a to the Experts. Duct Design Level 1: Fundamentals Technical Development Program‘Technical Development Programs (TDP) are modules of technical training on HVAC theory, system design, equipment selection and application topics. They are targeted at engineers and designers who wish to develop their knowledge in this field to effectively design, specify, sell or apply HVAC equipment in commercial applications Although TDP topics have been developed as stand-alone modules, there are logical group- ings of topics. The modules within each group begin at an introductory level and progress to advanced levels. The breadth of this offering allows for customization into a complete HVAC curriculum — from a complete HVAC design course at an introductory-level or to an advanced level design course, Advanced-level modules assume prerecuisite knowledge and do not review basic concepts, Introduction to HVAC Psychrometrics Load Estimating Refrigeration Cycle Equipment Systems Controls, Applications ‘This module will look at the way commercial duct design creates an airflow conduit for inter- connecting an air handler, rooftop unit, or fan coil with VAV and CV terminals and/or room air distribution devices as a means of delivering conditioned ait to the occupants of a building. A step-by-step design process will be presented covering such aspects of duct design as zoning. load determination, layout, sizing, and determining static pressure losses for system fan selection. Af ter completing the module, participants will be able to manually size ductwork using either a friction chart or a duct calculator. The second level TDP of duct design will cover the modified equal fiiction method of duct design, along with additional sizing and layout recommendations. ‘© 2005 Carrier Corporation. All rights reserved ‘Te information in ths manuals offered as a genera quid for he use of industry and consulting engines in designing systoms. Judgments requted for application of ths infomation fo specif instalaions anc desgn appiton. Cari nt responsible for ‘ny uses made of fis information and assures no respersiaty forthe performance ot desrabity of any resung system design “Te efrraton i ths publication f subject to change vou nate, No pat his pulaon may be reproduced or ans in ary fom of by any moans, elocvonc or mchanca, or any pubose, witout the express writen poemsson of Camar Corporation, Printed in Syracuse, NY CARRIER CORPORATION Carrier Parkway Syracuse, NY 13221, USA.Table of Contents Tntroduction nn Duct Design Criteria... Space Availability, Duct Terms Installation Cost Air Friction Loss... Noise Level. ‘Heat Transfer and Leakage. Codes and Standards ‘Theory and Fundamentals. Law of Conservation of Energy ~ Bemoulli’s Law... Friction Loss in Ducts Recommended Duct Velocities for Ductwork and HVAC Components, Effects of Shape. Surface Roughness of Duets. Recommended Friction Rates -f Fitting Dynamic Losses Equivalent Length Method Use of Fitting Loss Coefficients.. SYstEM EFFECT en Duct Sizing Methods... Equal Friction ... Modified Equal Frictio Static Regain. Other Methods Duct Design Process Steps. Design Step 1: Determine Numbet of Zones Design Step 2: Perform Cooling end Heating Load Estimates... Design Step 3: Determine Space, Zone and Block Airflows Design Step 4: Select Duct Material, Shape and Insulation... ‘System Classification. ‘What Can Be a Duct and What is it Made of?... How are Ducts put Together, Sealed and Insulated? Design Step 5: Lay Out Ductwork from AHU to Air Distribution Devices Fit Trunk Duct to Building : Create a System Sizing Schematic Design Step 6: Summarize Duct cfm and Label Duct Schematic Vise a Duct Sizing Worksheet Design Step 7: Size Ductwork frcm Fan, Out to Extremities Duct Sizing Using the Friction Chart... Example 1 ~ Using the Duct Friction Chart Circular Equivalent Diameters of Rectangular Duets. Example 2 ~ Converting From Round to Equivalent Rectangular Ducts Duct Sizing Using Duct Calculators Changing One Dimension at a Time... Extended Plenumn..... Return and Supply Air Plenums Design Step 8: Calculate Air System Pressure Losses Design Step 9: Select Fan and Adjust System AirflowsSummary... svn Example 3 ~ Equal Friction Sizing Example Using the Duct Friction Table 33 Work Session 1 — Fundamentals... snnnnnnnnnnnnnnnnnn 37 Work Session 2 ~ Duct Sizing 30 Appendix and Supplemental Materia... sovnsnnninnnnnnnnn a Chart 1 — Friction Loss Chart for Round Duct. 43 Table 1 — Circular Equivalent Diameter*, Equivalent Area of Rectangular Ducts for Equal Friction. 44 Table 2 — Recommended Maximum Duct Velocities for Low Velocity Systems (fpm)........47 Table 3 — Velocity Pressures. 47 Table 4 — Duct Material Roughiess Multipliers - svn 48 Table 5 — Friction of Rectangular Duct System Elements.. 49 Table 6 Friction of Round Elbows. - Table 7 — Friction of Rectangular Elbows Table 8 — Flat Oval Equivalent Duct Sizes... ‘Symbols for HVAC Systems... Duet Sizing Worksheet . Glossary References Work Session 1 — Answers. Work Session 2 — Answers...DUCT DESIGN, LEVEL 1: FUNDAMENTALS Introduction This Technical Development Program (TDP) covers the fundamental principles of duct sys- tem design for commercial building applications. The most popular duet sizing method — equal Sriction ~ is covered in detail. Modified equal friction, incorporating many of the benefits of static regain, is presented in the related TDP-505, Duct Design, Level 2. Although many other duct sizing methods exist (e.g. velocity reduction, T-method, extended plenum, constant velocity, slalic regain), rione are widely used by designers aud ae Leyoud de scope of this waintiu sn0d- ule. The reader should refer to other publications for information on these sizing methods. It is recognized that the use of manual duet calewiators is normal, and that computer-aided duct design is becoming more popular; however, it is important to learn the manual friction chart method of duct sizing that is the foundation of these other methods. This will provide the know!- edge necessary to recognize possible design errors and understand the effects of various design decisions. Once properly covered, wse of Carrier's Duct Calculator for equal friction sizing will be presented. Proper duct design requires performing load estimates to determine the zone and space cfim that the duct system will distribute. Once the cfm has been determined, the duct system compo- nents can be laid out. This includes locating the supply and retum diffusers and registers to provide adequate air distribution to the spaces. Load estimating and room air distribution princi- ples are covered in detail in other related TDPs. This TDP will cover each duct design step in sufficient detail to permit the participant to lay out and size ductwork into a coordicnted ayatcm that is energy efficient and coat effictive te fah= ricate, install and commission. The Level 2 Duct Design TDP will present many areas of design enhancement, such as SMACNA Duct Construction Standards, duct design code requirements, fitting selection using loss coefficients, avoiding acoustic issues, unique VAV system duct fea- tures, and using life cycle cost analysis as a design criteria. Level 1 Duct Design develops various aspects of sizing in detail because an oversized duet system will be difficult to balance and will increase the installed cost of the system. An under- sized duct system will create higher than necessary air pressure drops, generate noise, and will ‘not deliver the required airflow quantities. ‘Work sessions are included as part of this program to assist the participant in evaluating his orher understanding of these fundamental principles and sizing parameters. Duct Design Criteria Several factors must be considered when designing a duct system. Generally, in order of im- portance, they are as follows: + Space availability + Installation cost + Air friction loss + Noise level + Duct heat transfer and airflow leakage + Codes and standards requirements Distribution Syste:DUCT DESIGN, LEVEL 1: FUNDAMENTALS Space Availability ‘The sizing criteria will often be defined by the space ava‘lable to rum the ductwork (Figure 1). Ceiling plenums, duct chases, and obstructions such as walls and beams often dictate that a cer- tain size duct be used, regardless of whether or not it is the best size from a first cost or air friction loss perspective There are most likely other building sys- fem components competing for the Root, i cf available space. Coordination is required to avoid sprinkler piping, power and Boot Der Takeo Duct communication conduit, ight fixtures, and ——Layin-/|_| @ Speaker Concut audio speakers. Header ducts and minouts Thar | | Header Duct ® are easier to locate, especially out in the eld Sreewer/ Pre : perimeter areas of the floor. Larger trunk “ and branch ducts require greater coordina- tion with equally large piping and conduit service utilities that tend to get located in the core areas of the building Stuctral Gonerete Tee Sections Figure 4 ung Inthe Ducowork Duct Terms Before we go any further, let’s look at a simple duct system (Figure 2) and define some of the terms we will be using in this TDP (also, see Glossary). The trunk (or main) duct is the supply or return duct that connects to the air source (e.g. air handling vnit, rooftop unit or fan coil) and dis- tributes the air around the building. Branch duets extend ourward from the trunk duct, forming a tree pattem. across the floor Rimout duets connect VAV (vatiable air volume) and CV (constant volume) terminals Return Trunk to a branch duct or directly to the trunk duct, A takeoff (as a fitting) either connects a runout duct toa branch or trunk duct in order to distrib- ute sir to a terminal, or connects (as a duct) the header duct to the room air distribution devices (diffus- ets, registers or grilles). The header duct distributes zone air from the terminals. Outdoor Air Intet ‘Air Handling Unit ‘Takeot (Fitting) Return Branch Figure Duct Terms Distribution SysteDUCT DESIGN, LEVEL 1: FUNDAMENTALS Installation Cost First cost is often quite important. First cost is not only impacted by the size of ducts and types of materials used to construct the ductwork, but also by the number and complexity of the duct fitings, and the height/ complexity of the site conditions impacting duct installation Tabor. ‘The ductwork portion of the ex- ample system costs shown in Figure 3 mee, represent 15 percent of the total, indi- a cooled cating that most of the dollars ate coe Sieerning ot spent on creating the heating and 3% Ductwork cooling capacity. Keep in mind that duct system costs are predominantly —s% NAY teas labor. representing upwards of 85 per- Boituers cent of the total installed number. 18% ae Designers need to think of laber- Hiconvois saving designs, and be prepared to cousiler many suggestions from the Cost based on OX Packaged Split VAV System installing contractor on design modi Figure 3 fications that will economize the fabrication and installation for their *"Ple HVAC Cost Breakdo shop and field practices. eT TA ein Air Friction Loss ‘Air friction loss is affected by the duct size and shape as well as the material and fittings used, For instance, round galvanized sheet metal has the lowest friction loss per linear foot, while flexible ductwork has the highest fiiction loss per linear foot, Also, the quality of fittings has a direct effect om the overall pressure drop of a duct system. Look to use smooth, efficient fittings with low turbulence fo reduce the - - duct system air pressure drop, and use as few fittings as possible De to lower the installation cost. A direct route using round duct EL with fewer fittings and size changes can have an overall friction loss that compares favorably with a similarly sized rectangular system with a longer route and size changes at each branch duct; but it will always be the more economical design Pe aed ee ad Distribution SystemsDUCT DESIGN, LEVEL 1: FUNDAMENTALS Noise Level An undersized duct system, that is, one with higher velccities, creates noise that is often ob- jectionable to the occupants, Poorly selected or installed fitings also create turbulence, which creates additional noise and air. pressure drops. Dampers used ferodynami ri for balancing need to be located Fitngs | nee out of the turbulence and not {00 Line Shot ‘void Tuutence close to the diffusers and regis Rimouts\ Piace Balancing Dampers lieirenremomeee if t | No fers in the space. There are many ways to limit noise crea- tion (Figure 4) that need to be followed when designing duct- work. Dont Place Ditsers In} Trunk Ducts Keep—— Velocities wirin Recommended Range pice ties Perot igure 4 Limit Noise Creation Heat Transfer and Leakage Ductwork that runs through very warm or very cold areas can incur a heat gain or oss that ef- fectively reduces the capacity of the cooling and heating equipment, and will likely result in occupant discomfort and higher operating costs. Leaky duc’s have the same energy-wasting ef fect, and may create odors and stained ceiling tiles if duet thermal insulation becomes wet from the formation of condensation at the leak points. Minimum Duct Seal Level Doar Crete Duct Leston eee Ua ey Simwe | >2mwe || hewn PERM Sry sewmaies | UENO eames 62838 oaaos x ae * [ooneere poe | 6 Ape [8 [contones spaces | ats te ASHRAE 90.1 Energy Code dictates appropriate levels of Duct Seal Levels insulation and joint seal levels Seal Sean Regerenets for all ductwork in order 0 Tw tances Pecans etn pe thotact se ‘minimize these energy-wasting — ASIRARSS! ‘sedate may sea conditions. Figure $ shows the > | Meme ks a ea re, ee extent of sealing required. Two srt . extensive duct insulation tables [teen oy in ASHRAE 90.1 cover all ws Figures ages and climate areas. ar othe Espen Sealing Ductwork Reprinted by permission from ASHRAE Standard 90.1 Copyright (2001) American Society of Heating, Rerigerating and Air- Conditioning Engineers, In. (vw ASHRAE 07g) Distribution Syster