = 1.1 (0.15/0.075)
• =2.2 in. WC
 • Question? (Fan Law-3 • Question? (Fan Law-
(BHP-RPM)) 3(BHP-CFM))
• A fan is operating at • A fan is operating at
So, How do we a speed of 835 RPM. 25,000 CFM at 20
The motor is BHP. FIND the new
use the FAN operating at 10 BHP. BHP if the air volume
LAWS? In FIND the new BHP if is increased by 10
practice? (BHP- the fan speed is %.?
Brake increased to 920
Horsepower) RPM. ?

Answer: Answer: BHP2=BHP1

BHP2=BHP1 (rpm2/rpm1)3
(rpm2/rpm1)3
• =20 (25,000 x
• BHP2=10 (920/835)3 1.1)/25,000)3
• =13.4 BHP
• =26.6 BHP
 • Question? A fan is • Question? A pump is
delivering 30,000 operating at 2,000
cfm, and the motor gpm with a discharge
is operating at 22 valve wide open, and
BHP. the motor was
Examples; operating at a BHP of
• The fan NEEDS to 62.
Brake deliver 32,000 cfm. • Calculate the new
Horsepower What is the new BHP to DECREASE
BHP? the gpm to 1,850
“Fans and
Pumps” Answer: Answer:
bhp2= • bhp2=
bhp1(cfm2/cfm1)ᶟ bhp1(gpm2/gpm1)ᶟ
Bhp2= 22 Bhp2= 62 (1850/2000)ᶟ
(32000/30000)ᶟ =49 BHP
=26.6 BHP
 Fans Operating in
Series and Parallel
Popular Fan Types in HVAC

• Centrifugal
• Forward curved
• Backward curved
• Radial
• Airfoil
• Tubular
• Axial
• Propeller
• Tube axial
• Vane axial
 A set of
Parallel 10 HP
fans in an
AHU being
operated by
VFD’s
Fans
Operating in
Parallel

Parallel:
• Fans are commonly installed to
operate in parallel in the same
system , particularly when large
volumes of air must be moved.
• The combined performance curve
is obtained by adding the airflow of
each fan at the same pressure.
For example, two fans, each handling
20,000 cfm at 2 in. WC operate in
parallel; the combined curve will have
the output at 40,000 cfm at 2 in. WC.

• Note: CFMs add; Pressure remains

the same.
Fans
Operating in
Series

Series:
• Sometimes multiple fans are
installed in series.
• The combined performance curve
is obtained by adding the fan
pressures at the same air flow
volume.
• For example, two fans, each
handling 20,000 cfm, operating in
series, at 2 in. WC; the combined
curve will have the output at
20,000 cfm at 4 in. WC.

• Note: Pressure adds; CFM remains

the same.
Air Distribution
Duct Drawing
 Dampers Duct Devices (Assists
(Balancing) in making the air to
do what you want it
o Volume and to do)
Types of Balancing o Splitter dampers
dampers
Dampers o Extractors
o Single blade
and Duct o Multi-blade
o Turning vanes
(installed in
Devices (Opposed elbows)
blade or
parallel
blade)
o Temperature
control
o Fire and/or Fire-
Smoke
o Backdraft
Pictures;

Balancing
Dampers
HVAC systems use Dampers to control
temperature direction and volume of the air.

• This is a typical
splitter damper
that is installed
throughout the
duct systems that
are used for
balancing of
branch ducts.
Adjusting Duct Balancing damper
Air Balance Preparation
(+ pre-paperwork)
 Mechanical Site: • Motor starters installed
with proper overloads
• REQUEST and fuses and branch
circuit protection.
STARTUP SHEETS !!!!
• VFD’s operating not
• Record nameplate of over 60 Hz? Or not over
Site motors, fans , coils,
sheaves, belts, terminals
nameplate rated rpm
rating?
Inspections boxes, controls, etc.
• Are all inlets and
• Check ductwork ; make outlets to each room
sure it is complete; is it installed?
sealed with a sealant?
• Are all paths to all
• Make sure access doors rooms installed?
are installed where
needed for concealed • Are all duct paths un-
devices. obstructed?
• Make sure balancing • Are all fire dampers?
dampers are installed in Fire –smoke dampers
ducts where needed + installed? Fire caulked?
open
• Access doors to all fire
• Filters installed and and fire smoke
clean? dampers?
• Belts adjusted; fans and • Access doors to all
pulleys aligned? smoke detector and
smoke detector tubes?
• Are the drive components
installed (sheaves)
 • Air Handling Units:
o Check rotation of
fans
o Filter cleanliness
o Belt tightness and
condition
o Coil conditions
o Static pressure
profiles across fans,
filter banks,
dampers, air
monitors, coils,
heaters, etc.
o Damper conditions
o Enclosure leakage
o Duct connections
o Economizer
Inspections functions
o Control functionality
Basic Air Balance
Procedures
 Building Pressurization • It is important to set up the OA air flows
involves the Outside air with the exhaust flows in mind. If you want
the building to remain positively pressurized,
and Exhaust then the OA flows need to be more than the
exhaust flows.
Air Flow Monitoring
Stations for Ducts
 Design Test
Station No. Area Served Size Area Sq. Ft.
FPM CFM FPM 1 FPM 2 CFM

Air
Monitoring
Station
Data Sheet
 • Air flow monitoring devices are
frequently installed and used for
HVAC systems
• They typically measure differential
Air Flow pressure across a precision orifice
plate or Venturi throat.
Monitoring • They are useful in monitoring and
understanding the on-going
and Use in performance of mechanical
equipment
Sequences of • They are often used in control
Operation sequences of ventilation, exhaust
and relief air control systems
• TAB technicians work with BAS
technicians to calibrate these
devices
Draw out the AHU and duct-diffuser layout
 • Make sure all balancing
dampers are open

• Perform “preliminary
General Process: tests” to see where you
Air Balance (1) are starting at.

• Make sure AHU

traverses (OA/RA/SA)
at AHU are within 10%
of design
Perform PRELIMINARY tests to determine baseline % of design
 • On supply side;
oStart at the CLOSEST
BRANCH (HIGHEST
Flow) from the AHU;
Balance that leg; go
to the next HIGHEST
General Process: flow leg; work your
Air Balance (2) way AWAY from the
AHU; Balance
(proportionately) to
10% design.
oWhen complete; go
back and repeat.
 Look at the 2- closest branches,
and start with the HIGHEST branch
Start with this “highest” branch and proportionately balance
terminals/grilles
Measuring air flow on a ceiling grille
with a Hood
 Example: Balancing
as a practical matter
(SP)
• The design for branch “H” is
660 cfm. The traverse
indicates a total of 710 cfm .
The static pressure at the
traverse point is 1.85 “ WG.
• To obtain a total of 660 cfm,
the volume damper must be
closed until the static
pressure reads 1.6 in. WC.
• SP2=SP1(cfm2/cfm1)2
• SP2=1.85(660/710)2
• =1.6 in.WC
 Branches/Grilles/Terminal
COMBO
General • From pitot tube traverse –or- reading
of outlets, determine which branches
Process: are “over/under” design cfm;
investigate; correct blockages.
Air • Start with closest (and highest
branch), and adjust branch damper
Balance until flow is within 10% of desired
cfm
(3) • ADJUST THE Terminals/Grilles
PORPORTIONALLY FOR THAT BRANCH
[More • Go to next CLOSEST-HIGHEST branch;
Repeat process.
Detailed] • after all other branches are set, go
back and re-check each branch to
make sure all branches are within
10%;
 • On return and
exhaust side;
oGo to the closest
(and highest) to
the AHU; and work
General Process:
towards the
Air Balance (4)
farthest points
outward from the
AHU.
oWhen complete,
go back and
repeat.
Return + Exhaust; pick the HIGHEST and Closest to start with
Then go to next “Highest” and “Closest”
 VAV Terminal
Boxes with Reheat
Duct Drawing
 • Gather your plans and
submittals
• Go to the site
• Make sure the AHU
serving this VAV box is
delivering/operating at
the proper supply air
temperature and static
pressure
• Go to the room where
the VAV box is located
• Make sure the VAV box is
installed correctly
• Make sure the VAV box is
labeled for the correct
room that you are in
• Make sure that if the
heater (electric) is
installed, that the heater
VAV terminal with is not upside down.
(and/or airflow safety
switch is not wired
reheat backwards)
Look at the plans
and submittal
Observe the Max/Min and reheat
CFM requirements
TAB technician;
Make sure BAS
system has pre-
programmed Box
sizes, and all
minimum,
maximum, and
reheat flow
setpoints; SET the
MAXIMUM VAV
box setting at the
thermostat…
 After waiting for a
few minutes for the
control system to
respond to the set-
point, the
technician takes the
hood flow reading
to calibrate the VAV
box AT MAXIMUM.
 The technician does
the same process to
VERIFY AND RECORD
the VAV box test
information for the
MINIMUM cfm
settings, as well as its
temperature sensor,
and any other on-
board devices/sensors.
The technician
verifies and
DOCUMENTS
ALL the
Minimum,
Maximum, and
Reheat
setpoints and
performance
 • Depending if the VAV
box has Hot water
heating or Electric heat?
o Modulate the air
valve to it reheat
position (typically
50% of maximum
flow requirement)
o Operate the heating
device (electric
stages or heating
valve)
o Record cfm and
temperature of
supply air
temperature to
space
o Record space
temperature and
other sensor values
are required
REHEAT COILS o Document heating
devices are working
Typical VAV Box Data sheet

• Document your
VAV box findings
using a
standardized air
distribution
sheet
HVAC REFRIGERATION SYSTEMS
Direct
expansion (DX)
refrigeration
• Common systems used
for small to medium
buildings
• Uses various refrigerants
in a closed pressurized
system to produce
cooling and heating
effects
• TAB forms record all
performance parameters
 • Fan/Evaporator Data:
• Manufacturer Model #/Serial #/Location
o Total CFM
o OA CFM
o RA CFM
o Entering Air temperature (Dry bulb and wet bulb)
o Leaving Air temperature (Dry bulb and wet bulb)
o Amperage
o Volts
o Phase
o Air supply TH
Refrigerant o Cooling BTU/hr coil
o Room Temperature and space humidity

Unit TAB • Condenser Data:

information • Manufacturer Model #/Serial #/Location
o Entering Air temperature (Dry bulb and wet bulb)
o Leaving Air temperature (Dry bulb and wet bulb)
o Amperage
o Volts
o Phase

Note: record any issues or problems with noise, lack of coil

drain pan drainage, etc.
Mini
Split
Data
Sheet
During Balancing Stay Aware of Noise that may Happen
Specialty Room
TAB
Such as Hospital Procedure
and Operating rooms,
pharmaceutical rooms,
chemical mixing rooms, etc.
 Primary Secondary
Tests Tests
Special • Airflow Velocity • Airflow
Parallelism
Clean Room • Airflow Volumes
• Recovery times
TAB Tests • HEPA filter Leak
Tests • Lighting Levels
• Airborne Particle • Sound Levels
Count cleanliness • Vibration Levels
tests
• Electrostatic test
• Room
Pressurization • Conductivity test
• Temperature and • Electromagnetic
Humidity test
• Air change rates
• Bench scan filter
tests
Typical OR and Procedure rooms
USP 797 Limits at
0.5 microns
Clean Air ≥ 0.5 µm
Classification ISO Designation particles/m3

100 5 3,520

1,000 6 35,200

10,000 7 352,000

100,000 8 3,520,000
 United States Pharmacopeia
and The National Formulary
(USP-NF) is a compilation of
Example- drug monographs, biologics,
USP 797 medical devices, dietary
supplements, reference tests
Pharmacy and standards, and standards
Requirement for compounding of sterile and
nonsterile drug preparations.
• THE INTENT OF IS TO PREVENT HARM AND FATALITY TO
PATIENTS THAT COULD RESULT FROM MICROBIAL
CONTAMINATION (NONSTERILITY), EXCESSIVE BACTERIAL
ENDOTOXINS, LARGE CONTENT ERRORS IN THE STRENGTH OF
CORRECT INGREDIENTS, AND INCORRECT INGREDIENTS IN
COMPOUNDED STERILE PRODUCTS (CSPs).”
Typical Clean rooms-Pharma
The “crew” for TAB in “Clean rooms”
Getting ready
to enter the
clean room
Return Grille Velocity testing (with a handheld velometer)
Test Instruments
CO2
testing
Light
meter
tests
Door
Differential
Pressure
tests
Horizonal
Velocity/Draft
testing
 • The airborne particle count
cleanliness classification test is
Particle performed to determine the
actual particle count level within
Count the facility at the time of the test
(As-Built, At-Rest, or Operational).
Cleanliness
tests • The size of particles to be measured for room class
certification shall be as specified in the contract’
for an ISO-8 classification, 0.5 μm 1.0 μm 5.0 μm
are a minimum.
Handheld Particle counter
Using a
Handheld
Particle
meter
Lay out
your Test
Grids
Ambient Conditions

Outside-Ambient Temperature/Relative Humidity 82 DegF

(DegF) (% rh) -- Particle raw data) 84% rh 89543 7887 2164 415 135 12
Average particle counts per square meter (cfm x 35.31) 278490 76411 4767
Ambient CO2 (ppm) 420 ppm

Room-101 50 9 450 13
Room Use-Classification (Gown-Molding)
Test location 1 (raw data from instrument) 20 15 15 8 6 3
Test location 2 (raw data from instrument) 24 17 14 4 3 0
Test location 3 (raw data from instrument) 170 75 32 12 9 5
Test location 4 (raw data from instrument) 60 44 29 17 10 5
Test location 5 (raw data from instrument) 801 172 40 8 5 1
Test location 6 (raw data from instrument) 500 50 15 5 2 1
Average raw particle counts @0.1cfm 263 62 24 9 6 3
Avg. Particle counts per cubic foot (per ft3/min) 2625 622 242 90 58 25
High Particle counts per cubic foot (per ft3/min) 8010 1720 400 170 100 50
Average particle counts per square meter (cfm x 35.31) 92689 21951 8533 3178 2060 883
Maximum ISO-8 Classification allowed 3520000 832,000 29300
Status of Room relative to Code minimum Passed Passed Passed
Temperature (DegF)/Humidity (% rh) 59/64%
Grid - minimum #samples required//taken 6
Air changes per hour[ cfm/ft3 (350x60/450)] 46
Average Light Intensities (foot-candles) 46-112 fc
Carbon Dioxide (CO2) (parts per million) 460 ppm
Room Dimensions; cubic feet

Outside-Ambient Temperature/Relative Humidity 82 DegF

(DegF) (% rh) -- Particle raw data) 84% rh 89543 7887 2164 415 135 12
Average particle counts per square meter (cfm x 35.31) 278490 76411 4767
Ambient CO2 (ppm) 420 ppm

Room-101 50 9 450 13
Room Use-Classification (Gown-Molding)
Test location 1 (raw data from instrument) 20 15 15 8 6 3
Test location 2 (raw data from instrument) 24 17 14 4 3 0
Test location 3 (raw data from instrument) 170 75 32 12 9 5
Test location 4 (raw data from instrument) 60 44 29 17 10 5
Test location 5 (raw data from instrument) 801 172 40 8 5 1
Test location 6 (raw data from instrument) 500 50 15 5 2 1
Average raw particle counts @0.1cfm 263 62 24 9 6 3
Avg. Particle counts per cubic foot (per ft3/min) 2625 622 242 90 58 25
High Particle counts per cubic foot (per ft3/min) 8010 1720 400 170 100 50
Average particle counts per square meter (cfm x 35.31) 92689 21951 8533 3178 2060 883
Maximum ISO-8 Classification allowed 3520000 832,000 29300
Status of Room relative to Code minimum Passed Passed Passed
Temperature (DegF)/Humidity (% rh) 59/64%
Grid - minimum #samples required//taken 6
Air changes per hour[ cfm/ft3 (350x60/450)] 46
Average Light Intensities (foot-candles) 46-112 fc
Carbon Dioxide (CO2) (parts per million) 460 ppm
 Collect raw data from
particle counting device
Area of Height of Cubic Feet Cubic Meter Particle 0.3 Particle 0.5 Particle 1 Particle 3 Particle 5
Locations Value
room (ft2) Ceiling (ft) (ft3) (m3) micron micron micron micron micron
Particle 10 micron

Outside-Ambient Temperature/Relative Humidity 82 DegF

(DegF) (% rh) -- Particle raw data) 84% rh 89543 7887 2164 415 135 12
Average particle counts per square meter (cfm x 35.31) 278490 76411 4767
Ambient CO2 (ppm) 420 ppm

Room-101 50 9 450 13
Room Use-Classification (Gown-Molding)
Test location 1 (raw data from instrument) 20 15 15 8 6 3
Test location 2 (raw data from instrument) 24 17 14 4 3 0
Test location 3 (raw data from instrument) 170 75 32 12 9 5
Test location 4 (raw data from instrument) 60 44 29 17 10 5
Test location 5 (raw data from instrument) 801 172 40 8 5 1
Test location 6 (raw data from instrument) 500 50 15 5 2 1
Average raw particle counts @0.1cfm 263 62 24 9 6 3
Avg. Particle counts per cubic foot (per ft3/min) 2625 622 242 90 58 25
High Particle counts per cubic foot (per ft3/min) 8010 1720 400 170 100 50
Average particle counts per square meter (cfm x 35.31) 92689 21951 8533 3178 2060 883
Maximum ISO-8 Classification allowed 3520000 832,000 29300
Status of Room relative to Code minimum Passed Passed Passed
Temperature (DegF)/Humidity (% rh) 59/64%
Grid - minimum #samples required//taken 6
Air changes per hour[ cfm/ft3 (350x60/450)] 46
Average Light Intensities (foot-candles) 46-112 fc
Carbon Dioxide (CO2) (parts per million) 460 ppm
 ISO 14644-1 Cleanroom Standards
Maximum Particles/m3 FED STD
Class 209E
≥0.1µm ≥0.2µm ≥0.3µm ≥0.5µm ≥1µm ≥5µm Equivalent
ISO
10 2.37 1.02 0.35 0.083 0.0029
1
ISO
100 23.7 10.2 3.5 0.83 0.029
ISO 14644-1 2
ISO
Cleanroom 3
1,000 237 102 35 8.3 0.029 Class 1

ISO
Standard(Most 4
10,000 2,370 1,020 352 83 2.9 Class 10

current) ISO
5
100,000 23,700 10,200 3,520 832 29 Class 100

ISO 1.0 x 10<sup6<

237,000 102,000 35,200 8,320 293 Class 1,000
6 sup=""></sup6<>
ISO 2.37 x
1.0 x 107 1,020,000 352,000 83,200 2,930 Class 10,000
7 106
ISO 2.37 x 1.02 x Class
1.0 x 108 3,520,000 832,000 29,300
8 107 107 100,000
ISO 2.37 x 1.02 x
1.0 x 106 35,200,000 8,320,000 293,000 Room Air
9 108 108
Summary Particle Counts
and Pass/Fail
Outside-Ambient Temperature/Relative Humidity 82 DegF
(DegF) (% rh) -- Particle raw data) 84% rh 89543 7887 2164 415 135 12
Average particle counts per square meter (cfm x 35.31) 278490 76411 4767
Ambient CO2 (ppm) 420 ppm

Room-101 50 9 450 13
Room Use-Classification (Gown-Molding)
Test location 1 (raw data from instrument) 20 15 15 8 6 3
Test location 2 (raw data from instrument) 24 17 14 4 3 0
Test location 3 (raw data from instrument) 170 75 32 12 9 5
Test location 4 (raw data from instrument) 60 44 29 17 10 5
Test location 5 (raw data from instrument) 801 172 40 8 5 1
Test location 6 (raw data from instrument) 500 50 15 5 2 1
Average raw particle counts @0.1cfm 263 62 24 9 6 3
Avg. Particle counts per cubic foot (per ft3/min) 2625 622 242 90 58 25
High Particle counts per cubic foot (per ft3/min) 8010 1720 400 170 100 50
Average particle counts per square meter (cfm x 35.31) 92689 21951 8533 3178 2060 883
Maximum ISO-8 Classification allowed 3520000 832,000 29300
Status of Room relative to Code minimum Passed Passed Passed
Temperature (DegF)/Humidity (% rh) 59/64%
Grid - minimum #samples required//taken 6
Air changes per hour[ cfm/ft3 (350x60/450)] 46
Average Light Intensities (foot-candles) 46-112 fc
Carbon Dioxide (CO2) (parts per million) 460 ppm
 • Mini-Split and DX units
That is a general Air
• Constant Volume AHU’s
Balance Procedure; • Multizone AHU’s
There are much more • Terminal VAV Boxes
specific procedures o Single Duct Constant Volume
available for ;
o Dual Duct
o Induction Box
o Bypass Box
o With or with heaters

• Variable Volume AHU’s

o Single duct pressure dependent
o Single duct pressure independent
o Fan powered
o Dual duct
o With or without heaters
Are you Ready For
TAB-Water????
 Hydronic Instruments Water side
and Flow Measurement Balancing
Air and Water
• We are reminded that air
and water are BOTH fluids,
BUT….
• They behave similarly
• Water has a much
higher density than air
• Air weighs 0.08
Lbm/ft3
• Water weighs 8.33
Lbm/ft3
 gpm2= gpm 1 (rpm2/
rpm1)

Pump Law
Relationships h2=h1 (rpm2/rpm1)2

BHP2=BHP1
(rpm2/rpm1)3
WATER SYSTEMS
Chillers
Hot Water Boilers
Chiller and Pumps (ONA)
Pumping Systems
Solar systems
TAB helps to calibrate
water sensing devices
BTU-Energy Meters
Water Pressure Meters
Water flow Instruments
Water Differential Pressure
 Differential
Pressure gauges
• Used on Pumps to measure suction
and discharge pressures, strainer
pressure drop, flow rates across flow
meters, and pressure drop across
discharge valves.
• Differential gauges eliminate the
need for 2 separate gauges
• Can have manifolds that can be
switched to have multiple
functionality to read many different
configurations
Flow Meters
 Practical Flow
(gpm)
measurement
examples
• A water chiller is rated at
30 gpm with a 4.6 feet of
pressure drop. The
entering pressure drop is
measured at 28 feet and
the leaving pressure is 25.5
feet. FIND the actual flow
rate?
• Answer>
• Gpm2 = Gpm1 √∆P2 / ∆ P1
• Gpm2 = 30 √(28-25.5) / 4.6
• =22 gpm
 • Using Temperature
Difference (heat transfer
rate) through the Coil:
• Gpm=Btuh/500 x deltaT
• A chilled water coil has an
Practical Flow entering temperature of 44
DegF and a leaving
(gpm) temperature of 54 DegF. The
heat transfer rate through
the coil has been calculated
measurement at 60,000 Btuh.

examples • FIND the flow rate?

• Gpm=60,000/500 x 54-44
• Using a Control valve
manufacturers “flow • =12 gpm
coefficient” calculation.
• An automatic control valve
has a Cv of 25. the valve is
placed in the full open
positon and the entering
pressure is measured at 5
psi. the leaving pressure is
3.5 psi.
• FIND the flow through the
valve.
• Gpm = Cv √∆P
• Gpm = 25 √5-3.5
• =30.6 gpm
Pumps
Pump Layout
Types of Impellers
Common HVAC Pumps Characteristics
Common types of HVAC Pumps
• Volute
• Diffusion vane or Turbine
• Centrifugal
• radial flow impeller
• Mixed flow impeller
• Axial flow impeller
• Closed impeller
• Open impeller
• Semi-open impeller
• Positive displacement
• Reciprocating
• Rotary
• screw
Bad things that can happen with Pumps
that TAB watches out for(1):

Make sure:
• Pump seals are in-
tact and
operational
• Pump bearings
are smooth, quiet,
and lubricated.
• Pump couplings
are aligned
Bad things that can happen with Pumps
that TAB watches out for (2):

• Cavitation:
• A condition when inside the centrifugal pump,
the internal pressure falls below the operating
vapor pressure of the liquid, causing the liquid
to “boil and vaporize”
• Causes “snapping and crackling noises” at the
inlet; severe vibration; a drop in Head and
Brake horsepower; a reduction or stoppage of
flow.
• To eliminate cavitation, it is necessary to
maintain a minimum suction pressure at the
pump suction inlet to overcome the internal
losses in the pump. See (NPSH) Net Positive
Suction Head graph.
 gpm2= gpm 1 (rpm2/
rpm1)

Pump Law
Relationships h2=h1 (rpm2/rpm1)2

BHP2=BHP1
(rpm2/rpm1)3
 Theoretical Water
Horsepower formula:
Brake horsepower
• Whp = gpm x head x uses a pump
sp. Gr. / 3,960 efficiency factor.
“Theoretical” • Note: SP. Gr. =1
(water between 32- • Bhp = gpm x
head x sp. Gr. /
Water 212 DegF)
3,960 x pump
• Since all pumps are efficiency
Horsepower NOT 100% efficient,
(due to friction and • Example: FIND
turbulence losses) the BHP of a
we do not typically pump operating
use “theoretical”
and water horsepower.
at 142 feet of
head and 980
gpm, with an
efficiency of
74%.
“Brake”
Horsepower • Bhp = 980 x 142
x 1 / 3,960 x 0.74
=47.5
 ❑Question? (Pump Law-1 (RPM))
• A pump is operating at a flow of
100 GPM. The speed of the
motor is 1755 rpm. FIND the
So, How do we use the new GPM when the speed is
Pump LAWS? In raised to 1900 rpm?
practice? (RPM-GPM) • Answer: gpm2= gpm 1 (rpm2/
rpm1)
• =100(1900/1755)
=108.2 GPM
 • Question? (Pump Law-2 • Question? (Fan Law-
So, How do we (Head-RPM)) 2(Head-GPM))

use the Pump • A pump is operating at a

head pressure of 125
• A pump is operating at
a head pressure of
LAWS? In feet of water. The speed
of the motor is 1755
125 feet of water. The
flow is 200 GPM. FIND
practice? rpm. FIND the new head
pressure when the
the new head
pressure when the
speed is raised to 1900 flow speed is raised to
rpm? 300 GPM?
(Head • Answer:
Answer:h2=h1
Pressure) • h2=h1 (rpm2/rpm1)2 (gpm2/gpm1)2
• h2= 125 (1900/1755)2 • h2=125 (300/200)2
=146.4 feet of water = 281.25 GPM
 ❖ Question? (Pump Law-3 ❖ Question? (Pump
(BHP-RPM)) Law-3(BHP-GPM))
• A pump is operating at a • A pump is operating
speed of 835 RPM. The at 100 GPM at 20
So, How do we motor is operating at 10 BHP. FIND the new
BHP. FIND the new BHP
use the Pump if the pump speed is
BHP if the flow
volume is increased
LAWS? In increased to 920 RPM. ? to 150 GPM.?
practice?
Answer:
BHP2=BHP1 (rpm2/rpm1)3
(BHP-Brake BHP2=10 (920/835)3 Answer:
Horsepower) • =13.4 BHP • BHP2=BHP1
(gpm2/gpm1)3

• =20 (150/100)3

• =67.5 BHP
 Question? (Pump Law-3
(BHP-Density)
• A pump is operating at
20 BHP with an impeller
How do we use the diameter of 10” . FIND
Pump LAWS? In the new BHP if the
practice? impeller is increased to
(BHP-Impeller
11.5”?
Diameter)
Answer: BHP2=BHP1
(d2/d1)3
• BHP2=20 (11.5/10)3
• =30.41 BHP
Pumps Operating in
Series and Parallel
 Parallel: Series:
➢ When pumps are ❑ When pumps operate
installed to operate in in Series, Heads and
parallel, in the same Horsepower's are
system, GPM’s and BHP’s additive (+++)
are additive (+++).
❑ GPM’s (Flows remain
Pumps in ➢ Heads (Pressures remain
constant.)
constant)
❑ For example: if a single
➢ For example: if a single pump operating at 60
pump operating at 60 gpm, 120 feet of head,
gpm, 120 feet of head, 3 3 BHP, is added in

Series BHP, is added in parallel

with an identical pump
operating at 60 gpm and
series with an identical
pump operating at 60
gpm and 120 feet of
120 feet of heat, head,
➢ the result would be , a ❑ the result would be , a
total flow of 120 gpm, at total flow of 60 gpm, at
and 120 feet of head,
requiring 6 BHP.
240 feet of head,
requiring 6 BHP.
➢ Note: GPMs and BHP ❑ Note: Heads and BHP
add; Heads remains the add; GPM remains the
same. same.
Parallel
 Series and Parallel Pump Curves

SERIES Parallel
 Basic Hydronic
(Pumping) Systems
Simple Example of a Hydronic (pumping) system
Simple Examples of Hydronic pumping systems
(Open + Closed)

Closed System Open System

Water Balance
Preparation
 • START UP REPORTS!!! • Are the piping devices accessible for
maintenance and measurement?
• Is equipment installed and has
it been started by the
contractor or manufactures'’ • Is the piping totally installed and free
representative ?? of leaks
• Is the piping insulation installed
• Check rotation of shafts and
Inspections •
impellers
Are strainers clean
• Ae all valves, flow meters and
pressure taps accessible for
measuring
• Are all balancing valves accessible
• Alignment of shafts
• Has the system been cleaned and
• Is there excessive vibration or flushed
noise
• Has the system been filled to the
• Proper lubrication proper level and the PRV set up to the
proper pressure
• Take Pressure measurements • Are the air vents set up and the air
across suction and discharge, purged from the system; do you hear
control valves, diffusers, any air noise?
meters, Static pressure profiles • Is the water expansion tank installed
across fans, filter banks, and working
dampers, air monitors, coils,
heaters, etc.
• Look for Piping connections
(with flexible connections for
vibration)
• Insulation and drainage into
pan and floor drain
• Control functionality
More • Are the pump motors • Are the flexible
wired and energized connectors installed
Inspections…. • Are the starters and • Are the start up
overload protection reports completed
installed
• Are the operational
• Are the motors secured and safety
on their frames temperature and
pressure devices
• Are the motors and installed and
pump bearings operational
lubricated
• Is the rotation
direction checked
• Is the maintenance
clearance adequate
Basic “Water” System Balance
Procedures
 • Record nameplate data on forms
• Record design data on forms
• Check rotation of each pump
• Check for un-due noise or
vibration (when rotating in
correct direction)***
Pre-setting • Take electrical measurements
…..Pre-filling out and record as “actual” data on
Paperwork….. forms. (Amperage should not
exceed nameplate rating; voltage
should be within 10%)
• Calculate and the record the BHP
(brake horsepower)
 *** Mechanical
Contactor checking
for proper Pump
shaft alignment and
balance; installed
sheaves and
balancing (This and
next two PPT
slides>>>)
Technician
balancing
Pump
shaft
 Set in
Sheaves
under pump
motor when
necessary for
balancing
 Start at the
Central plant
Primary Secondary Chiller Plant
 • Water quality is IMPORTANT to the TAB process; maintain
the best water quality as possible.
• Flow meters and DP sensors need “clean water”.

Start the TAB • Check the settings and gauge readings for the make-up
water pressure (typical low-rise buildings;30-35 psi)
process- • Make sure all large AHU/FCU control valves are open in the
secondary systems
Prepare
• Start 2-pumps and 2-chillers (all systems on)
• Test each pump BY ITSELF (Parallel INDIVIDUALLY;;; or Series-
RUNNING TOGETHER)
Make sure pressure taps and gauges are installed and
working
Connect water pressure meter to pressure ports
Primary Secondary Chiller Plant
SET BLOCK OFF/SHUT OFF:: TO VERIFY IMPELLER SIZE
 Block-0ff; Deadhead; in the Plant-
Primary side
• Block off Pump-1; Verify the impeller size of the pump by
“dead-heading” the pump and reading its pressure and
comparing it to its pump curve data.
• Block off Pump-2; Verify the impeller size of the pump by
“dead-heading” the pump and reading its pressure and
comparing it to its pump curve data.

• Determine the flow at the pump by reading the pressure

differential across the pump with accurate gauges, (double
check with pipe mounted gauges), and/or with pipe-installed
flow meters.
o It is important to start with the flow to be within 10% of
design
Consult pump curves to understand and plot pump operation AND
DETERMINE IMPELLER size
 Set Primary pumps; the TAB process
in the Primary side

• Throttle VFD in order to get chiller evaporator barrel required

DP (+10% of design)
o After adjustments are made, record all electrical,
pressure, flow, and impeller sizes on the TAB forms. (and
write in magic marker on chiller and VFD’s)
o Set the high limit speed at the VFD control panel

Note; Better to control flow thru the chiller barrel by

DP and not rely on flow meters only.
Primary Secondary Chiller Plant
Take readings of Differential Pressure
Record DP and % speed of VFD
Primary Secondary Chiller Plant
SET BLOCK OFF/SHUT
OFF: TO VERIFY
IMPELLER SIZE
Block-off; Deadhead; at the
Secondary Pumps
• Make sure all large AHU/FCU control valves are open in
the secondary systems, and the chiller plant primary
pumps are operating—Very Important!!!
• Test each secondary pump BY ITSELF (Parallel
INDIVIDUALLY;;; or Series-RUNNING TOGETHER)
• Block off Sys Pump-1; Verify the impeller size of the pump
by “dead-heading” the pump and reading its pressure and
comparing it to its pump curve data.
• Block off Sys Pump-2; Verify the impeller size of the pump
by “dead-heading” the pump and reading its pressure and
comparing it to its pump curve data.
Compare to pump curves and calculate performance of
pump flow and pressure
Importance of Secondary
flows and pressures
• Make sure all large AHU/FCU control
valves are open in the secondary
systems
• New technology introduces Pressure
independent control valves with built
in maximum flow devices.
• Keeps flows restricted to a maximum per
valve
• TAB should check initial valve installation and
operation
• Helps with pressure regulation of pumping
systems
Setting the Flow at the Secondary
Pumps
• Determine the flow at the pump by reading the pressure differential
across the pump with accurate gauges, (double check with pipe
mounted gauges), and/or with pipe-installed flow meters.
o It is important to start with the flow to be within 10% of design

• Throttle VFD in order to get the desired flow (GPM) -+10% of design
o After adjustments are made, record all electrical, pressure, flow,
and impeller sizes on the TAB forms. (and write in magic marker
on VFD’s)
o Set the high limit speed at the VFD control panel
o Make sure do not pump more than design flow +105%, when
VFD’s are at 60 Hz during full cooling mode (all valves open)

Note; Do not use triple duty valve (TDV) to adjust flow---use VFD.
Question?? Making adjustments to flow using VFD’s (or Triple
duty valve) to match “desired design requirements”
Balancing the Distribution System
next; Using the diagram Let’s
identify the Mains, risers,
branches and take-off at each
terminal
Typical Water
distribution
system
components
Main +
Headers
 ➢ Mains:
➢ Using the data obtained from
reading the pump data, determine
the “main’ common output is
delivering 100-110% of design flow
(gpm).
➢ Headers:
➢ Adjust the “headers” starting with
Balancing mains, the headers with the HIGHEST
headers… (1/4) flow. Set this headers balancing
valve until the water flow is within
10% of the desired amount for that
header.
➢ Read the other headers, set their
balancing valve to within 10% of
their design flow rates.
➢ Cont’d…….
Start at
HIGHEST
Header
Go to next
HIGHEST
Header
 ➢ Risers:
➢ Go to the “highest riser” (WITH THE
MOST FLOW) and adjust risers
balancing valve until the water flow
is within 10% of the desired amount
for that riser.
➢ Continue to balance all of the
Balancing risers, branches and coils on that branch
(proportional)
and
➢ Read the other risers, Go to tbe
branches/Coils.. “Next Highest Riser” (most flow); set
(2/4) their balancing valve to within 10%
of their design flow rates.
➢ Continue to balance all of the
branches and coils on that branch
(proportional)

➢ Next….Cont’d…….
Risers
 ➢Branches:
➢Go to the “highest branch” and
adjust branch balancing valve
until the water flow is within 10%
of the desired amount for that
branch.
➢Read the other branches, starting
from the highest to its lowest,
Balancing and then set their balancing valve
to within 10% of their design
branches/Coils.. flow rates.
(3/4) ➢After all branches are adjusted;
go back and re-check them. This
will usually take going back 2-3
times.
➢Cont’d…….
 Pick the
highest Riser;
then balance
the branches
and coils
 Go to the
next highest
Riser; then
balance the
branches and
coils
 Finish the
entire Riser;
then move to
the next
Risers
 • Many times….

• We get a lot of TAB devices to

(adjust) TAB at the Plant
• After that….
• Typically, when we leave the Plant,
(all we get) we get auto-balancing
(Reality) is…… valves at the AHU’s, FCU’s, etc.
• Or, we get “automatic
balancing/PICCV, or energy
valves” provided as a part of the
BAS/Controls that monitor
pressure and adjust flow rates
with the DDC control algorithm
Put together the TAB report
Remarks or Issues Found
Remarks or Issues Found
 Typical
AHU Data
sheet
Typical EF
Data sheet
Typical AHU
Data seet
Typical
Chiller Data
sheet
Thanks !!!!!
• I hope you enjoyed a BASIC >>>
• Testing Adjusting and Balancing TALK

• Please let me know if you have any Questions or

Comments…

• Thanks for allowing ASHRAE to be of service to your

chapter….
Questions
?