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DESIGN OF DUCT FOR A THREE STOREY RETAIL SHOP

Mr. Virendra V. Khakre1 Dr. AvinashWankhade2 Prof. M. A. Ali3

Abstract - In this paper importance of duct designing has of this metal prevents rusting avoids the cost of painting.
been analyzed which create an impact on system The sheet thickness of galvanized iron duct varies from
performance. In this a duct system for a three storey retail 0.55 mm to 1.6 mm. The aluminum is used because of its
shop has been designed, the main purpose of this is to make lighter weight and resistance to moisture. The black sheet
proper calculation of supply air quantity and to decide size metal is always painted unless they withstand high
of duct by using Equal Friction method so person in the shop temperature.
can feel comfortable. In equal friction method, the frictional Now a day, the use of non-metal ducts has
pressure drop per unit length of the duct is maintained increased. The resin bounded glasses are used because
constant throughout the duct system. This paper attempt to they are quite strong and easy to manufacture according to
formulate a methodical approach to select the perfect duct the desired shape and size. They are used in low velocity
design for a given situation. application less than 600 m/min and for a static pressure
below 5mm of water gauge. Sometimes cement asbestos
Key words: Duct design, Equal Friction Method duct also used for underground air distribution. The
wooden duct may be used in places where moisture
1. Introduction content in the air is not very large.
In the present day, the human being needs more
comfort because of inferior environment (like light, sound, 3. Supply Duct Systems
machine which produce heat). Sound, light and heat affect
human comfort a lot. They may adversely affect the human Supply ducts deliver air to the spaces that are to
comfort positively or negatively. The field of air be conditioned. The two most common supply duct
conditioning design is more technologically challenging systems for residences and commercial spaces are the
than ever before. Today the emphasis is no more on trunk and branch system and the radial system because of
understanding air conditioning products but on creating their versatility, performance, and economy.
solutions and not just solutions , but customized
solutions. One of the important modules in the process is
the duct design. The efficient duct design process enables
the proper supply of air quantity, equal distribution of air
at every corner of the Air conditioned space.
The efficiency of air distribution systems has been
found to be 60-75% or less in many houses because of
insufficient and/or poorly installed duct insulation and
leaks in the duct system. Properly designed and installed
duct systems can have efficiencies of 80% or more for little
or no additional cost.Duct systems that are undersized, are
pinched, or have numerous bends and turns may lead to
low air flow rates and high air velocities.Low air flow rates
cause the heating and cooling equipment to operate Fig- 1: Reduced Trunk and branch System
inefficiently and the high air velocities increase noise.

A three storey retail shop has been selected for


calculation of cooling loads on the basis of floor area,
temperature of heat sources, humidity, climate structure,
occupancy and location. These results will help in
determining the duct design. The rectangular cross-section
of the duct is selected as they are easy to fabricate.

2. Duct Material

The ducts are usually made from galvanized iron


sheet metal, aluminum sheet metal or black sheet. The
most commonly used duct material in the air conditioning Fig -2:Radial Duct System
system is galvanized sheet metal, because the zinc coating
A large main supply trunk is connected directly to
the air handler or its supply plenum and serves as a supply
plenum or an extension to the supply plenum. Smaller
branch ducts and runouts are connected to the trunk. The
principal design limitation of the extended Plenum system
is the length of single-size trunk duct. To maintain
reasonably uniform air pressures in the air-distribution
system, the length of a single-size trunk duct should be
limited to about 24 feet. When this length is exceeded Fig3: Various types of air duct: (a) rectangular duct; (b)
pressure tends to build up toward the end of the duct,
resulting in too much airflow in branches near the ends, round duct with spiral seam; (c) flat oval duct; (d) flexible
and insufficient airflow in branches closer to the duct.
equipment.
5. Duct Sizing
4. Classification of duct systems The main goal of designing HVAC duct systems is
to use the lowest cost (read smallest) duct sizes that can be
a. Low pressure systems: Velocity 10 m/s, static used without violating certain sizing constraints. First and
pressure 5 cm H2O (g) operating cost considerations in dictate that duct systems
b. Medium pressure systems: Velocity 10 m/s, should be designed to operate at the lowest possible static
static pressure 15 cm H2O (g) pressure. The most widely used method to size duct is
c. High pressure systems: Velocity > 10 m/s, static constant friction loss method. The other methods are
pressure 15<p 25 cm H2O (g) velocity reduction method and static regain method.

Recommended air velocities depend mainly on the 5.1 Equal friction method
application and the noise criteria.
Typical recommended velocities are: Duct systems in small buildings are generally
a. Residences: 3 m/s to 5 m/s sized using the equal friction or modified equal friction
b. Theatres: 4 to 6.5 m/s method. The equal friction method, as its name implies, is
c. Restaurants: 7.5 m/s to 10 m/s based on maintaining the same pressure drop per unit of
High velocities in the ducts results in: duct length (or friction rate) throughout the system. The
a. Smaller ducts and hence, lower initial cost and duct size is based on the flow rate through a particular
lower space requirement section of duct, and design value for the friction rate. Each
b. Higher pressure drop and hence larger fan power section is sized using the design friction rate criterion, and
consumption. the total pressure drop for each run is simply the sum of
c. Increased noise and hence a need for noise the pressure drop of each individual section. The duct
attenuation sections pressure drop includes straight duct friction loss,
pressure losses through fittings such as elbows, takeoffs,
4.1 Types of Air Duct and registers and /or diffusers. In the sections entering
and leaving the HVAC unit, pressure losses associated with
The duct may be classified as follows: the flow transitions entering the leaving the unit (the
a) Supply air duct system effect) are also included. The unit fan speed is
b) Return air duct selected to provide the design cfm and produce enough
c) Fresh air duct pressure difference to overcome pressure losses in the
d) Low pressure duct supply and return branches having the greatest pressure
e) Medium pressure duct drop. Note that duct systems designed using the equal
f) High pressure duct friction method is not self-balancing. Balancing dampers
g) Low velocity duct must be installed in lower pressure loss branches to
h) High velocity duct balance the system.

4.2 Duct Shape Advantages

1. The equal friction method is straightforward and easy


to use and gives an automatic reduction of the air flow
velocities throughout the system. The reduced
velocities are in general within the noise limits of the
application environment.
2. The advantage of this design method is its simplicity:
calculations can be made using simple tables and duct
calculations
3. A design flow, each 100 feet of duct has roughly the 6. Duct Design Criteria
same total pressure drop that requires less balancing
for symmetrical layouts. Many factors are considered when designing a duct
4. Automatically reduces air velocities in the direction of system.
airflow. This reduction will decrease the chances of a. Space availability
introducing airflow generated noise from high b. Installation cost
velocities. c. Air friction loss
5. System velocity may be readily checked at any point. d. Noise level
This method is most appropriate for constant air e. Duct heat transfer and airflow leakage
volume (CAV) systems.
6.1Steps in Duct Design
Limitations
Following are the basic steps in Duct Design
The method can increase the numbers of a. First find out the air flow rate
reductions compared to other methods, and often a poorer b. Based on air flow rate select fan unit which is to be
pressure balance in the system require more adjusting installed.
dampers. This may increase the system cost compared to c. Select initial velocity [Main duct air velocity: -6 m/s,
other methods. Branch duct air velocity: - 4 m/s
d. Duct area = Air flow rate/ Velocity
5.2 Velocity Reduction Method e. Determine Equivalent duct diameter and find Duct
size/dimension from ASHRAE table for rectangular
shape.
The velocity criterion for sizing duct is fairly
f. Then initial friction rate is determined by using equation
simple and straightforward. With this method, the ducts
on the basis of air quantity and equivalent duct
are sized fixing the speed in the duct immediately
diameter.
downstream from the delivery fan and empirically
g. Determine the static and dynamic pressure drop for
reducing this speed over subsequent duct trunks, normally
fittings from ASHRAE table for duct fitting codes.
close to each branch. Velocity limits are commonly used as
a surrogate for limiting duct breakout noise. Many argue it
is a poor indicator since noise is more likely to result from 7. Pressure Losses in Ducts
turbulence than velocity; e.g., a high velocity system with
smooth fittings may make less noise than a low velocity Pressure is lost due to friction between the moving particle
system with abrupt fittings. Nevertheless, limiting velocity of the fluid and the interior surfaces of a duct. When the
to limit noise is a common practice. It is important to pressure loss occurs in a straight duct, then this loss is
consult with the projects acoustical engineer on this issue. known as friction loss. The pressure loss is due to the
Many rules-of-thumb for velocity limits exist depending on changes of direction of air flow such as bends, elbows etc.
the noise criteria of the spaces served and the location of and at the change of cross section of the duct, this loss is
the duct. known as dynamic losses.
The pressure drop due to friction is known as
5.3 Static Regain Method frictional pressure drop or friction loss, p . The pressure
f
drop due to momentum change is known as momentum
This method refers to increase or regain of static pressure drop or dynamic loss, p . Thus the total
d
pressure in the ductwork when the air velocity decreases. pressure drops p is given by:
The Static Regain method of duct sizing is based on t

Bernoulli's equation, which states that when a reduction of


velocities takes place, a conversion of dynamic pressure pt = pf + pd
into static pressure occurs.
With this method, the air speed in the duct is 8. Dynamic Losses in Ducts
reduced near each branch or diffuser so that the dynamic
pressure conversion obtained exactly balances the
The dynamic losses are caused due to the change
pressure drop of the air in the trunk of the next duct. This
in direction or magnitude of velocity of the fluid in the
means there is the same static pressure near all the
duct. The change in the direction of the velocity occurs at
branches and all the diffusers, thereby obtaining an
bends and elbow. The change in the magnitude of velocity
intrinsically balanced air distribution system without
occurs when the area of duct changes i.e. enlargement,
having to use throttling devices.
contraction, suction etc.
Compared to the two previous methods, this
V 2
method usually involves a larger surface area of the panels, pd = C
but lower electric fan power and easier balancing of the 2
plant. Where,
C is the dynamic loss coefficient, which is normally
obtained from experiments.
9. Building Structure (34.75 X 22.6 X 8.42)X 3 X 22
CFM =
60
The dimension of the building which is to be air CFM = 7274 f 3 /min
conditioned is, 10.596.12 m in size. It has three floors Q air = 3.43 m3 /s
including the ground floor. The exterior walls of building Q air = 12360 m3 /hr
consist of 102 mm face bricks and 203 mm face brick with Considering
15 mm cement mortar sand 6 mm plaster on each side. Main duct air velocity: - 6 m/s
The roof consists of 102 mm HW concrete with 6 mm Branch duct air velocity: - 4 m/s
plaster& air gap with pop 457 mm below the slab. The 3.43
= = = 0.57 2
front display glass consists of single glass materials of 12 6
mm thick with frame panel. Frictional pressure drop at section A is given by
0.022243 1.852
=
Table - 1: Summary of Building Specifications 4.973
The frictional pressure drop for all sections should be
Ite
Description
Ground
1st Floor 2nd Floor
same as 0.83 Pa/m for Equal Friction Method.
m Floor

1
Total Interior Space
187.52 m2 187.52 m2 187.52 m2 Hence,
(Volume)
Q1.852 Q1.852 Q1.852
( 4.973 ) = ( 4.973 ) = ( 4.973 ) =
2 Total Exterior Wall Area 82.53 m2 82.53 m2 82.53 m2 Deq Deq Deq

3 Total Roof Area 56.13 m2 56.13 m2 64.8 m2


Equivalent diameter of Main Duct section Deq A
Total Glass/ Window
4 7.36 m2 18.48 m2 18.48 m2 1
Area
4.973
0.022243 Q 1.852
A
Deq A = ( Pf
)
10. Duct Calculations (
L
)
A
Deq A = 0.67 m
Deq A = 668 mm
Rectangular duct dimensions for main duct
a=500 mm b= 750 mm

Table - 2: Frictional loss per unit length calculations

1 Section
C F O P Q R

Ground ( ) ( ) ( ) ( ) ( ) ( )
Floor = 1.62 = 1.49 = 0.56 = 0.74 = 0.74 = 0.56

2 Section
B E K L M N

First Floor ( ) ( ) ( ) ( ) ( ) ( )
= 1.62 = 1.49 = 0.56 = 0.74 = 0.74 = 0.56

3 Section
Fig 4: Front view and Side view of duct layout. A D G H I J

Second ( ) ( ) ( ) ( ) ( ) ( )
Floor = 0.88 = 1.49 = 0.56 = 0.74 = 0.74 = 0.56

Table - 3: Air Flow Rate at Each Grill

Section
C F O P Q R

Ground Q C QF QO QP QQ QR
Floor = 1.144 m3 = 1.144 m3 = 1.144 m3 = 0.858 m3 = 0.572 m3= 0.286 m3
/s /s /s /s /s /s

2 Section
B E K L M N

First QB QE QK QL QM QN
Floor = 2.286 m3 = 1.144 m3 = 1.144 m3 = 0.858 m3 = 0.572 m3= 0.286 m3
Fig 5: Top view of duct for first floor /s /s /s /s /s /s

3 Section A D G H I J
Supply Duct Calculations
Second QA QD QG QH QI QJ
Volume X ACH Floor = 3.43 m3 = 1.144 m3 = 1.144m3 = 0.858 m3 = 0.572 m3= 0.286 m3
CFM = /s /s /s /s /s
60 /s
Table - 4: Calculated Dimensions of Ducts
References
1 Section
C F O P Q R
[1] Bhatia A. HVAC How to Size and Design Ducts
PDH online Course No. M06-032, pp 22-25.
Ground
Floor

= 400 = 400

= 400 = 300 = 225 = 150
[2] Al-Rabghi,O. and Khalid A. , " Utilizing transfer
function method for hourly cooling load calculations"
= 450 = 450 = 450 = 450 = 450 = 450
2 Section
Energy Conversion and Management,1997; 38: 319-
B E K L M N 332.
First Floor [3] Robert Parsons, ASHRAE HANDBOOK: Fundamentals.
= 500 = 400 = 400 = 300 = 225 = 150 American Society of Heating; 2005.
= 450
= 550 = 450 = 450 = 450 = 450 [4] G.S. Sharma and B. Sharma. Duct designing in air
3 Section
A D G H I J
conditioning system and its impact on system
performance. VSRD International Journal of
Second a
Floor

=500 mm = 400

= 400 = 300 = 225 = 150
Mechanical, Automobile and Production Engineering,
Vol. 2 No. 9 November 2012.
b
= 750 mm
= 450 = 450 = 450 = 450 = 450
[5] R.Whalley, A. A. Ameer. Heating, ventilation and air-
conditioning system modeling. Building and
Environment 46 (2011) 643-656
For GI sheet, as duct material, the pressure drop per unit [6] C. Aydin, B. Ozerdem. Air leakage measurement and
length is given by equation below analysis in duct systems. Energy and Buildings 38
(2006) pp207213.
Pf A 0.022243 1.852
=
LA D4.973 BIOGRAPHIES
The section A-B-C-F-O-P-Q-R after calculations is found to
be index run.
Total static frictional pressure loss at A-B-C-F-O-P-Q-R Mr. VirendraV. Khakre,
(Pf ) = (Pf )A + (Pf )B + (Pf )C + (Pf )F + (Pf )O PG student, Department of
+ (Pf )P + (Pf )Q + (Pf )R Mechanical Engineering,
(Pf )AJ = 0.88 + 1.62 + 1.62 + 1.49 + 0.56 + 0.74 + 0.74 B.N.C.O.E. Pusad.
+ 0.56
= 8.21 Pa.
Dynamic losses in section A-B-C-F-O-P-Q-R are Suction, 2
no. of Tee, 2 no. of Elbow, 3 no. of Contraction, 1 fire Dr. Avinash Wankhade,
damper followed by Discharge. Professor & Head
Total Dynamic Pressure loss Department of Mechanical
(P)dy = Ptee + Pelbow + Pcontraction + Pfire damper Engineering, B.N.C.O.E. Pusad.
+ Psuction and discharge + Pgrill
(P)dy = 25.33 + 22.08 + 2.21 + 4.10 + 2.59 + 38.4
= 94.71 Pa Prof. M. A. Ali
Pressure loss = Total static + Total dynamic Associate Professor, Department
= 8.21 + 94.71 =102.92 Pa of Mechanical Engineering,
Pressure loss across the cooling pad B.N.C.O.E. Pusad.
( )= 55 Pa or 5.6 mm of wg
Total pressure loss = 102.92 +55
(P)T = 157.92 Pa
(P)T = 16.10 16 mm of water gauge

Conclusion

For designing the duct, building cooling load and


air flow rate is calculated and the duct design for building
is done by using equal friction method.Frictional pressure
drop are different for all floors. The calculated value of
frictional pressure drop is less, due to less value, duct
diameter is increased but loss in static pressure and
velocity pressure can be avoided.Due to increased duct
diameter the use of damper may be decreased. In the index
run total pressure loss is 102.9 Pa and duct size in mm
reduces from 500 x 750 to 150 x 450. Pressure loss in duct
fitting can be minimized by proper design the elbow shape.

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