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    Duct Design and Installation

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    Olanrewaju Abyss
    Duct Design ACCA Manuals J, T, and D or Equivalent Proper Design and Selection - Estimate Loads 1. Determine Design Heating Loads 2. Determine Design Cooling Loads - Sensible and Latent 3. Determine the airflow required to each room Proper Design Provides Quiet Efficient Comfort Recommended Velocity (in fpm) Continuous Fan 5000 Annual kWh 4000 3000 2000 1000 0 PSC Motor ECM Auto Fan 1. Continuous duct leakage losses and conduction losses 2.

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    Duct Design and Installation

    Uploaded by

    Olanrewaju Abyss
    712 views61 pages
    Duct Design ACCA Manuals J, T, and D or Equivalent Proper Design and Selection - Estimate Loads 1. Determine Design Heating Loads 2. Determine Design Cooling Loads - Sensible and Latent 3. Determine the airflow required to each room Proper Design Provides Quiet Efficient Comfort Recommended Velocity (in fpm) Continuous Fan 5000 Annual kWh 4000 3000 2000 1000 0 PSC Motor ECM Auto Fan 1. Continuous duct leakage losses and conduction losses 2.

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    Duct Design ACCA Manuals J, T, and D or Equivalent Proper Design and Selection - Estimate Loads 1. Determine Design Heating Loads 2. Determine Design Cooling Loads - Sensible and Latent 3. Determine the airflow required to each room Proper Design Provides Quiet Efficient Comfort Recommended Velocity (in fpm) Continuous Fan 5000 Annual kWh 4000 3000 2000 1000 0 PSC Motor ECM Auto Fan 1. Continuous duct leakage losses and conduction losses 2.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    712 views61 pages

    Duct Design and Installation

    Uploaded by

    Olanrewaju Abyss
    Duct Design ACCA Manuals J, T, and D or Equivalent Proper Design and Selection - Estimate Loads 1. Determine Design Heating Loads 2. Determine Design Cooling Loads - Sensible and Latent 3. Determine the airflow required to each room Proper Design Provides Quiet Efficient Comfort Recommended Velocity (in fpm) Continuous Fan 5000 Annual kWh 4000 3000 2000 1000 0 PSC Motor ECM Auto Fan 1. Continuous duct leakage losses and conduction losses 2.

    Copyright:

    Attribution Non-Commercial (BY-NC)
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
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    The document discusses proper duct design and installation based on industry standards like ACCA manuals. Key factors for an efficient system include proper sizing, sealing, insulation, and layout.

    Proper duct design involves estimating heating and cooling loads, determining airflow requirements, selecting register locations and sizing the ductwork to available pressure based on manuals like ACCA T and D.

    Factors that contribute to an efficient duct system include low duct leakage through sealing, short runs with fewer larger diameters, insulation, and using metal ducts and fittings.

    Duct Design and Installation

    John Proctor, P.E. Proctor Engineering Group, Ltd. San Rafael, CA

    1-888-455-5742 [email protected] www.proctoreng.com 2004 Proctor Engineering Group, Ltd.

    Duct Design
    ACCA Manuals J, T, and D or Equivalent

    Proper Design & Selection Estimate Loads


    1. Determine Design Heating Loads 2. Determine Design Cooling Loads Sensible and Latent 3. Determine the airflow required to each room

    Proper Design

    1. Determine the best locations for the air terminals (registers) Use ACCA Manual T 2. Design the duct system to the available pressure and minimize the effective length Use ACCA Manual D or Equivalent

    A Good Duct Design Provides


    Quiet Efficient Comfort

    Recommended Velocity (in fpm)


    Supply Duct Type Trunk Branch Outlet Return Grille Face Filter Grille Rigid 700 600 Size for Throw <500 <300 Flex 600 600 Return Rigid 600 400 Flex 600 400

    Efficient
    FAN WATT DRAW REDUCTION SUFFICIENT AIRFLOW LOW DUCT LEAKAGE
    SEAL WITH MASTIC OR SNAP-DUCT PUT INSIDE THE CONDITIONED SPACE

    LOW CONDUCTION LOSS


    SHORT RUNS FEWER LARGER DIAMETER RUNS PUT INSIDE THE CONDITIONED SPACE USE METAL DUCT AND FITTINGS

    Comfort
    TEMPERATURE DIFFERENCE BETWEEN ROOMS < 2 F IDEAL 4F MAXIMUM SO USE A CONTINUOUS FAN?

    NO

    Why not just add an Electrically Commutated Motor (ECM) and use a continuous fan?
    Continuous Fan 5000 Annual kWh 4000 3000 2000 1000 0 PSC Motor ECM Auto Fan

    1. An ECM uses as much power running continuously as a PSC motor does running on Auto
    (Scott Pigg, Wisconsin Study)

    2. Continuous duct leakage losses and conduction losses 3. ECM motors are not magic When pressures are too high they can use more electricity and burnout

    ECM Motors Maintain Airflow (up to a point) but can use more watts than a PSC
    1,800 1,600 1,400 1,200 Airflow (CFM) Watts 1,000 800 600 400 200 0 0.0 0.2 0.4 0.6 0.8 1.0 Static Pressure (IW) ECM 800 700 600 500 PSC 400 300 200 100 0 0.0 0.2 0.4 0.6 0.8 1.0 Static Pressure (IW) ECM PSC

    Comfort comes from a designed system


    Duct System Must Be Designed to Deliver Correct Amount of Air to Each Supply Terminal AND Each Supply Terminal Must Be Carefully Sized and Located AND Each Supply Terminal Must Be Chosen With Adequate Mixing and Throw AND There Must Be an Adequate Return Path for Each Supply

    Terminals
    SUPPLY LOCATION (old recommendation) PERIMETER UP OUTSIDE WALL (HEATING) CEILING PARALLEL TO CEILING OUT TO WALLS (COOLING) HIGH INSIDE WALL PARALLEL TO CEILING TO OUTSIDE WALL (COOLING)

    Returns Adequate Air Pathways


    Return Type Single Advantages Disadvantages

    Low Cost Potential for Inadequate Provides Accessible Filter Return Pathways (Pressure) Location Potential for Noise Low Surface Area Adequate Return Paths High Cost Excessive Duct Leakage Unnecessary in Open Floor Plan

    Every Room

    Return Location
    Mixing in a Room is Largely Unaffected by Return Location Return Location MAY Have a Small Effect on House Level Stratification House Level Stratification is More Affected by AC Size

    Duct Design Considerations


    WHAT DETERMINES FLOW THROUGH UNIT? EXTERNAL SYSTEM PRESSURE DROP = EQUIPMENT PRESSURE GAIN

    AT DESIRED FLOW

    External System Pressure Drop = Equipment Pressure Gain


    Fan Pressure Gain External System Pressure Drop

    Operating Point

    Generic External System Pressure Drops


    DEVICE Standard Filter High Efficiency Filter Humidifiers/Electric Heaters Supply Outlet Return Grille Balancing Damper Coil Duct System PRESSURE DROP .10 Clean .20 Clean .10 to .20 .03 .03 .03 Open .15 to .45 wet coil

    What is left

    Coil Pressure Drop

    CFM 1000 1200 1400

    Static Pressure (Wet Coil) 0.23 0.33 0.45

    G2FD036(S,H)21(T)

    Filter pressure drop is .05 0.24 in H2O Median is 0.15


    Cooling Filter Pressure Drop
    0.25 0.20 0.15 0.10 0.05 1 6 11 16 21 26 31 36 41 46 Number

    in of w a te r

    20" X 20" MERV 8 Air Filter


    1 0.9

    Static Pressure Drop

    0.8 0.7 0.6 0.5 0.4 0.3 0.2 0.1 0 0 200 400 600 800 1000 1200 New Filter Filter Loading

    Air Flow (CFM)

    Example Pressure Drop


    DEVICE Supply Register Return Grille Balancing Damper Coil Total EXCLUDING DUCTS PRESSURE DROP .03 .03 .03 .33 wet coil

    .42

    Equipment Pressure Gain

    .45 IWC at 1200 cfm

    Cannot work only .03 IWC available for duct system


    WHAT DETERMINES FLOW THROUGH UNIT? EXTERNAL SYSTEM PRESSURE DROP = EQUIPMENT PRESSURE GAIN

    0.42 IWC + Ducts

    0.45 IWC

    AT DESIRED FLOW

    1200 cfm

    Stick with Smaller Air Handler Smaller Fan Motor

    Solution
    Keep smaller air handler Use a less restrictive coil (0.21 IWC) Drop the dampers External system pressure drop becomes:
    Return Grille Supply Register Coil TOTAL .03 .03 .21 .27 + Ducts 0.45

    Equipment Pressure
    at Med. Hi and 1200 cfm

    Available for ducts

    0.45 0.27 = 0.18

    Now we need to know the friction rate (IWC/100 ft.)


    We have an available static pressure of 0.18 Inches of Water Column What do we want to divide that by to get the friction rate?

    The Total Effective Length

    How Long is the Duct System? (from an air molecule's view)


    A 200 ft. straight pipe is 200 feet long

    This 4 ft. section of pipe is how long?

    Supply Boots
    4-G
    Fitting Number 4-G 4-J Effective Length 80 ft. 30 ft.

    4-J

    Supply Plenums and Takeoffs


    Fitting Number 1-O 1-P with Vanes Effective Length 60 ft. 40 ft.

    1-O

    1-P

    2-A
    Downstream Branches 2-A 2-B 0 35 20 1 45 30 2 55 35

    2-B
    3 65 40 4 70 45 5 or + 80 50

    A Simple Duct Design


    4-G

    10 ft.

    Run 1 5 ft.

    15 ft.

    2-A 1-O
    Plenum Trunk

    2-B
    Run 2

    10 ft.

    Furnace

    4-J

    A Less Simple Duct Design


    550 CFM

    4-J
    20 ft.

    4-J

    4-J

    4-J

    18 ft.

    Run 1

    Run 2

    12 ft.

    160 ft EL Return

    10 ft.

    2-B
    5 ft. 5 ft.

    2-B 1-P 2-B


    Run 3

    2-B

    2-B
    5 ft.

    5 ft. 5 ft. Trunk

    5 ft.

    Plenum

    2-B
    Run 6

    12 ft.

    12 ft.

    Furnace

    4-J

    4-J
    90 CFM

    Calculate the Total Effective Length from the return grille to the supply register

    A simple takeoff can be as little as 10 feet Or as much as 115 feet Through good design we got the overall equivalent length to 300 feet So we have 0.18 IWC available static pressure over 300 ft. The friction factor is .06 IWC per 100 ft (0.18/300 = 0.06)

    Recommended Velocity (in fpm)


    Supply Duct Type Trunk Branch Outlet Return Grille Face Filter Grille Rigid 700 600 Size for Throw <500 <300 Flex 600 600 Return Rigid 600 400 Flex 600 400

    Why not just use 0.10 IWC /100 ft. Friction Rate on a Ductalator?
    BECAUSE DESIGN VALUE FOR FRICTION RATE IS NOT ARBITRARY FRICTION RATE DESIGN VALUE DEPENDS ON AVAILABLE STATIC PRESSURE AND TOTAL EFFECTIVE LENGTH

    Desirable Design
    SHORT DUCT RUNS LOW STATIC PRESSURES INSIDE CONDITIONED SPACE GOOD THROW ON REGISTERS

    Duct Installation
    Put in what is designed Straight Leakless Proper Flow Proper Distribution

    Duct Testing
    Leakage Flow Distribution

    Duct Leakage in Existing Homes


    12% 10%
    % of Sample

    8% 6% 4% 2% 0% 5% 15% 25% 35% 45% 55% 65% 75% >80%


    CFM 25 / Nominal Airflow
    Sample size: 1210 (no mobile homes) Test method: Duct Blaster at 25 pa. (0.10WC) Source: CheckMe! database

    Duct Sealing Saves Energy and Peak


    Required Sensible Cooling (BTUh)
    25,000

    20,000

    15,000

    10,000
    Manual J7 16% Supply Leakage, 11% Return Leakage 2%Supply Leakage, 11% Return Leakage 2% Supply Leakage, 3% Return Leakage

    5,000

    0
    80 85 90 95 100 105 110 115 120

    DUCT LEAKAGE TESTING


    Total Leakage Leakage to Outside Supply Side Leakage Return Side Leakage Operating Leakage

    TOTAL LEAKAGE SET-UP


    REMOVE FILTERS MOUNT DUCT BLASTER @ AH OR RETURN GRILLE ALL SUPPLY REGISTERS COVERED ALL RETURN GRILLES COVERED DUCT TEST REFERENCE PRESSURE IN SUPPLY PLENUM (STATIC PRESSURE PROBE)

    Duct Blaster Test Method


    MEASURE CFM TO KEEP DUCTS AT 25 PA MEASURE CFM TO KEEP DUCTS AT 25 PA

    DUCT TESTING PROCEDURE


    KEEP FAN PRESSURE ABOVE 30 PASCALS (SWITCH FLOW RING IF NEEDED) FLOW RING SELECTION
    OPEN RING 1 RING 2 RING 3 1,500 TO 500 800 TO 200 300 TO 75 125 TO 30

    Duct Leakage Standards


    CFM 25 as % of Cooling Nominal Flow
    Nominal Flow as 400 CFM per ton 5%, 6%, 8%

    CFM 25 as % of Actual Flow CFM 25 as % of Floor Area

    Low Airflow
    Arizona New Construction Blasnik et al. 1996

    All of the audited forced air systems showed low air handler flow Danny Parker Florida Study 1997

    Measuring Airflow
    Temperature Split Method

    Duct Blaster Flow Capture Hood Flow Grid


    Coil Pressure Drop Fan Curve Pitot Tube Traverse Anemometer

    AC Temperature Split
    Run to steady state (15 minutes) Measure return wet bulb and dry bulb temperatures Measure the supply dry bulb temperature This is the most critical part of the procedure
    System stabilized The measured temperatures as close to the mixed PLENUM AIR TEMPERATURES

    55

    80 67 wb

    Determining Target Temperature Split


    Target temperature split is not constant
    Target temperature split varies with Return dry bulb Return wet bulb

    Determine the target temperature split


    Based on chart or slide rule

    Maximum Temperature Split Table


    50 23.9 24.9 26 27.1 52 23.6 24.7 25.8 26.9 54 23.1 24.2 25.3 26.4 27.5 Return Air Wet-Bulb (F) 56 58 60 62 64 22.5 21.7 20.7 19.5 18.2 23.6 22.8 21.8 20.6 19.3 24.7 23.9 22.9 21.7 20.4 25.8 25 24 22.8 21.5 26.9 26.1 25.1 23.9 22.5 28 27.2 26.2 25 23.6 28.2 27.2 26.1 24.7 28.3 27.2 25.8 66 16.7 17.7 18.8 19.9 21 22.1 23.2 24.3 68 14.9 16 17.1 18.2 19.3 20.4 21.5 22.5 70 13 14.1 15.2 16.3 17.4 18.5 19.6 20.6 72 12 13.1 14.2 15.3 16.4 17.5 18.6 74

    Return Air DryBulb (F)

    70 72 74 76 78 80 82 84

    11.9 13 14.1 15.2 16.3

    TrueFlow Flow Grid

    Grid Installs in Filter Slot

    Duct Blaster Test Method


    Take supply static pressure with air conditioner running Block blower compartment from return system Install Duct Blaster on the blower compartment door Turn on air handler Adjust Duct Blaster speed to duplicate supply static Read airflow from Duct Blaster

    Desired Air Flow


    SHR Below 0.74 0.74 to 0.79 0.80 to 0.85 Above 0.85 CFM per Ton 300 350 400 450

    Flow to Rooms
    Within +- 10% +- 20% Max.

    Write the Specifications Sign the Contract Breathe Easy --- NOT
    Any equipment installed must perform as intended

    These items are accomplished by human beings and are subject to error.

    With Initial Feedback the Crews Learned Rapidly. With Continued Feedback They Maintained Good Savings When Feedback Was Removed the Savings Dropped to 30% of the Maximum
    Measured Savings as a Percent of Achievable Savings (running average)

    100% 80% 60% 40% 20% 0%


    Program Startup, Learning Curve with Technician Feedback Production with Feedback M aintained Disaster when Feedback was Removed

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