COMMERCIAL/INSTITUTIONAL KITCHEN EXHAUST AND MAKE-UP AIR ANALYSIS, DESIGN AND SELECTION APPLICATION GUIDE

Preface

The procedure of ventilation equipment selection should follow an analysis based on the cooking line-up, menu, operating hours and quantities of cooked food. Predetermined selections based on initial costs are very short sighted and unrealistic. Kitchen ventilation is subject to many constraints and forces which must be examined and evaluated together. Cooking as a process within a building must be treated as such. When any consideration is understated operating costs will increase and sanitation will suffer. Climatic conditions vary greatly, therefore each application must be related to its local characteristics, It is unrealistic to design a system the same for northern Alaska as for Southern Texas. This simply is not possible. With energy costs having dramatically risen to a point where the kitchen exhaust hood system is the biggest energy user in the kitchen, it has unleashed those who would prey on the uninformed. They speak of free air or no cost to you exhaust/make-up systems when, in reality, the costs are greater than if a system had been analyzed an designed for its intended purpose. New building and fire code requirements have recently been enacted which have caused significant changes in engineering requirements. These code requirements are in a constant state of flux and must be monitored constantly to assure compliance of the hoods and all related equipment. Indoor air quality, air pollution control methods and heat recovery systems are also becoming integral parts of the exhaust hood system.

PART 1 Contemporary Exhaust Control Devices Kitchen Exhaust Ventilation

Currently there are two common types of exhaust hoods. Those with internal baffles which are called grease extractor hoods. These may include an internal wash system or may be manufactured as cartridges for manual washing. Those which use removable filters are called grease filter hoods. These must be removed and manually washed. Both are subject to the same standards when evaluated by an independent testing agency. Grease Extractors By design Grease Extractors should remove in excess of 95%, by weight, of the grease produced by the cooking process. This very efficient method of grease and particle removal from the air stream is especially important when the exhausted air must be cleaned to satisfy ecological requirements or where very high grease loads will cause damage when deposited on the roof or sides of a building. Most extractors utilize centrifugal force as the grease extraction method. The ventilator causes the exhaust air to be pulled through a series of tight turns at high velocity causing the heavier grease particles to agglomerate, separate from the air stream and collect on the interior surfaces. When an automatic wash system is a part of the Grease Extractor, automatic controls should include a hot water and detergent wash down system to remove the debris collected during the cooking operation. The exhaust fan normally does not operate during this sequence. The wash system should be automatically activated in the event of high exhaust gas temperatures above 325oF. This will serve as a secondary back up to the fire suppression system. Activation of the system maybe used to shut off the exhaust fan and close a fire damper located either at the chamber inlet or outlet. The Grease Extractor has the highest grease removal efficiency and is suited for applications where grease loading is high. Grease Extractors may utilize continuous cold water sprays to congeal grease particles in the air stream as a secondary method of extraction. Such systems offer an advantage over centrifugal type extractors when 2

extremely high (140oF or greater) exhaust air temperatures are encountered. The cooling water spray will cause vaporized grease to congeal, yielding an extraction efficiency higher than the straight centrifugal unit. Furthermore, these systems serve to regulate exhaust gas temperatures, there by stabilizing or reducing exhaust requirements between idle and load use of the cooking equipment. High operating and maintenance costs are associated with continuous water sprays. Grease Extractors are also available with removable cartridges in lieu of the wash system. This allows for the cleaning of the cartridges in a dishwasher and a significant additional initial cost saving. When labor costs are high or when little shut down time is available for hood cleaning, the addition of a wash system is advantageous. It should be noted here that products claiming to be grease extractors are being manufactured which are intended for use in filter hoods. These products have a horizontal slot opening. However the grease extracting performance is much lower and not suitable for use as a Grease Extractor. (See filter hoods) Filter Hoods The filter hoods use metal filters to remove already agglomerated grease droplets from the air stream prior to entering the exhaust duct. Filter hoods are referred to as Bulletin 96 canopies, a reference to NFPA Bulletin 96 which governs construction requirements for commercial kitchen applications. Filter hoods are available as Listed if they have been successfully tested. Underwriters Laboratories establishes the standards for the filters which are known as UL Classified Filters. The primary purpose of these filters is to remove liquid grease droplets from the air stream, drain the grease away and serve as a fire stop. All classified filters cause grease removal by centrifugal force and the collected grease drains from the surface into a grease gutter. The filters are installed in a vertical position to no less than 45 degrees off horizontal plane. The efficiency of these filters is approximately 50 to 60%, by weight. It should be noted that these filters do not reduce duct grease buildup as efficiently as grease extractors do. Pre-code filters were typically wire mesh that removed grease by impingement. Such filters are no longer permitted due to their flammability and the rapid increase in pressure drop associated with grease collecting and congealing in the filters. High Velocity Hoods High Velocity (HV) hoods combine a high velocity type slot with a filter hood. Their design incorporates the UL classified filter as the primary grease removal means. The opening is limited to only a few inches in order to accelerate and direct the inlet of gases, thereby 3

improving smoke capture. Air volume selections are the same as for the grease extractor, when applying rules of directional air flow. They are applied in moderate grease load applications. Initial cost is slightly above the standard filter hood and below that of the grease extractor. UL Hood and Damper Assemblies Exhaust hoods may be constructed as UL Hood and Damper Assemblies through the addition of an automatic fire damper located in the exhaust duct collar. The automatic damper prevents fire from reaching the duct work and contains the fire. The use of Hood and Damper assemblies is determined solely by local fire codes. UL 710 (as revised in 1992) The UL 710 testing procedure is the nationally accepted method of determining the suitability of a manufacturers hood for use over cooking equipment.

The results of this test procedure places restrictions on how a specific hood may be used. The main restrictions include: The maximum cooking surface temperature over which the hood may be placed. The maximum vertical distance between the front lower edge of the ventilator and the cooking equipment. The minimum allowable exhaust air volume The maximum allowable internal make up air volume for each type of internal makeup air delivery method The maximum overall length of the hood per exhaust collar location Special methods of construction This information is available from the independent testing agency which performed the tests.

Devices - Principles of Operation

Figure 1
Bulletin 96 Design UL Listed Hood

Figure 2
Grease Extractor UL Listed Hood

The most frequently used hood arrangement contains filters (Figure 1).The exhaust fan draws room air into the canopy and through the filter. The pan on top of the range is the source of contaminants and heat that are working against the air curtain. The air curtain is denoted by the arrowed lines from the front edge of the equipment. When the air curtain is not strong enough to contain the contaminants, it is very easy for these contaminants, at the velocity emanating from the range, to escape into the room. This why it is important to maintain a 20 to 60 feet per minute velocity at the front edge, depending upon the type of equipment being ventilated, Note that these velocities are obtained without any internal make-up air. The heat of the cooking equipment creates an upward thermal current that will naturally enter the canopy if not disturbed by external air currents. The edge velocity is in part related to the speed of exhaust gases entering the filters but diminished by the distance away from the same filter. The use of very large filters will cause low pressure drop and very low edge velocity. Frequently the area nearest the duct connection works well but spillage (leakage) occurs at the ends. The Grease Extractor (Figure 2) draws exhaust air through a lineal slot and creates velocities at the front edge of the cooking equipment of 20 to 60 feet per minute, depending on the manufacturers design and the equipment being ventilated. Because a grease extractor uses higher extraction velocities than a filter hood it can create higher capture velocities at the front edge of the cooking equipment (or lower CFM/lineal foot). The rising thermal currents are accelerated into the high velocity inlet slot. As the capture speed increases air rushes in to take its place causing a draft and thus capture. 5

Figure 3
High Velocity 96 Design

(Figure 3) The high velocity filter hood utilizes a moderately high slot speed to establish capture. The slot may vary from 3" to 5" of opening to accommodate 200 to 350 CFM/lineal feet of hood in the same manner as the more familiar grease extractor. Consequently required static pressure for the velocity increase must be in addition to the usual requirements for a conventional filter. The major advantages are capture with less cfm/lineal foot and reduced system initial cost over grease extractors.

TABLE 1: TYPICAL EXHAUST HOOD DATA Hood Style Filter Hood 96" Figure 1 Greatest 250 - 400 Least .4 - .9" W.G. Same Lowest Highest Fair 40 -60% Grease Extractor Wash Hood Figure 2 Lowest + 150 - 350 High 1.3 - 1.7" W.G. Same Highest Least Best 90 - 95% High Velocity HV96" Figure 3 Moderate 150 - 350 Moderate .7 - 1.3" W.G. Same Moderate Moderate Moderate 50 -60%

Per Lineal Foot CFM Static Pressure HP Initial Cost ** Operational Cost * Grease Removal

* Includes cost of energy exhaust, routine daily and periodic maintenance. ** Lower figures are for use with light duty cooking equipment. + Use in conjunction with higher volume island and sectionalized hood for combined rating.

Contemporary Make-Up Air Methods Evolution has been from no make-up air, to opening doors and windows, through health and sanitation codes and finally the evolution of high energy costs. Engineers now must make exact value judgements on the selection of how to introduce make-up air. The reason for make-up air is profound. The exhaust system is the most expensive consumer heating and air conditioning source in the building.

Figure 4
Front Grill, Style F

The first filter canopies with make-up air were grills (Figure 4) in the front panels that introduced air in the a manner which diffused the air into the kitchen, allowing it to drop and be pulled into the hood, similar to a hood without make-up air. The results were the same capture effect as a standard filter canopy without makeup air. Grills are ideal for dry climates where evaporative cooling is used. However, if the kitchen is air conditioned a draw back results in the temperature of the make-up air in the summer time being higher than that of the conditioned air in the kitchen. The make-up air is mixed into the return air of the HVAC system of the kitchen causing an increased air conditioning load. The system is ideal for desert climates such as Arizona.

Figure 5
Down Discharge, Style D

The first attempts at air curtain make-up air delivery were the use of down discharge grills (Figure 5), slots or holes. Unfortunately, excess velocity caused many problems which included loss of inbound edge velocity. This permits the contaminants produced by the cooking equipment to move into the kitchen. Another problem is that air delivered from the perimeter slot does not tend to flow in a straight line - it feathers. Any smoke caught in this situation has a tendency to work its way to the outside and, because of the feathering, some of the smoke rolls into the kitchen atmosphere. The make-up air should be heated to 65 degrees to make it comfortable for the chef. Another objection to this system is that the air velocity striking the cooking staff is so strong that it is very annoying. It is common to find in practice that the chef has turned off or reduced the make-up air supply to such a low velocity that it defeats the initial purpose.

Figure 6
Air Curtain/ Low Velocity, Style EZ

In the final evolution of curtain air delivery two factors emerged which have proved vital for good air delivery to enhance capture; low velocity and downward orientation delivered from a front supply point. The EZ Air system (Figure 6) is a low velocity air curtain that creates a make-up supply area directly in front of the hood. The air supply, working in conjunction with the lower pressure developed under the hood from the exhaust, causes a controlled air movement through the area between the bottom of the hood and the cooking surface. Using low velocity, the system can utilize makeup air temperatures of 45 to 50 degrees F when allowed by code. In most localities this will reduce the energy consumption of the hood by 50% to 75% over the utilization of room air at 65 degrees or above.

Short Circuit Make-up Air Essentially, there are only two types of make-up air chamber distribution methods. These are air curtain as described above, and internally injected make-up air known as short circuit or internal space compensating. Short circuit hoods were designed initially to circumvent initial equipment mandated by codes which set dilution air (room air) requirements for fire safety. The code official gave little consideration to the initial operating cost of systems, The requirements were simply to reduce the exhaust temperature. Thus, an unwitting discussion has opened the door for many ideas: mostly short sighted. Short circuit hoods have several common failings. The air introduced under the hood reduces the air curtain effect. As the percentage of air introduced inside the hood air increases, the edge velocity reduces. At the equivalent of 50% of exhaust as make-air, the edge velocity is 0 to 15 FPM. From that point on the designer must realize that cross current form other air systems and employee movements will cause spillage. Additional sudden flare-ups such as charbroiling, frying and opening of compartment/oven doors will emit grease vapor to the room. Use of short circuit hoods beyond low input cooking lineups such as for nursing homes, soup line-up and grills will emit grease vapor to the atmosphere and floor.

The following three designs have seen their trials and failed: Figure 7 High Velocity Short Circuit Make-up Air Figure 8 Slow Velocity Short Circuit Make-up Air Figure 9 Multi-point Short Circuit Make-Up Air

Figure 7 While high velocity make-up air injected as shown in (Figure 7)can induce room air near the aspirating point the effect is nearly zero FPM at the surface edge. As the percentage of make-up air increased above 50%, it negates the room air or drives out the contaminated gas from under the hood. The design velocity at the make-up air slot is usually 1,000 to 2,000 FPM. The filter velocity is around is around 300 to 400 FPM. The make-up air rebounds off of the filter because it cannot accept the velocity. Imagine a water hose with a quarter inch orifice and a full flow of water. Try to force the water through a 1 inch hole 3 feet away. The same effect is true with the air in a canopy. When the outside temperatures fall below freezing, the air that normally flows straight across the canopy from the front to the filter has a tendency to drop because it is heavier or more dense. When the temperature drops in to the teens, the air will prevent the contaminants from rising. Cold air does not mix well with hot air being produced at the surface of the cooking equipment. A good analogy of this is a weather front. When a cold front from the north meets warm air form the south, a storm develops. The same thing is true of a short circuit hood. As the Cold air enters and falls, it will force the contaminated hot air into the room or down to the floor.

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Canopies designed on the principle that hot air will eventually rise utilize larger overhangs, such as 12 to 24 inches plus 30 inch deep hoods to help capture lighter smoke. However, the heavier contaminated particles will be lost below the hood.

Figure 8 Slow velocity short-circuit hoods, as shown in use a series of large linear grills. The purpose of the grills is to bring the air in at a lower velocity to avoid causing the air to bounce off the filters as discussed above. Because it is a low velocity type the problem is the thermocline effect commonly known as inversion. Hot, polluted vapors cannot penetrate the colder, denser barrier above the cooking equipment. The grease and water vapors condense and fall to the floor or onto the cooking personnel. Figure 9 The difference between Figure 8 and Figure 9 is that the manufacturer is introducing make-up at the rear as well. As outside temperatures fall below freezing, the raw air will expand and push out the contaminants and therefore negate capture in the attempt to increase the percentage of make-up air by introducing air behind the cooking equipment. If the amount of this air is too great a large amount of grease may be deposited behind and below the cooking equipment as the cold outside air comes in direct contact with the hot highly contaminated fumes of the cooking equipment. This causes a severe sanitation problem if not properly designed. Furthermore, this air may cause a problem with gas pilot lights and could cool the cooking surface thus interfering with cooking operations and greatly increasing cooking equipment energy usage. Short circuit designs such as Figures 7, 8, and 9 are very limited by physical conditions. Many manufacturers depend on the cook to change damper settings for winter or summer to compensate for changing air volume due to changes of air density of outside air. It is likely that the cook will eventually close the outside air because it interferes with his work or blows on him. When the make-up air supply is eliminated the more expensive air from the building is used in its place.

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A New Design In light of the well established short comings of present designs, the Tri-Air hood has been developed to minimize the physical and thermal impact of raw air injected inside the hood. Figure 10 Style Tri-Air The Tri-Air is a truer design of the short-circuit system than ever offered before. Approximately 50% of the exhaust gas volume A , is injected at the top of the hood. It is slip streamed across an air foil surface and into the area between the filter and the HV baffle. The venturi action induces the rising current carrying vapors and particulate to enter the filters. The temperature/thermal expansion impact is very minimal since the exposure area is limited to only a few inches externally. The mixing will occur at or beyond the filters. Two additional make-up air volumes of approximately 15% of exhaust each are injected under the hood. The volume B moves gently across the interior of the hood and contains the effluent toward the HV baffle and filters. The additional volume, C , is introduced as curtain air and cools the cooking personnel. The cold outside air expands when mixed with the internal source of heated air, thus increasing the actual percentage of volume of short - circuit air. In all short -circuit hoods, the volume of make-up air supplied during the cold season must be less than the volume during the warm season. Two speed makeup air fans will manage the volume by moving full volumes of warm air and 2/3 volume of cold air. More on this matter in Part III.

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TABLE 2: TYPICAL MAKE-UP AIR DATA

Expansion Volume And/0r Room Air Loss Summer Winter

Distribution

For A/C Kitchen

Discharge Temperature Required

Relief from Radiant Heat

Max. % Of Make-up Air Recommended Summer-Winter

Personal Comfort

Comments

Figure 4 Front Grill STYLE F Figure 5 Down Discharge STYLE D Figure 6 E-Z AIR Curtain Style Figure 7 High Velocity Short Circuit Figure 8 Low Velocity Short Circuit STYLE IM Figure 9 Multi Point Short Circuit Figure 10 Tri-Air

Room

No

70o F

Poor

85%

85%

15%

15%

None

Evap. Cooled kitchens only. Discomfort caused by velocity supply air. Ideal for cold climate with high radiant heat. Ideal for A/C kitchens Requires excessive amount of room air. Requires excessive amount of room air.

Chefs Work Area Chefs Work Area Inside Hood Inside Hood

Yes

70o F

Fair

60%

60%

40%

40%

Poor

Yes

40-50o F

Good

85%

85%

15%

15%

Good Excellent None

Yes

35oF

None

50%

35%

50%

65%

Yes

35oF

None

60%

40%

40%

60%

None

Inside Hood Inside Hood

Yes

35oF

None

50%

35%

50%

65%

None

Requires greater overhangs and excess room air. Ideal for mild to hot humid climates or A/C kitchens. For light to medium duty line-up

Yes

Any

Fair

80%

54%

20%

46%

Excellent

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PART II DESIGN ANALYSIS Exhaust

Why Use A Hood? 1. To control an environment for capture of effluent. 2. To induce air flow. 3. To protect the region from flame, heat and particulate matter. What is Important? 1. An exhaust hood should shape the air flow characteristics, be easily cleanable, be constructed of non-combustible materials and not interfere with the process which it is ventilating. Hood designs relate directly to process characteristics: the energy load beneath it, the contaminant load, the process and the characteristics of the building in which it is contained. The process energy is the cooking line input which expands gases; i.e., products of combustion, water vapor, grease, hydrocarbons. An exhaust fan creates an air flow that moves the gases in a specific direction.

2.

So The Primary Considerations Are: 1. 2. Exhaust volume is determined by heat energy input of the cooking line. The exhaust air volume must be greater than the heat expansion from the cooking surface plus any internally injected make-up air. Capture can only be maintained if air movement between the lower edge of the hood and the cooking surface has an inward velocity of not less than: a. 15 feet per minute for light duty b. 25 feet per minute for medium duty c. Exceptional heat loads may require up to 60 feet per minute d. Particulate loads should determine the efficiency requirement of the grease extraction unit.

3.

14

How Does It Work? Capture is the controlled movement of gases in a specific direction which combines those gases into one mixed gas temperature. The mixed gas condition of a kitchen exhaust system is comprised of room air, make-up air at another temperature and the expanded effluent produced by the cooking line. The hot effluent rising from the heated surfaces will create a slight pressure differential which induces room air replacement. It is this volume of rising gas which must be exhausted since it contains grease as liquid and vapor, water vapor, various odors and noxious gases. To achieve capture, a mechanical draft establishes the direction of flow through the physical structure of the hood. The capture characteristic is constant and must be great enough to overcome the movement of gases emanating from the cooking line and other air turbulence from outside sources including make-up air and room air. The capture effect of a hood can be improved by overhangs which restrict the outward expansion of the gases. Overhang is the space between the edge of the cooking equipment and the edge of the hood in a vertical plane. The exhaust volume requirement for capture is determined by the process and the distance of the hood from the process. Normally, a shelf hood requires less draft than a wall canopy for the same process.

Make-up Air Why Use Make-Up air? 1. 2. 3. To replace the excess air needed to control capture and dilute gas temperatures. To manage energy expenses. To manage building air pressure.

What Is Important? Air Density Hoods function at ranges of conditions 70 to 110 F. degrees and approximately 14.7 PSIA. The operating conditions of the exhaust gas as measured at the exhaust collar of the hood will range between 90 and 140 degrees F. depending upon the cooking load and make-up air temperature. Most cooking lines have a fairly constant energy input controlled by thermostats. The kitchen room temperature varies and the make-up air can vary greatly. Since the exhaust fan is a constant volume device, it is critical that the make-up air variable be controlled. 15

Variations in the make-up air load are related directly to the air density. Example: St. Paul - winter design -10 degrees F and a summer roof-top temperature of 110 degrees F yields a 26% to 37% variation (depending on relative humidity) which must be compensated for during the course of the year in order to maintain uniform conditions. Raw air cannot be brought in without seasonal adjustment. Make-up air tempered to 50 degrees F or evaporatively cooled to 84 degrees F has a density controlled within +4.8% to -2.5%.
Table 3: TEMPERATURE CORRECTION FACTORS Outside Air Temp. Degree F -40 -30 -20 -10 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Density Correction Factor 1.26 1.23 1.20 1.18 1.15 1.13 1.10 1.08 1.06 1.04 1.02 1.00 .98 .96 .95 .93 .92 .91 .89 .87 Dry Air (@29.921" Hg.) Lbs/CFT .095 .092 .090 .088 .086 .085 .083 .081 .079 .078 .076 .075 .074 .072 .071 .070 .068 .067 .066 .065 Moist Air (@29.921' HG.) Lbs/CFT .095 .092 .090 .088 .086 .085 .083 .081 .079 .077 .075 .073 .071 .069 .066 .064 .061 .057 .05 .049

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This table has been designed as a convenient method to determine the actual exhaust gas volumes being applied in an exhaust/make-up system. To determine the actual air volume for other than standard air at 70 degrees F and 29.92" barometer, multiply the air volume (CFM) by the LBS/CFT dry air at the initial temperature divided by the LBS/CFT at the new temperature to equal the ACFM. Since the conditions include substantial water vapor, then use the Moist Air values. CFM X Initial LBS/CFT / New LBS/CFT = ACFM @ 29.921" Hg. Primary considerations Are: 1. The kitchen area must be negative in pressure in relation to surrounding public areas, but may remain positive in relation to atmosphere. Exception: Health care facilities. Make-up air injected internally to the hood does not improve capture but only serves to reduce gas temperatures under the hood. Internal make-up air reduces room air changes. Make-up air volume is determined by exhaust air volume. Make-up air distribution location is determined by room air change requirements. The type of make-up air distribution is determined by radiant heat load. Make-up air design temperature should be based on rooftop temperature conditions rather than climatic temperature conditions.

2.

3. 4.

5.

Room Air Sufficient supply air should be introduced to compensate for air being exhausted through the ventilator, but not being made up for by the hood system. This can be accomplished through HVAC supply ceiling diffusers located a minimum of six feet from the ventilator. The volume required must be calculated by the HVAC designer/contractor taking into account: 1. 2. 3. All exhaust and supply sources in the kitchen area (code may require no more than .02 inches water column negative pressure in the kitchen areas). Air flow patterns in the kitchen area (making sure no drafts interfere with smoke capture). HVAC heat/cooling loads

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PART III SIZING AND APPLICATION DETAILS Quantifying Exhaust Gas Volumes By Prevailing Code Prevailing local codes specify required minimum exhaust standards. The code requirement may exceed traditional rates per lineal foot or square foot rating established by the Uniform Mechanical Code. By Experience Through experiences based on trial and error an art has emerged which factors numerous values into a judgement call. The designer will judge the line-up for energy input, flash load, radiant and contaminant loads, overhangs and other design characteristics in order to establish an exhaust volume. Third Method Through comparative analysis an engineer can determine the exhaust requirements for a hood section. He will assign a value of 1 to 5 for each of the four (4) characteristics relating to each appliance in the cooking line-up. Each value is the squared and added together. The square root of the total is the average rating per foot of the appliance. Table 4 offers some typical examples of cooking equipment. Second step: the average rating per foot is multiplied by the length in feet of the appliance. The total ratings are added and then divided by then length of the line-up to establish an aggregate rating for the hood section. Overhangs are added at the same rating when required. Gas Versus Electric Input The energy input of a device causes some expansion of surface gas without any frying, broiling or boiling actually occurring. The HVAC industry requires 80% to 90% combustion efficiency in boilers and furnaces. Typically up to 65% efficiency is usual with kitchen cooking equipment. Gas fired cooking lines require greater exhaust air flow. Electric cooking inputs are a precise measure since flue gases have to be handled by the exhaust system with greater input per foot. Radiant Value 18

The radiant value is a device which is a strong indicator of its input value. A slow walk past a cooking line-up will teach a physical lesson showing radiant heat discharge to the room can be as much as 40% of the input of a unit. Flash Load Flash loads are indicative of high input, direct fired equipment such as deep fryer, ovens, char-broilers, roasters. Steady load is found in equipment which maintains food at low temperatures such as is found in convalescent homes. Kettles, compartment steamers and other indirect fired appliances are typical steady load equipment. Contaminant Loads Char-broiling produces the greatest concentration of grease and hydrocarbon particulate. Second in the line of priority is deep fat frying followed by griddling. Ovens, convection ovens and steam holding are minimal contaminant loads. The use of food additives (such as marinated meats) greatly increases the contaminant load. Chinese cooking on wok lines is also an exceptionally heavy grease load. Frozen potatoes produce more airborne grease than fresh or refrigerated. Procedure to Establish Exhaust volume: 1. Third Method

List cooking equipment; width of item in feet and rating average values for each cooking appliance from Table 4. Multiply and total. Divide total in #1 by length (in feet) of line-up. Refer to equivalent capture chart (Table 5) and select the CFM/FT under the specific hood to be selected. Round off to next higher whole number, i.e. 6.7 select #7 rating. Multiply the CFM/FT. x the length of the cooking line. Overhangs, if required, must be added to establish length of hood.

2. 3.

4.

Example: Cooking line contains:

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Table 4 1 each - Griddle 2 each - High Output Fryers 1 each - Dump Station - 4' 4 x 6.6 = 26.4 - (2x1-1/2)= 3' - 3 x 9.1 = 27.3 1' - 1 x 0.0 = 00.0 Total Line 8'0" Total Rating 53.7 / 8 Aggregate Rating = 6.7 Refer to Table 5, Equivalent Capture Chart. For 6.7 aggregate rating, use 7 rating. Therefore: Filter Hood 400 CFM/FT. x 8 ft. = 3200 CFM Wash or HV 96 300 CFM/FT. x 8 ft. = 2400 CFM Note: The above air volume estimate is based on minimum practical requirements for typical conditions. Local codes or special considerations may require the use of high volumes.

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Table 4: TYPICAL OF COOKING EQUIPMENT RATINGS

TYPE TYPICAL MBH INPUT 120 120 140 110 95 132 34 80 TYPICAL MBH FT2 15 13.3 39.4 31 10 16.5 8.6 9.2 30 105 82.5 24 49.5 17 26.7 MBA LINEAL FT LOAD RATING VALUE
Low 1 High 5 normal range Extra High 6 Extremely High 7

INPUT | RADIANT | FLASH | CONTAMINANT

*UNIT RATING AVG/FT

CHAIN BROILERS CHARBROILERS (4') FRYER High output Standard GRIDDLE (4') RANGE Heavy Duty Hot Top With Oven FRYER Counter Type BROILER (Upright) BAKING OVEN Upright RESTAURANT RANGE Open Burner, Griddle, Oven RANGE Heavy Duty, Open Burner w/ Oven TILTING SKILLET(4') CONVECTION OVEN ( 1 Deck ) STEAM KETTLES 40 Gallon 2 Gallon Compartment Steamer WORK TABLES/ DUMP STATIONS

7 5 5 4 3 3 2 2

1 5 4 3 3 5 3 4

5 5 4 3 3 1 3 3

6 5 5 4 4 2 4 1

10.5 10.0 9.1 7.1 6.6 6.3 6.2 5.4

90 175

6.5 13.2

20.5 35.2

3 2

3 3

3 2

1 3

5.3 5.0

125 120 110 75 7 17 0

15.2 10 11 15 7.5 4.3 0

45.7 30 33 33.3 6.3 8.5 0

3 2 3 1 1 1 0

2 2 2 2 1 1 0

2 2 3 1 1 1 0

2 3 1 1 1 1 0

4.6 4.6 4.1 2.6 2.0 2.0 0

*IF OTHER EQUIPMENT IS USED ABOVE THE LINE-UP SUCH AS CHEESE MELTER OR SALAMANDER THEN ADD 1.0 TO THE AVERAGE / FOOT FACTOR

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TABLE 5

EQUIVALENT CAPTURE CHART CFM / LINEAL FOOT

TYPE OF HOOD

AGGREGATE RATING 10 9 8 7 6 5 4 3 2

FILTER C96 700 600 500 400 350 300 250 200 200

GREASE EXTRACTOR 500 400 350 300 275 250 200 150 150

HIGH VELOCITY HV96 500 400 350 300 275 250 225 200 200

BACK SHELF * * * 350 300 250 225 200 200

Notes: * Use overhead canopy style hood

SECTIONAL HOOD DESIGNS Dual Volume Ratings Each application should be viewed by the designer to minimize exhaust volume requirements without jeopardizing capture. The engineer has a number of tools to work with including zoning of the line-up. One half of the cooking line might be high intensity whereas the other would be medium. Two different ventilation rates can be utilized on a single cooking line. Perhaps the left side might be 350 CFM per foot over a char-boiler, deep fat fryer hot top range side of a cooking line where the right side with ovens, steam kettles and urns could be ventilated at only 200 CFM per foot. The average volume per foot meets U.L. listing and code requirements and the total air volume is less. A single hood could be used with two duct collars, different filter sizes and an internal divider would separate the hood functionally. Example: Within a 16 foot hood the left hand 8 foot side includes a 4 foot char-broiler and a 4 foot hot top range while the right side is urn, convection ovens and steamers. The left side aggregate value is 8.1 and requires 350 CFM per foot X 8 feet. The right side aggregate value is 3.0 which requires only 200 CFM per foot, for a total of 4400 CFM or 275 CFM per foot average.

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The conventional methods would require the selection to be rated on requirements of the char-broiler at 350 CFM per foot or more. 350 CFM X 16 feet equals 5600 CFM exhaust. The sectionalized approach offers a reduction of 1200 CFM. However, it will be necessary to provide two duct collars, both requiring the same static pressure if a single exhaust fan is used. Table 6: Exhaust Volume / Static Pressure Relationships At The Exhaust Collar
Filter Hoods CFM/ FT 200 250 300 350 400 500 Filter hoods are balanced by Pressure drop of the filters. Multiply the filter pressure drop X 1.15 this equals the total pressure drop of the hood Grease Extractor Static Pressure N/A 1.3 1.7 1.7 1.3 1.3 Slot Width 3" 3" 3" 4" (2) 3" (2) 3" High Velocity Static Pressure 1.25 1.25 1.25 1.5 N/A N/A Slot Width 3.5" 4" 5" 5" N/A N/A Filter Size 10" 12" 16" 16" N/A N/A

Overhangs Canopy hoods enclose a large area between the canopy and the line-up which must overcome any expansion. Overhangs are employed to restrict the outward thrust of the gasses. The height of the hood is determined by the process, the personnel activities, overhangs and application, but not over 84 inches above the finished floor. Back shelf hoods do not usually require overhangs. Overhang minimums are frequently set by codes. Consider the following table as minimum for good design. Canopy Only Sides Back Front Walled 0" 0" 12" No Wall 6" 12" * 12"

* The use of a single inlet exhaust plenum as an island ventilator should locate the inlet vertically over the rear edge of the equipment. Use of the aggregate rating is for the full length of the line-up if enclosed on three sides. 23

If not walled, then add the overhang length to the cooking line-up and use the aggregate rating for the full length of the hood.

Make-up Air Selection Guide 1. 2. The kitchen should always be negative pressure in relation to adjacent public areas. Is the kitchen area air conditioned? A. Yes - Use Tri-Air, PLV or EZ Air. B. No - Use grills facing out (F) or air through ceiling grills for maximum ventilation effect. Kitchen air changes: A. Air conditioned kitchen - 6 to 12 air changes per hour (5 to 10 minutes each change) B. Non air conditioned kitchen - 20 to 30 air changes per hour (2 to 3 minutes each change) Use E/Z Air over high radiant equipment. Use E/Z Air in areas where heating and air conditioning costs are a prime factor. Use Tri-Air for light duty line ups, to 78% make-up air. Use of E/Z Air for medium and heavy duty line-ups is good for up to 85% make-up air.

3.

4. 5. 6.

Make-up Air Roof Top Units Make-up air units are selected as a percentage of the exhaust air volume, typically, 80 to 85% make-up air depending upon the method of distribution. However, other exhaust points such as condensate hoods, dishwashers, and storage room exhaust may be added into the total to be supplied. The delivery air temperature is dependant upon the method of introduction. In air curtain distribution systems a temperature averaging 50 to 55o F air should be satisfactory. As low velocity air is introduced as an air curtain, it may operate at 45o F or lower outlet temperature. When grills distribute the air through the room 55 to 60o F air should be utilized, In short circuit applications, a minimum air temperature of 35o F should be maintained or reduce the volume of make-up air to allow for the thermal expansion.

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Some codes require make-up air heating capacity be sized to provide air tempered to no less than 10o F lower than design room air temperature. Generally codes stipulate that 10 feet horizontal or 3 feet vertical clearance exist between the make-up air intake and the exhaust outlet. Check local code requirements. The solar heat gain on the roof top machinery is greater than the heat loss. Insulation is beneficial for exposed duct runs above the roof for both summer and winter operation.

Exhaust Fans The following criteria should be used for the selection of exhaust fans operating for commercial kitchen hoods: 1. Wheel design should be the non-overloading type, i.e., backward inclined or backward curved. Select adjustable belt driven fans which protect the motor from grease buildup and exhaust air heat. Use of direct drive fans prohibits accurate system balancing since volume dampers are not permitted ( see dampers). Fans should discharge away from building surfaces, normally vertical in direction. Most codes require that the fan discharge be located a minimum or 40 above the roof surface, at the same time the requirement for maintaining the horizontal duct run at least 18" above the roof surface is satisfied. Fans should be able to be cleaned of any grease accumulation. Drain provisions to a catch pan or drain should be used. The fan mounting should allow access to the adjacent ductwork. Fans should be sized with the largest diameter wheel turning at the slowest RPM permitting the most laminar air flow.

2.

3.

4.

5. 6.

Exhaust Duct Exhaust ducts are designed by a constant velocity method. A minimum of 1500 and maximum of 2200 to 2500 feet per minute (depending upon various codes) is mandated. A fully welded 16 gauge black iron or 18 gauge stainless steel is required by NFPA. Square or rectangular ducts are most common to meet the fully welded construction requirement.

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The routing of exhaust duct is controlled by codes which require that the duct leading to the exterior of the building be the most direct possible route. Horizontal exhaust duct should be pitched either toward the hood or toward a clean out sump located at the lowest point. Usually a sump is located where the horizontal duct changes to the vertical. Properly designed clean out ports must be provided at specified distances and at each change of direction in the duct run. Cleanout access panels should be located on the sides of the duct with the bottom edge of the opening not less than 1" from the bottom of the duct. The plates should be gasketed and fastened with bolts for a liquid tight seal. Exhaust ducts should not be installed closer than 18" to combustible surfaces. The clearance requirements may be reduced by shielding the combustible materials with fire rated material. NFPA 96 allows joints in ductwork to be made with companion flanges and high temperature seals. However, some counties require all joints to be fully welded. Codes require that exhaust ducts penetrating the roof extend at least 18" above the roof surface. When a duct runs horizontal to the roof the bottom of the duct must be 18" above the roof surface. The clearance from combustible requirements apply above the roof as well as below the roof and also include the roof curb. Steel pre-fabricated and insulated roof curbs are recommended. Local codes may exceed these requirements and should be consulted.

Dampers 1. Exhaust Building codes state that no damper may be used in a kitchen exhaust duct unless that damper is a integral part of a listed grease extractor or hood and damper assembly. The requirement prohibits the use of back draft, volume, smoke, fire or balancing dampers. Exact sizing must assure the design of the ductwork along with pressure drop calculating. Make-up Air Dampers NFPA Bulletin 91 mandates a U.L. fire damper as part of supply air plenum which introduces make-up air inside the hood cavity, i.e., short circuit. The use of back draft dampers in cold climates is highly recommended to prevent cold air from entering the building in off hours. Dampers in make-up air ducts for back draft, volume, smoke and/or fire control are governed by NFPA Bulletin 91 sections referring to air ducts.

2.

Fire Protection Systems National codes require automatic fixed type fire protection systems to protect ducts, 26

plenums, and cooking surfaces whenever the cooking process releases grease vapors. The respective systems and the general code and standards which covers the application are as follows: Wet chemical system - NFPA 17A Water sprinkler system - NFPA 13 NFPA 10 also encompasses requirements for portable hand type extinguishers in addition to fixed systems. National codes require that activation of the automatic fire protection system also disconnect the supply of fuel from the cooking line protected by the system. Fuel shut-off is by means of shunt trip beakers, contactors, solenoid activated or mechanically activated gas valves through a spring and cable system linkage. The application of these systems is a specialty. Codes require the system be designed and installed by certified personnel. Some systems and regional codes require that exhaust and/or make-up air systems be interlocked with the automatic fire system. Generally, wet chemical, and sprinkler type systems require the exhaust fan remain operational during system activation. It is desirable, and in most localities mandatory, for activation of the fire protection system to shut off the make-up air supply which will cause the space in which the hood is located to become greater in negative pressure to prevent the migration of smoke to other areas.

Stop Station and Control Interlock A simple push button or switch control should start exhaust and make-up air systems for use by unskilled kitchen personnel. Under normal operation, the exhaust fan should start and operate an interlock with the make-up air system. Since the make-up air system may require provisions for heat, cooling or vent air, the function should be provided by a selection switch or outside air thermostat. A wash hood must incorporate the mandatory wash cycle at the end of each operation through a control cabinet supplied by the hood manufacturer.

Lighting The requirement for minimum levels of lighting measured at the working surface is defined by the local health codes. Some form of lighting device is required in all canopy type hoods. The application of these lights is specifically covered under NFPA Bulletin 70, the National Electrical Code. 27

All lighting fixtures used in a commercial cooking hood must be listed for the application. U.L. has specified that the fixtures must be installed a minimum of 48" above the cooking surface which effectively prohibits the use of lights on shelf type hoods. If the hood being used is not listed under U.L. 710 for a lower distance. Three types of lights bear the necessary listing for the application: surface mounted incandescent, recessed mounted incandescent and recessed mounted fluorescent fixtures. The National Electrical Code considers the inside portion of a hood to be contaminated air duct and prohibits the mounting of wiring or conduits inside the hood. It also requires that high temperature insulation types be used. The hood shell may be penetrated for lighting and fire equipment fixtures utilizing approved grease penetration fittings. Both OSHA and NSF (National Sanitation Foundation) require that the globe be protected from breakage by either a removable (thus cleanable) metal guard or be a non-shattering type globe. Shatterproof glass and plastic coated globes are commonly used. The glass must be of a type that is resistant to the high temperatures.

National And Local Codes Principle codes which apply to commercial kitchen hood equipment are: NFPA, Bulletin 96; Uniform Mechanical Code, BOCA Mechanical Code, Southern Building Congress Code, and miscellaneous state and local codes. Additional attention is required in some areas as they have city and/or state codes that differ greatly from the national codes. E.G. State of Michigan, State of Maryland, City of Chicago, Denver, New York City, Los Angeles and others. The installation and design of commercial kitchen hoods are governed under the mechanical code; however, many areas allow the products to be covered under the Department of Public Health. Hoods may be covered under the jurisdiction of the mechanical and health inspectors and therefore must meet both codes. Some areas to note with regard to conflicting health and mechanical codes are Denver, Miami, State of Maryland, New York and Chicago.

Ecological Codes Many areas, especially communities with high population density and communities with air quality problems, as determined by the EPA, may require that the air be cleaned of grease, particulate and odor before releasing the exhausted air into the atmosphere. These must be inquired about and if required designed into the job on an individual basis. 28

Test and Balance Test and balance is the final step in assuring that a project meets the design and engineering criteria. It is the customers assurance that the maximum effectiveness of the system is achieved. It is most often the responsibility of the contractor which furnished the exhaust fans and the make-up air unit to do the test and balance. After the entire building HVAC system and hood system meet the design and engineering criteria, final adjustment can be made to achieve optimum building comfort and cost efficiency. Air balance should be checked on an annual basis to ensure the system is performing at peak efficiency. In order to accomplish this, it is important to know the proper method used to determine the air volume required. On all ventilators the air volumes required should be listed on a label under the canopy on each section of hood. Air volume is commonly read as cubic feet per minute CFM. Once the volume requirements are known, the velocity at the exhaust can be determined by dividing the stated volume by the area of the opening expressed in square feet. Example: Length of exhaust slot equals 120 inches at 4 inch width. 4" X 120" = 480 square inches, divided by 144 = 3.333 square feet of slot opening. Therefor, if the design CFM is 3500 CFM divided by 3.333 square feet, the velocity at the slot will average 1050 FPM. By using a vane type air meter with a 3" head and taking three reading per section, average actual face velocity can be determined. At this point the blower wheel speed should be increased or decreased depending on readings taken in order to coincide with design requirements. Because there are several types of air meters available, a thorough knowledge of their use is important. Check the instrument manufacturers instruction to ensure measurements are accurately recorded.

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