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Fundamentals of Duct design


Webinar, 06 February 2017
1. Introduction.
2. Air flow principles.
3. Duct classification.
4. Duct shapes.
5. Duct sizing.
6. Duct insulation.
7. Conclusions.
1. Introduction

3 Fundamentals of Duct design - Internal use only


Introduction

Design criteria:
- Space availability
- Space air diffusion
- Noise level
- Duct leakage
- Duct heat gains & losses
- Balancing
- Fire & smoke control
- Investment costs
- Operating costs of the system
- …

4 Fundamentals of Duct design - Internal use only


2. Air Flow Principles

5 Fundamentals of Duct design - Internal use only


Air flow principles

Air flow is the result of a pressure differential between two points.

𝑝1 𝑝2

𝑝1 > 𝑝2

6 Fundamentals of Duct design - Internal use only


Air flow principles

Fundamental laws of physics:

1. Conservation of mass:
- Air mass is neither created nor destroyed.
- A duct size can be recalculated for a new air velocity by using the
formula:

𝒗𝟏 ∗ 𝑨𝟏 = 𝒗𝟐 ∗ 𝑨𝟐

𝑣1 𝑣2
Where:
v = velocity [m/s]
A = surface [m²]
𝐴1 𝐴2
7 Fundamentals of Duct design - Internal use only
Air flow principles

Fundamental laws of physics:

2. Conservation of energy:
- Based on the Bernouilli equation: the difference in total pressure
between two points, is equal to the pressure loss between these
two points.

∆𝒑𝟏>𝟐 = 𝒑𝒕𝟏 − 𝒑𝒕𝟐

3. Conservation of momentum.
- Based on Newton’s law that a body will maintain its state of rest
or uniform motion unless compelled by another force to change
that state.

8 Fundamentals of Duct design - Internal use only


Static, velocity & total pressure

Static pressure: Velocity (or dynamic) pressure:


- Is the result of compressing air within a duct. - Is the energy component due to the fluid
- Static pressure reaches a peak at the fan unit velocity
and decreases throughout the duct due to - Is used for air flow determination
frictional pressure losses and declines to
almost zero at the exit of the duct.
- Static pressure is “positive” during “suction”
and “negative” during “discharge”
- Is used for fan selection
𝝆 ∗ 𝒗𝟐
𝒑𝒔 = 𝝆 ∗ 𝒈 ∗ 𝒉 𝒑𝒗 =
𝟐

Total pressure (𝑝𝑡 ) 𝒑𝒕 = 𝒑𝒔 + 𝒑𝒗

9 Fundamentals of Duct design - Internal use only


Air flow characteristics in a duct.

- The static pressure is equal in all directions


- The velocity pressure is only in the direction of the air flow.
- Since static pressure is also pushing in the direction of the airflow, it is difficult to measure the
velocity pressure in a duct.
- Velocity pressure is calculated by measuring the static pressure (perpendicular to the air flow)
and the total pressure (parallel to the air flow).

10 Fundamentals of Duct design - Internal use only


Pressure losses

The system resistance in duct work can be divided into:

1. Friction losses
Resistance to air flow caused by the duct size (length and diameter),
roughness of the duct walls and the air velocity.

2. Local or dynamic losses


Resistance to air flow caused by changes in air velocity and air
direction.

3. Equipment pressure losses


Resistance to air flow caused by components such as diffusers, coils,
filters, …

11 Fundamentals of Duct design - Internal use only


Pressure losses

1. Pressure losses by friction (Darcy-Weisbach)

𝒍 𝝆 ∗ 𝒗𝟐
𝒑𝒇 = 𝒇 ∗ ∗
𝒅𝒉 𝟐

Where:
𝑝𝑓 friction losses [Pa]
𝑓 friction factor [dimensionless]
𝑙 length [m]
𝑑ℎ hydraulic diameter [m]
𝜌 specific density [kg/m³]
𝑣 velocity [m/s²]

12 Fundamentals of Duct design - Internal use only


Pressure losses

𝒅𝒉 ∗ 𝑽
- Reynolds number: 𝑹𝒆 =
𝟏𝟎𝟎𝟎 ∗ 𝒗
With:
𝑅𝑒 Reynolds number
𝑑ℎ Hydraulic diameter [m]
𝑉 Velocity [m/s]
𝑣 Kinematic viscosity [m²/s]
𝑣 = 14,5 * 10−6 𝑚²Τ𝑠

𝑅𝑒 < 2.300 Laminar flow


𝑅𝑒 > 10.000 Turbulent flow
In between: transitional flow.

For standard air:


𝑅𝑒 = 66,4 ∗ 𝑑ℎ ∗ 𝑉
13 Fundamentals of Duct design - Internal use only
Pressure losses

Friction factor
Colebrook’s equation

𝟏 𝜺 𝟐, 𝟓 𝒍
= −𝟐 𝐥𝐨𝐠 +
𝒇 𝟑, 𝟕 𝒅 𝒉 𝑹𝒆 𝒇
Where:
𝜀 = Material absolute roughness factor [mm]
𝑅�𝑒 = Reynolds number

Altshul developed a simplified formula which was modified by Tsal


𝟎,𝟐𝟓
𝜺 𝟔𝟖 If 𝑓 ′ ≥ 0,018 → 𝑓 = 𝑓 ′
𝒇′ = 𝟎, 𝟏𝟏 ∗ + If 𝑓 ′ < 0,018 → 𝑓 = 0,85 ∗ 𝑓 ′ + 0,0028
𝒅𝒉 𝑹𝒆
14 Fundamentals of Duct design - Internal use only
Pressure losses

Roughness factor (𝜀 ):

15 Fundamentals of Duct design - Internal use only


Friction chart

𝑘𝑔
16 Fundamentals of Duct design - Internal use only 𝜌 = 1,2 𝑎𝑛𝑑 𝜀 = 0,09 𝑚𝑚
𝑚3
Pressure losses

2. Local or dynamic pressure losses.

- The dynamic losses are caused due to the change in direction


or magnitude of velocity of the fluid in the duct. The change in
direction of velocity occurs at bends and elbows.
∆𝒑𝒊 ∆𝒑𝒊
𝑪= 𝝆∗𝒗𝟐ൗ
=
𝒑𝒗
𝟐

Where:
𝐶 = local loss coefficient [-]
∆𝑝𝑖 = total pressure loss [Pa]
𝑝𝑣 = velocity pressure [Pa]
𝜌 = density [kg/m³]
𝑣 = velocity [m/s]
17 Fundamentals of Duct design - Internal use only
3. Duct classification

18 Fundamentals of Duct design - Internal use only


Duct classification.

Duct systems can be classified in terms of their:

- Purpose
- Velocity
- Pressure

19 Fundamentals of Duct design - Internal use only


Duct classification by purpose.

- Air supply duct


- Return air duct
- Fresh air intake duct
- Exhaust air duct

20 Fundamentals of Duct design - Internal use only


Duct classification by air velocity.

Three categories:

Duct system Air velocity


Low velocity 2~10 m/s
Medium velocity 10~12,5 m/s
High velocity 12,5~17,5 m/s

21 Fundamentals of Duct design - Internal use only


Duct classification by air velocity.

Low Velocity Duct Systems - Guidelines:

Application Air velocity


Residences, Theatres, … 3~5 m/s
Hotel rooms, Offices, … 4~6,5 m/s
Restaurants, banks, … 7,5~10 m/s

22 Fundamentals of Duct design - Internal use only


Duct classification by pressure.

Three categories:

Duct system Static Pressure limit (Pa)


Positive Negative
Low pressure 500 500
Medium pressure 1000 750
High pressure 2000 750

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Duct classification.
Impact of velocity & pressure
Velocity: Pressure:

- Noise - Duct strength


- Vibration - Deflection
- Friction loss - Leakage

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4. Duct shapes

25 Fundamentals of Duct design - Internal use only


Duct shapes

26 Fundamentals of Duct design - Internal use only


Duct shapes

- Round ducts:
- Are the most efficient in conveying moving air due to the greatest
cross sectional area and a minimum contact surface.
- Advantages:
- Lower pressure drop
- Less surface and less insulation
- Are available in longer length than rectangular ducts (less
joints)
- Better acoustic performance (the curved surface allows
less breakout noise).
- Less chance of dirt accumulating inside the duct
- Disadvantage:
- Need more clear height for installation

27 Fundamentals of Duct design - Internal use only


Duct shapes

- Rectangular ducts:
- Aspect ratio (AR) = width / height

- Rule of thumb: keep the aspect ratio as


low as possible (AR ≈ 1)
- AR > 4 much less efficient in
material use and great pressure b
drops
- 2 < AR > 3: best solution in trade
off added duct cost of material a
and pressure drop

28 Fundamentals of Duct design - Internal use only


Duct shapes

- Rectangular ducts:
- Disadvantages:
- Higher pressure drops
- More material is required for the same air flow rate
compared with round ducts
- The joints are difficult to seal (bigger risk on leakage)
- Duct with high aspect ratio can transmit excessive noise if
not properly supported.

29 Fundamentals of Duct design - Internal use only


Duct shapes

- Oval ducts:
- Advantage:
- Smaller height requirements than round ducts while
maintaining most advantages of the round ducts
- Disadvantages:
- Fittings for oval flat ducts are more difficult to fabricate or
modify in the field.
- Difficult of handling and shipping larger sizes
- Tendency to become more round under pressure
- Difficulties of assembling oval slip joints in case a large
aspect ratios

30 Fundamentals of Duct design - Internal use only


Duct shapes

- Flexible ducts - Regulated in Europe according to


standard EN 13180-2002
- Application of flexible ducting:
- In most countries, regulations restrict
the use to maximum 15 metres.
- Used mainly from a main duct to a
terminal unit (diffuser, …)
- Disadvantages:
- High pressure drops
- Acoustics

31 Fundamentals of Duct design - Internal use only


Duct shapes

- Equivalent duct diameter:

1,30 ∗ (𝑎 ∗𝑏)0,625
- Rectangular ducts: 𝐷𝑒𝑞 = (𝑎+𝑏)0,250

1,55 ∗ 𝐴0,625
- Oval ducts: 𝐷𝑒𝑞 = 𝑝0,250

and: Where:
𝜋 ∗ 𝑏2 𝑎 length of major axis [m]
𝐴= + 𝑏 ∗ (𝑎 − 𝑏) 𝑏 length of minor axis [m]
4
𝐴 cross sectional area [m²]
𝑝 = 𝜋 ∗ 𝑏 + 2 ∗ (𝑎 − 𝑏) 𝑝 perimeter of oval [m]

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5. Duct sizing.

33 Fundamentals of Duct design - Internal use only


Duct sizing.

Three duct sizing methods are used:

1. Velocity method
1. Method of equal velocities
2. Method of reducing velocities

2. Equal friction method

3. Static regain method

34 Fundamentals of Duct design - Internal use only


Duct sizing: Velocity method

- This method sizes the duct by varying the velocity in the main and
the branch ducts. The maximum air velocity is situated near the fan
and the velocities are gradually decreasing towards the end of the
main duct.

- Evaluation of this method:


₊ Simple calculation
₊ Gives the possibility to choose the velocities in function of the
required level of comfort
- Arbitrary selection of velocities

- Application:
- Normally not used. Sometimes used for simple small duct lay-outs.

35 Fundamentals of Duct design - Internal use only


Duct sizing: Velocity method

- Duct design method:


1. Select suitable velocities in the main and branch ducts.

Air velocity v [m/s]


Main section Side section
Ventilation and low pressure airconditioning Recommended Max. Recommended Max.
Residential buildings 3,5~5 6 3 5
Public buildings 5~7 8 3~4,5 6,5
Industry 6~9 11 4~5 9
High pressure air-conditioning 8~12 15~20 8~10 18

36 Fundamentals of Duct design - Internal use only


Duct sizing: Velocity method.

- Duct design method:


2. Find the diameters of the main and branch ducts from air flow
rates and velocities.

𝑸 4∗𝑄
𝑨= 𝑑=
𝒗 𝜋∗𝑣
Where:
A Duct area [m²]
Q Air flow rate [m³/s]
v air speed [m/s]
D diameter [m]

Based on the calculated diameter, choose a commercially


available duct size and recalculated the velocity.
37 Fundamentals of Duct design - Internal use only
Duct sizing: Velocity method.

- Duct design method:


3. From the velocities and duct dimensions obtained in step 2, find
the frictional pressure drop for the main and branch ducts using
the friction chart.

38 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise.

Given: 2 𝒎³Τ𝒔 1 𝒎³Τ𝒔


2 3

15 m 12 m D 18 m F
6m

A C E
Fan

6m - Velocity in the main duct (A) v = 8 m/s


B
- Dynamic loss coefficient
- for upstream to downstream = 0,3
1 𝒎³Τ𝒔 1 - for upstream to branch = 0,8
- for elbow = 0,8
- For the outlets = 1
39 Fundamentals of Duct design - Internal use only
Duct sizing: Exercise – Velocity method.

Solution:

1. Select a velocity for the downstream ducts and branches: 5 m/s


2. Calculate the ducts cross sectional surface and diameters.
3. Select a commercially duct diameter and recalculate the velocity.

Duct Q [m³/s] v [m/s] A Calculated Commercial Corrected


[m²] diam. [m] diam. [m] v [m/s]
A 4,00 8,00 0,500 0,798 0,800 7,96
B 1,00 5,00 0,200 0,505 0,500 5,09
C 3,00 5,00 0,600 0,874 0,900 4,72
D 2,00 5,00 0,400 0,714 0,710 5,05
E 1,00 5,00 0,200 0,505 0,500 5,09
F 1,00 5,00 0,200 0,505 0,500 5,09

40 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Velocity method.

Solution:

4. Calculate the pressure drop:


- Friction losses:
- Formula

0,022243 ∗ 𝑄1,852 ∗ 𝑙
∆𝑝𝑓 =
𝑑4,973
- Graph (Ashrae)
- Dynamic losses:
- formula
- Equipment losses: outlets

41 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Velocity method.

4. Calculate the pressure drop:


- Friction losses:

Duct Q [m³/s] v [m/s] d [m] l [m] Friction loss Graph Formula


[Pa/m] Pa Pa
A 4 7,96 0,800 15 0,85 12,75 13,19
B 1 5,09 0,500 6 0,70 4,20 4,19
A+B 16,95 17,38
C 3 4,72 0,900 12 0,30 3,60 3,45
D 2 5,05 0,710 6 0,50 3,00 2,65
A+C+D 19,35 19,28
E 1 5,09 0,500 18 0,70 12,57 12,57
F 1 5,09 0,500 6 0,70 4,20 4,19
A+C+E+F 33,12 33,40

42 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Velocity method.

4. Calculate the pressure drop:


- Dynamic losses:

Duct C v [m/s] ρ [kg/m³] l [m] Dynamic pressure loss


[Pa]
𝜌 ∗ 𝑣²
∆𝑝𝑑 = 𝐶 ∗
B --> B 0,3 5 1,200 4,500 2
B --> O 0,3 5 1,200 4,500
M --> B 0,8 5 1,200 12,000 C = 0,3 for Branch to Outlet
O 1 5 1,200 15,000 0,8 for Main to Branch
Legend: B = Branch; M = Main; O = Outlet 1,0 for outlet

43 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Velocity method.

5. Balancing:

Duct Friction Dynamic Outlet Total Balancing requirement


A+B 17,38 12,00 15,00 44,38 25,022
A+C+D 19,28 16,50 15,00 50,78 18,620
A+C+E+F 33,40 21,00 15,00 69,40 0,000

44 Fundamentals of Duct design - Internal use only


Duct sizing: Equal friction method.

- Is used for supply, exhaust & return air duct systems and
employs the same friction loss per unit of length for the entire
system

45 Fundamentals of Duct design - Internal use only


Duct sizing: Equal friction method.

- Duct design procedure:


1. Select the maximum air velocity in the main duct close after the
fan outlet.
2. Use the friction chart: knowing the velocity and the air flow,
determine the friction rate per meter of duct length and select
the diameter

46 Fundamentals of Duct design - Internal use only


Duct sizing: Equal friction method.

- Duct design procedure:


3. Use the friction rate value obtained in step 2 to determine the
diameters for all the other sections of the ductwork.
4. The total friction loss in the duct system is calculated by
multiplying the friction loss per meter of length to the equivalent
length of the most critical path of the ductwork, having the
maximum resistance.

47 Fundamentals of Duct design - Internal use only


Duct sizing: Equal friction method.

- Advantages:
- Straight forward and simple
- It reduces the air velocities in the direction of the air flow, which
reduced the potential air flow generated noise
- Most appropriate method for Constant Air Volume (CAV) systems.

- Limitations:
- There is no equalization of pressure drops in duct branches unless the
system has a symmetrical lay-out. Balancing dampers must be installed
to balance the system.
- Not recommended for Variable Air Volume (VAV) systems. If used for
VAV supply duct design, the terminal unit require pressure
independent control capability to avoid excessive flow rates when duct
pressure is high.
- Not flexible and adaptable for future lay-out changes.

48 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal Friction Method

Exercise:

1. Velocity in Main duct: 8 m/s


(given)
2. Frictional pressure drop:

∆𝒑𝒇 𝟎, 𝟎𝟐𝟐𝟐𝟒𝟑 ∗ 𝑸𝟏,𝟖𝟓𝟐 𝑃𝑎


= = 0,89
𝒍 𝒅𝟒,𝟗𝟕𝟑 𝑚

49 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal Friction Method

Exercise:

3. Calculated the duct sizing for the other branches:

∆𝒑𝒇 𝟎, 𝟎𝟐𝟐𝟐𝟒𝟑 ∗ 𝑸𝟏,𝟖𝟓𝟐


=
𝒍 𝒅𝟒,𝟗𝟕𝟑

∆𝒑𝒇𝑨 ∆𝒑𝒇𝑩 ∆𝒑𝒇𝑪 ∆𝒑𝒇𝑫


Equal friction method: = = = =…
𝒍𝑨 𝒍𝑩 𝒍𝑪 𝒍𝑫

𝑄1,852 𝑄1,852 𝑄1,852


= = = …
𝑑𝑒𝑞 A 𝑑𝑒𝑞 B 𝑑𝑒𝑞 C

50 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal Friction Method

3. Calculated the duct sizing for the


other branches:

e.g.
1,852
𝑄𝐵 4,973
Duct Q [m³/s] d [m]
𝑑𝑒𝑞,𝐵 = 𝑑𝑒𝑞,𝐴 ∗
𝑄𝐴
1,852 A 4,00 0,798
4 4,973 B 1,00 0,476
𝑑𝑒𝑞,𝐵 = 0,798 ∗ C 3,00 0,717
1
D 2,00 0,616
𝑑𝑒𝑞,𝐵 = 0,476 m E 1,00 0,476
F 1,00 0,476

51 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal Friction Method

Exercise:

4. Pressure drop calculation:


- First we need to know the new
velocity in the ducts:
• Calculate the surface Duct Q [m³/s] d [m] A [m²] v [m/s]
from the diameter
• Calculate the new A 4,00 0,798 0,500 8,00
velocity [A*v = constant] B 1,00 0,476 0,178 5,62
C 3,00 0,717 0,404 7,43
D 2,00 0,616 0,298 6,70
E 1,00 0,476 0,178 5,62
F 1,00 0,476 0,178 5,62

52 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal Friction Method

Exercise:

4. Pressure drop calculation:


I. Friction losses:
- Using the friction diagram
- Using the formula (more accurate) Duct Q [m³/s] v [m/s] d [m] l [m] Friction loss Graph Formula
[Pa/m] Pa Pa
A 4 8,00 0,798 15,000 0,89 13,37 13,36
B 1 5,62 0,476 6,000 0,00 5,35
A+B 13,37 18,71
C 3 7,43 0,717 12,000 0,00 10,69
D 2 6,70 0,616 6,000 0,00 5,35
A+C+D 13,37 29,40
E 1 5,62 0,476 18,000 0,00 16,04
F 1 5,62 0,476 6,000 0,00 5,35
A+C+E+F 13,37 45,44

53 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal friction method.

Exercise:

3. Pressure drop calculation:


II. Dynamic losses:
Duct C v [m/s] ρ [kg/m³] l [m] Dynamic pressure loss
[Pa]
B --> B 0,3 5 1,200 4,500
B --> O 0,3 5 1,200 4,500
I 0,8 5,62 1,200 15,141
0,8 6,70 1,200 21,567
II 0,3 7,43 1,200 9,947
III 0,3 5,62 1,200 5,678
O1 1 5,62 1,200 18,926
O2 1 6,70 1,200 26,959
O3 1 5,62 1,200 18,926
Elbow 0,8 5,62 1,200 15,141
Legend: B = Branch; M = Main; O = Outlet

54 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal friction method.

Exercise:

3. Pressure drop calculation:


III. Total pressure losses:

Duct Friction Dynamic Outlet Total


A+B 18,710 15,141 18,926 52,778
A+C+D 29,402 31,514 26,959 87,874
A+C+E+F 45,439 30,766 18,926 95,131

55 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Equal friction method.

4. Balancing:

Duct Friction Dynamic Outlet Total Balancing requirement


A+B 18,710 15,141 18,926 52,778 42,354
A+C+D 29,402 31,514 26,959 87,874 7,257
A+C+E+F 45,439 30,766 18,926 95,131 0,000

56 Fundamentals of Duct design - Internal use only


Duct sizing: Exercise – Velocity method versus Equal Friction Method.

- The velocity method results in larger duct diameters than the


equal friction method due to the velocities selected in main
and branch ducts

- Due to the larger ducts in the velocity method, the required fan
power is lower than for the equal friction method.

57 Title - Internal use only


Duct sizing: Static regain method.

- Static regain is the process of converting velocity pressure into


static pressure.

𝒑𝒕 = 𝒑𝒔 + 𝒑𝒗
- The objective of the static regain method is to obtain the same
static pressure at diverging flow junctions by changing the
downstream duct sizes.
- The static regain method applies to supply systems only.

58 Fundamentals of Duct design - Internal use only


Duct sizing: Static regain method.

Selection procedure:
1. Select the velocity in the main duct.
2. The velocities in the successive runs are reduced so that the gain in
static pressure due to the reduction in velocity pressure equals the
frictional pressure drop in the next duct section.

59 Fundamentals of Duct design - Internal use only


Duct sizing: Static regain method.

1 ∆𝑝2 = 𝑝𝑓,2 + 𝑝𝑑,2 2

∆𝒑𝟐 = 𝒑𝒇,𝟐 + 𝒑𝒅,𝟐 = 𝑹 ∗ 𝒑𝒗,𝟏 − 𝒑𝒗,𝟐

𝑅 is the static pressure regain factor.

60 Fundamentals of Duct design - Internal use only


Duct sizing: Static regain method.

Selection procedure:
3. If section 1 is the outlet of the fan, the flow and the velocity
(see 1.) are know. In section 2 both flow and velocity are
unknown. A trial and error method needs to be followed to
give the dimensions of section 2.
4. The procedure is followed in the direction of the airflow, and in
the same way all the dimensions for the downstream ducts are
obtained.
5. The total pressure drop is obtained from the pressure drop in
the longest run and is used for the fan selection.

61 Fundamentals of Duct design - Internal use only


Duct sizing: Static regain method.

- Advantages:
1. All duct sections have uniform static pressure at all branches and
outlets: simple outlet selection & correct air quantity at each
outlet.
2. The duct system will stay in balance because the losses and gains
are proportional to a function of the velocities: excellent method
for designing Variable Air Volume systems.
3. Less material
4. Less noisy.

62 Fundamentals of Duct design - Internal use only


Duct sizing: Static regain method.

- Disadvantages:
1. Calculations ay become difficult in case of many dynamic losses.
2. In systems with a large pressure drop in a section near the fan
outlet, the velocity could be reduced to the minimum within a
few sections in such a way that all the ductwork downstream
would be sized using minimum velocity.
3. Another disadvantage could stem from specifying a very low
minimum velocity. Ducts would then tend to be very large at the
end of long branch runs. The velocity at the end of long duct runs
may become too small for proper air distribution in the space to
be conditioned.

63 Fundamentals of Duct design - Internal use only


6. Duct insulation

64 Fundamentals of Duct design - Internal use only


Duct insulation

Designer:
- Building thermal load
- Comply with Building regulations

Minimum Thermal insulation

Maximum thermal performance Thermal losses:

1. Heat transfer (due to temperature


difference between the air in the duct
Energy savings
and the environment)
2. Condensation risk

65 Fundamentals of Duct design - Internal use only


Duct insulation.

Heat transfer in ducts.


Where:
𝑼∗𝑷∗𝒍 𝒕𝒆 −𝒕𝒍 𝑞𝑙 heat loss/gain through duct walls [W]
𝒒𝒍 = − 𝒕𝜶 𝑈 overall heat transfer coefficient of duct wall [W/(m²K]
𝟏𝟎𝟎𝟎 𝟐
𝑃 Perimeter of bare or insulated duct [mm]
𝑙 duct length [m]
𝑡𝑖 ∗ 𝑦 + 1 − 2 ∗ 𝑡𝛼
𝑡𝑒 = 𝑡𝑒 temperature of the air entering in the duct [°C]
(𝑦 − 1) 𝑡𝑙 temperature of the air leaving the duct [°C]
𝑡𝛼 temperature of the air surrounding the duct [°C]
𝑡𝑒 ∗ 𝑦 − 1 + 2 ∗ 𝑡𝛼 𝐴 cross sectional area of the duct [mm²]
𝑡𝑙 = 𝑉 average velocity [m/s]
(𝑦 + 1) 𝜌 density of the air [kg/m³]
𝑐𝑝 specific heat of the air [kJ/(kg*K)]
𝐴𝑉𝜌𝑐𝑝 d diameter of the duct [mm]
y = 2,0 ∗ for rectangular ducts
𝑈𝑃𝐿
𝑑𝑉𝜌𝑐𝑝
y = 0,5 ∗ for round ducts
𝑈𝑃𝐿

66 Fundamentals of Duct design - Internal use only


Duct insulation.

Supply ducts:
• Insulation reduces the rate of thermal loss to the surroundings.
• Due to the relative small temperature difference between supply
air and the space through which the ducts are routed, a 25 mm
fiberglass blanket is almost always sufficient.

Return air ducts:


• Only need to be insulated if they pass through an environment
which adversely affect the return air temperature.

Exhaust air ducts:


• Are normally not insulated

67 Fundamentals of Duct design - Internal use only


Duct insulation.

Exterior insulation:
• Contact with hangers, supports, … .

Interior insulation:
• Do not apply for clean rooms, laboratories, … .

Ducting on roofs:
• In cooling load dominated areas, ducts should be covered with
highly reflecting coating.

68 Fundamentals of Duct design - Internal use only


Duct insulation.

Duct liner:
• Is used “to line” the inside of rectangular metal ductwork.
• 25 mm material is used for thermal protection of
ductwork that passes through unconditioned spaces
• 13 mm material is frequently used as acoustical insulation
for reducing air and equipment noises.

Duct wrap:
• Is a blanket insulation used on metal ductwork passing through
un-conditioned spaces.

Duct wrap is providing better thermal protection than duct liner


but is of little benefit acoustically.

69 Fundamentals of Duct design - Internal use only


7. Conclusions

70 Fundamentals of Duct design - Internal use only


Thank you

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