BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

1 of 8

HVAC Consulting , Installation & Validation

Document Title

Procedure Duct Leakage Test

BG/ES/HV/008/00

Sop No.

OBJECTIVE
To lay down a procedure for the Duct Leakage Test
Duct leak testing is to find out actual quantity of air leaking out through duct system and
checkingthe same with standard leakage rate so as to confirm whether leakages in the
system are within limits.

SCOPE:
This SOP is applicable for checking Air leak rate from G. I. Ducting.

PROCEDURE:
The leak testing rig consist of a fan with fan motor, flow measuring arrangement, flow
adjusting ,arrangement & magnehelic guage / PLC Control panel
A] Testing using Analog Magnehelic Gauge & B] Using PLC Control Panel
EQUIPMENT REQUIRED:
a) Blower with motor and Volume control damper
b) Magnehelic Gauges
0 50 mmwc .. 1 No.
0 100 mmwc .. 1 No.
c) Flexible Duct

3.1

Close all Duct Opening with temporary seals

3.2

Calculate the area of Duct in Ft2

Note: The construction class of the Duct as per requirement in Pharma industry is
not more than 3. Hence Leakage class (CL) for rectangular duct is
12. (as per Table 4.1)

BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

2 of 8

HVAC Consulting , Installation & Validation

Document Title
Sop No.

Procedure Duct Leakage Test

BG/ES/HV/008/00

3.3

Connect the apparatus as per drawing Fig 3.1.

3.4

Connect Magnehelic gauge (0 50 mmwc) across orifice plate.

3.5

Connect high pressure port of 0 -100 mmwc Magnehelic Gauge in the duct and
keep the low pressure port of the gauge open to atmosphere

3.6

Adjust Blower to require Static Pressure

3.7

Calculate the Leakage factor (F) by using the relation

CL = F/P0.65
F = CL x P0.65
CL = Duct leakage class
P = Testing pressure in inches of WC.

3.8

Calculate the allowable leakage by using the following expression

Allowable leakage = (Area of duct in Ft2 x F)/100

3.9

Note down the orifice and tube diameter.

3.10

Note down the Differential pressure reading across Orifice.

3.11

Refer table 1.1 and find out the actual Leakage through duct for the
corresponding values of Differential pressure.

3.11.1

B] Using PLC Control Panal

3.11.1.1

Connect the Testing Blower to section of ductwork to be tested

3.11.1.2

Start the fan and adjust the flow so as to develop the static pressure in duct 25mm of wg or
as per requirement

3.11.1.3

Check the measured leakage is within the permitted rate.

3.11.1.4

Maintain the test for 10 - 15min and check that the leakage rate has not increased

3.11.1.5

Record the test results/print the test results

3.11.1.6

If the leakages are above the permissible limits carryout rectification of leaks by
Tightening the duct joints properly with nut-bolts, change the sealant

BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

3 of 8

HVAC Consulting , Installation & Validation

Document Title

Procedure Duct Leakage Test

BG/ES/HV/008/00

Sop No.

Reseal the ducts wherever locations have been identified.

3.11.1.7
3.12

Repeat the procedure till you get the leakages within permissible limits.
ACCEPTANCE CRITERIA:-.
a) For 2 testing Pressure leak rate should be Less than or equal to
18.8 CFM / 100 Sqft Duct.
b) For 3 testing Pressure leak rate should be Less than or equal to
24.5 CFM / 100 Sqft Duct.
c) For 4 testing Pressure leak rate should be Less than or equal to
29.5 CFM / 100 Sqft Duct.

3.13

Prepare check sheet for duct leak test as per attached format.

BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

4 of 8

HVAC Consulting , Installation & Validation

Document Title

Procedure Duct Leakage Test

BG/ES/HV/008/00

Sop No.

Table 1.1:-

Delta P mm WG

Flow Rate CFM

Delta P mm WG

Flow Rate CFM

1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25

14.56
20.49
25.03
28.84
32.20
35.23
38.01
40.60
43.03
45.32
47.50
49.58
51.58
53.50
55.35
57.14
58.87
60.56
62.19
63.79
65.34
66.86
68.34
69.79
71.21

26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50

72.60
73.96
75.30
76.61
77.90
79.17
80.42
81.65
82.86
84.06
85.23
86.39
87.54
88.66
89.78
90.88
91.96
93.04
94.10
95.15
96.18
97.21
98.22
99.23
100.22

BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

5 of 8

HVAC Consulting , Installation & Validation

Document Title

Procedure Duct Leakage Test

BG/ES/HV/008/00

Sop No.

120

Flow Rate (CFM)

100
y = 14.56x0.493
R = 0.998

80

60

40

20

0
0

10

20

30
Delta P (mm WC)

40

50

60

BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

6 of 8

HVAC Consulting , Installation & Validation

Document Title
Sop No.

Procedure Duct Leakage Test

BG/ES/HV/008/00

BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

7 of 8

HVAC Consulting , Installation & Validation

Document Title
Sop No.

Procedure Duct Leakage Test

BG/ES/HV/008/00

BOTTOMGRASS ENGINEERING & HVAC

SERVICES

Issue Date

April 2013

Effective Date

April 2013

Standard Operating Procedure

Review Date

Nil

Rev

R0

Page

8 of 8

HVAC Consulting , Installation & Validation

Procedure Duct Leakage Test

Document Title

BG/ES/HV/008/00

Sop No.

ABBREVIATIONS

4.1

SOP
No.

REFERENCES

5.1

SOP BGES-00-800

RESPONSIBILITY

6.1
7
7.1

Standard Operating Procedure

Number

Validation Department.
ANNEXURES
Format for Duct Leakage Test