Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work

for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Client:

INDUS CONSULTRANS
Detailed Design PVT. LTD.
Consultant:
GEED Simulations PVT.
LTD.

Design Consultancy Services for Preparation of Detailed Design &

Project:
Drawings of Tunnel Ventilation System Installation Work for Tunnels at
Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)
Title:
Tunnel Ventilation System – Design and Calculation Report – Tunnel 1
This document is the property of ICPL and must not be either loaned, Document No.: ICPL-KPNC-TVS-R-005
copied or otherwise reproduced in whole or in part or used for any
purpose without the prior written permission.

Design Stage Preliminary Definitive x Construction Reference

Revision Details:

0 11/05/2018 First Submission Zia Adil VB

INT SIGH INT SIGN INT SIGH INT SIGH

Rev. Date Details
Prepared Checked Approved Approved

ICPL & GSPL ITNL

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Table of Contents
1 Design Basis ................................................................................................................... 3
1.1 Fresh Air Requirement ............................................................................................ 3
1.1.1 Normal Operation ............................................................................................ 3
1.1.2 Congestion Operation ...................................................................................... 4
1.2 Make-up Air Requirement ....................................................................................... 4
1.3 Smoke Generation Rate .......................................................................................... 5
1.4 Axial fan size for emergency operation ................................................................... 6
1.5 Jet Fan Sizing ........................................................................................................... 7
1.6 Escape tunnel pressurization................................................................................. 10
1.7 Axial Fan Sizing...................................................................................................... 12
2 Ventilation Equipment ................................................................................................. 13
2.1 Jet Fans ................................................................................................................. 13
2.1.1 Jet fan type .................................................................................................... 13
2.1.2 Number and arrangement of jet fans ............................................................. 14
2.2 Dampers ............................................................................................................... 14
2.3 Axial Fans .............................................................................................................. 14
2.3.1 Number and arrangement of axial fans .......................................................... 15

List of figures
Figure 1: Enthalpy balance for exhaust fan ........................................................................... 7
Figure 2: Schematic plan and elevation for ventilation room layout .................................. 15

List of tables
Table 1-1: Fresh air requirement in normal tunnel operation .............................................. 4
Table 1-2: Fresh air requirement in congestion tunnel operation......................................... 4
Table 1-3: Make-up air requirement in emergency operation .............................................. 5
Table 1-4: Aerodynamic and fire loss for jet fan in main tunnel ........................................... 9
Table 1-5: Aerodynamic and fire loss for jet fan in escape tunnel ...................................... 11
Table 1-6: Axial fans operation points for different modes of operation............................ 12
Table 2-1: Jet fan data ........................................................................................................ 13
Table 2-2: Axial fan data .................................................................................................... 14

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

1 Design Basis
1.1 Fresh Air Requirement
As per PIARC, the required amount of fresh air for a given traffic condition in the tunnel
depends on the number of vehicles in the tunnel, the average emission per vehicle, the
admissible concentration for the particular emission and the ambient air concentrations.

The fresh air demand required is calculated as the maximum of the air volumetric flow rates
needed to dilute each of the contaminants. These air volumetric flow rates, for each
contaminant, are obtained using below equation by adding up the individual contribution for
each type of vehicle.

1
𝑉̇ = (𝑛 . 𝑄 ).
𝐶 −𝐶

Where,

𝑉̇ – Air volume flow [m3/h]

𝑛 - Number of vehicles in tunnel [-]

𝑄- Emission for CO/Emission for particle matter

𝐶 - Admissible concentration of pollutant [g/m3]

𝐶 - Ambient concentration of pollutant [g/m3]

𝐾 - Admissible extinction coefficient

For the opacity due to diesel smoke and non-exhaust PM, (𝐶 −𝐶 ) is replaced by 𝐾 .

1.1.1 Normal Operation

As per Table 2-8, peak traffic density was found at 7:00 PM, considering the peak traffic
volume following amount of fresh air is required for dilution of CO and Extinction coefficient
(K) in tunnel.

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Table 1-1: Fresh air requirement in normal tunnel operation

Fresh Air CO Extinction Required (Greater of CO and

Required Coefficient (K) Extinction Coefficient)
(m3/s)
LDV HGV Total LDV HGV Total

12.4 11.9 24.3 - 95 95 95

Supporting Annexure A
Doc

1.1.2 Congestion Operation

In case of congested operation when vehicular speed is limited to 10 km/hr, following amount
of fresh air is required for dilution of CO and Extinction coefficient (K) in tunnel.

Table 1-2: Fresh air requirement in congestion tunnel operation

Fresh Air CO Extinction Required (Greater of CO and

Required Coefficient (K) Extinction Coefficient)
(m3/s)
LDV HGV Total LDV HGV Total

23.6 29.9 53.5 - 211.3 211.3 211.3

Supporting Annexure B
Doc

1.2 Make-up Air Requirement

Make up requirement arises in emergency ventilation operation. As the design system is a
semi-transverse ventilation, the prime criteria is to exhaust a stratified smoke without any
occurrence of plug-holing. As per PIARC, for semi-transverse ventilation system the
longitudinal tunnel velocity to assist the smoke confinement shall not exceed 2 m/s.

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Tunnel 1 has a -2.17% gradient (Left to Right), therefore it is required to maintain 1.5 m/s air
velocity from left portal and 1 m/s velocity from right portal. Due to axial fan operation,
certain amount of make up air shall be available at fire location without any operation of jet
fan. The criteria for jet fan operation shall be to provide the required amount of make-up air
after axial fans operation. Based on the input data (Tunnel geometry), following amount of
make-up is required in emergency operation.

Table 1-3: Make-up air requirement in emergency operation

Portal Required make-up air (m3/s)

Left 85.59

Right 57.06

1.3 Smoke Generation Rate

As per NFPA 92B, the volumetric smoke exhaust rate to maintain a given smoke layer height
can be calculated as follows:

𝑄 = 𝜒𝑄

/
𝑧 = 0.166𝑄

/ /
𝑚 = 0.071𝑄 𝑧 + 0.0018𝑄

/
𝑚 = 0.032𝑄 𝑧 𝑓𝑜𝑟 𝑧 ≤ 𝑧

𝐾𝑄
𝑇 =𝑇 +
𝑚𝐶

𝑝
𝜌 =
𝑅(𝑇 + 273)

𝑉 = 𝑚/𝜌

𝑄 = Heat release rate of the fire (kW)

𝑄 = Convective portion of heat release rate of fire (kW)

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

𝑧 = Distance from base of fire to smoke layer interface (m)

𝑧 = Limiting elevation (m)

𝑚 = Exhaust mass flow (kg/s)

𝑅 = Gas constant (287 J/Kg.K)

𝑇 = Smoke layer temperature ( oC)

𝑇 = Ambient or outdoor temperature (oC)

𝐾 = 1 for steady smoke exhaust

𝜌 = Smoke density (kg/m3)

𝜌 = Atmospheric pressure (Pa)

𝑉 = Volumetric flow of smoke exhaust (m3/s)

𝜒 = Convective fraction (dimensionless)

Based on the tunnel geometry, fire HRR (30 MW), 0.7 convective fraction, ambient conditions
and required smoke layer height (2.1 m), smoke generation rate of 82.9 m3/s was obtained.
Installed axial fans shall be able to exhaust 82.9 m3/s of smoke along with required make-up
air to maintain the smoke stratification inside tunnel.

Calculation has been performed and appended as Annexure C.

1.4 Axial fan size for emergency operation

During emergency operation, the axial fans shall operate in exhaust mode to remove the
smoke generated due to fire and make-up air. The ventilation system during fire shall be
design on the basis of mass balance as shown below.

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Figure 1: Enthalpy balance for exhaust fan

The governing equation for mass balance is derived as follow:

Total exhaust flow rate (at STP), Q4 = Q1 (STP) + Q2 (STP) + Q3 (STP)

Where, Q3 (STP) = Q3 (Smoke layer temperature) * Density of Smoke / Density of air (STP)

Here, Q1 = 85.6 m3/s (As per Section 4.2)

Q2 = 57.06 m3/s (As per Section 4.3)

Total exhaust flow rate (at STP) is obtained to be 166.8 m3/sec.

1.5 Jet Fan Sizing

Jet fans are required to provide the required longitudinal velocity in emergency operation. Jet
fans at both portal ends shall ascertain that the required amount of longitudinal velocity (1.5
m/s & 1 m/s) is available during emergency operation. Jet fans have been sized based on the
equation provided in section 3.1.1. Different components of the equation are elaborated as
follows:

1
Inlet losses   air Vup2
2

Frictional loss,sec tion without fire  H V@inlet f (L Tunnel  L Fire ) / D H

Frictional loss,sec tion with fire  H V @exit f L fire / D H

 A   L  Lf 
Vehicular losses  Cd q  v   T  N (N t )
 A T   1000

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

1
Wind allowance   Vportal
2

Loss at tunnel outlet  12  V 2

 grad xL f 
Fire buoyancy pressure  (  d   u ) 9.81   or 20 Pa as per PIARC
 100 

Blockage due to fire  0.055 x Fire size x Vup

Where,

𝜌 - Density of ambient air

𝑉 - Design air flow velocity upstream of fire

𝐻 @ - Inlet velocity head

f – Tunnel friction factor

𝐿 or 𝐿 - Length of tunnel

𝐿 or 𝐿 - Distance of fire location from portal (Maximum)

𝐷 - Hydraulic Diameter

𝐻 @ - Exit velocity head

𝐶 - Vehicular drag factor

q – Tunnel air dynamic pressure

𝐴 - Area of vehicle

𝐴 - Area of Tunnel

N- Number of congested lanes

𝑁 - Number of vehicles

𝑉 - Adverse wind speed at portal

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

V- Exit velocity of air

𝜌 - Air density before fire

𝜌 - Air density after fire

𝑉 - Air velocity upstream of fire

Based on the input data, following amount of pressure drop was observed due to different
components

Table 1-4: Aerodynamic and fire loss for jet fan in main tunnel

S.N Type of losses Pressure drop (Pa)

Flow from left Flow from right portal

portal

1 Inlet losses 0.63 0.28

2 Frictional loss (Section 5.64 2.51

without fire)

3 Frictional loss (Section with 0.08 0.18

fire)

4 Vehicular losses 15.43 6.86

5 Wind Allowance 2.46 2.46

6 Exit losses 0.30 0.67

7 Fire buoyancy pressure 20 20

8 Blockage due to fire 2.475 1.65

Total Pressure Drop (Pa) 47 35

Total Thrust of system (N) 2683 1975

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Required Thrust (Including installation η) 3676 2706

Supporting Doc Annexure D

For given tunnel area and assuming an installation efficiency of 73% (for jet fans placed at
wall), required thrust of 3675 N & 2706 is obtained. Jet fans shall be selected to provide
minimum thrust requirement for tunnel.

1.6 Escape tunnel pressurization

During a fire scenario in a vehicle tunnel people escape route shall be maintained free from
dangerous smoke. Cross-passages must be free of smoke to provide a visually safe evacuation
paths to escaping passengers, to protect passengers while they are traversing the cross-
passages, and to ensure that the non-incident tube is kept clear of smoke.

The required critical velocity of air to prevent smoke escalation in cross-passage is given by
the coupled solution of following equations.

(𝑚̇𝐶 𝑇) + (𝑚̇𝐶 𝑇) + 𝑄̇ = (𝑚̇𝐶 𝑇 )

𝑔𝐻(𝜌 − 𝜌 .
𝐹𝑟 = = 4.5(1 + 0.0374|min(𝑔𝑟𝑎𝑑𝑒, 0)| )
𝜌𝑉

Where the subscript ‘T’ refers to the main tunnel, the subscript ‘d’ refers to the cross-passage
door and all the other terms have relevant meaning. Tf,t refers to the mixed-out temperature
downstream of the tunnel fire.

From the solution of above two equations and incorporating all the input details such as fire
size, area of tunnel and cross-passages, critical velocity of 1.8 m/s was obtained for cross-
passage.

Escape tunnel pressurization depends on the required flow velocity through cross-passage,
and leakage through closed cross passages.
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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Leakage through door gaps is represented by:

Qleakage = Kf* Aleak *(∆P)1/2

Where,

Qleakage = Flow rate (cfm)

Kf = Coefficient, 2610

Aleak = leakage Flow area, ft2

(∆P) = Pressure Difference., 0.18 in-H2O (As per NFPA 92A)

Assuming cross-passage door area of 1.8 m x 2.1 m, total leakage area for 3 closed cross-
passage shall be 0.04 m2. Hence, total leakage flow rate come out to be 0.22 m3/s.

Air flow through open door can be determined by using the cross-passage area and
recommended critical air velocity. For enlarged communication gallery (having maximum
area of 31.2 m2), required flow rate comes out to be 56.2 m3/s. For enlarged communication
gallery, total flow rate required shall be 56.4 m3/s.

The required thrust to induce 56.4 m3/s of air from tunnel portal (right) to cross-passage shall
depend upon the resistance of tunnel against flow (pressure). The distribution of different
components of pressure losses for flow from right portal into enlarged communication gallery
are provided in below table.

Table 1-5: Aerodynamic and fire loss for jet fan in escape tunnel

S.N Type of losses Pressure drop (Pa)

1 Inlet losses 0.91

2 Frictional losses 7.64

3 Wind allowance 2.46

4 Loss at outlet 2.24

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

5 Buoyancy pressure between main tunnel and escape 14

tunnel

Total pressure drop (Pa) 27.25

Total pressure drop with 10% FOS 30

Total thrust (N) 936

Required Thrust (Including installation η) 1282

Supporting Doc: Annexure E

The above calculated thrust is from one end of tunnel (Right). Total thrust for installed jet fan
shall be assumed as the two times the above calculated thrust. Hence, total required thrust
shall be 2564 N.

1.7 Axial Fan Sizing

Axial fans shall be sized based on the maximum fresh air/exhaust requirement for any mode
of operation. Based on the calculations performed in previous sections, it has bee observed
that fresh air requirement is maximum is congestion mode of operation i.e., 211 m3/s. Hence,
maximum size of axial fan shall be 2 x 110 m3/s to provide the required amount of fresh air
for dilution of pollutants. Axial fans shall operate on minimum three duty points, the power
requirement for different operating points shall vary based on flow rate and pressure drop
encountered by axial fans. The operating requirement for axial fan is given in below table:

Table 1-6: Axial fans operation points for different modes of operation

Flow Pressure (Pa) kW Supporting Doc

Normal 50 512 43 Annexure F

Operation

Congestion 110 1374 256 Annexure G

Operation

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Emergency 85 1196 172 Annexure H

Operation

These shall be two axial fans (One at each portal end) having a maximum capacity of 110 m3/s
@ 1400 Pa.

2 Ventilation Equipment
2.1 Jet Fans
During emergency operation, the jet fans shall operate to maintain the minimum velocity
requirement at the fire zone. Jet fans shall operate to provide the required thrust for air flow
towards the fire and assist in maintenance of smoke layer height in coordination with smoke
extraction axial fans.

2.1.1 Jet fan type

Table shows the jet fan data used for the design

Table 2-1: Jet fan data

Type Main Tunnel Escape Tunnel

Diameter internal (mm) 710 630

Diameter external (over 852 756

silencer) (mm)

Area (m2) 0.396 0.311

Stand-Thrust (N) 943 672

Jet velocity at stand-thrust 44.6 42.4

(m/s)

Volume flow at stand-thrust 17.6 13.2

(m3/s)

Installation efficiency (%) 73 73

Motor Rating (kW) 40 27

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Weight (kg) 379 310

2.1.2 Number and arrangement of jet fans

The main tunnel shall be equipped with 8 jet fans (4 on each end of tunnel). The escape tunnel
shall be equipped with 4 jet fans (2 fans on each end of tunnel). This leads to a total of 12jet
fans in tunnel.

As the jet stream of a jet fan need some distance to build up the pressure, the jet fans need
a minimum clearance distance to portals, other jet fan groups and other obstacles like traffic
signs. Therefore, jet fans shall be installed at a distance of 150 m from each end of main tunnel
and 200 m from each end of escape tunnel. In main tunnel, jet fans shall be placed at a
distance of 100 m from each pair.

2.2 Dampers
Over the length of main tunnel, 14 dampers (Size 3000 mm x 3000 mm) shall be arranged at
100 m distance along the transverse duct. The distance of outer most damper from portal has
been kept at 200 m. Additionally one damper to bifurcate the transversal duct at the mid-
chainage shall also be provided.

2.3 Axial Fans

For normal and congestion operation, the axial fans shall operate in supply mode to provide
the required amount of fresh air inside the tunnel. In emergency operation, axial fans shall
operate in exhaust mode for smoke extraction from tunnel.

Following are the details of axial fans.

Table 2-2: Axial fan data

Axial Fan Data

Internal fan diameter (mm) 2000
Fan isolation damper (mm) 3500 x 3500
Nominal volume flow (m3/s) 110

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Document No.: ICPL-KPNC-TVS-R-004
Design Consultancy Services for Preparation of Detailed Design & Drawings of Tunnel Ventilation System Installation Work
for Tunnels at Kiratpur in Punjab and Ner-Chowk in Himachal Pradesh (T1, T4 & T5)

Nominal static pressure (Pa) 1400

Motor Rating (kW) 260
Fan efficiency (%) 65

2.3.1 Number and arrangement of axial fans

Both the ventilation rooms shall be equipped with 2 axial fans (1 at each end). Below figure
shows a tentative layout of ventilation room along with axial fans.

Figure 2: Schematic plan and elevation for ventilation room layout

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Document No.: ICPL-KPNC-TVS-R-004