HVAC DESIGN GUIDE

1. Duct Design

1.1 The proper design of Ducting for air distribution has the following benefits :

1.1.1 Uniform air distribution

1.1.2 Lower fan horse power

1.1.3 Lower noise Level

1.1.4 Lower ducting cost.

1.2 Hence, it is essential to understand the basic fundamentals of ducting design to be

above to get the above benefits.

2. Classification of Ducts

2.1 The air ducts are classified according to the pressure of air (positive or negative)
within the ducts These are :

2.1.1 Low Pressure ducts - Upto 50 mm S.P.

2.1.2 Medium Pressure - Upto 125 mm S.P.

2.1.2 High Pressure Ducts - 125 to 250 mm

2.2 The low and medium pressure are generally sufficient to meet the requirement of
airconditioning systems.

2.3 The High Pressure ducts are used in Marine application where space is limited.

2.4 The low pressure ducts are adequate to meet the needs of average commercial
building, shopping Malls, Hotels, Cinemas & Theatre etc.

2.5 Medium pressure ducts are required where high level of air cleanliness is required as in
Pharma Industry, clean room applications, certain type of Research Labs etc.

3. Methods of Duct Design

3.1 There are three established method for duct sizing. These are :

3.1.1 Equal Friction Method

3.1.2 Velocity Reduction Method

3.1.3 Velocity Regain Method

3.2 Equal Friction Method

3.2.1 In this method a particular rate of Friction is selected. Then the complete ducting is
selected at this friction Rate (F.R.).

DUCT DESIGN Page 1

 HVAC DESIGN GUIDE

3.2.2 This method is described in detail as this is the most commonly used method for duct
design.

3.2.3 The usual F.R. that is selected is 0.1” (3mm) WG per 100 ft.(30 m) of Duct length or
less then the above F.R.

3.2.4 In SI units this is equivalent to one Pa (Pascals) per meter length.

3.2.5 The initial velocity in ducts is kept at or below the figures given below in order to have
a duct system within acceptable Noise Level.

The acceptable Velocity are:

a. Sound Studios - 1000 FPM (5 m/s)

b. Television Studios - 1200 FPM (6 m/s)
c. Deluxe Office buildings - 1600 FPM (8 m/s)
d. Call Centre/General Office - 1800 FPM (9 m/s)
e. Industrial Building - 2000 FPM (10 m/s)

3.2.6 Therefore, in selecting the friction rate for duct design the following procedure is
adopted.

a. Check the air velocity for the given air quantity (CFM/CMH) at 0.1” (3mm) Friction
Rate. If the velocity is within the above prescribed limit then this friction rate (of 0.1”)
is adopted.

b. If the air velocity is higher then the prescribed limit, then a new friction rate is found
which will be below 0.1”.

c. This new rate is then used for all the duct design (and not just the initial duct design).

d. An example is given below to clarify.

- Assume Air quantity = 10000 CFM

- Velocity @ 0.1” WG = 1700 FPM
- Desired Velocity = 1600 FPM
- Friction Rate for 10000 CFM @ 1600 – 0.8” WG
- Hence use 0.8 friction Rate for this particular design.

3.3 Velocity Reduction Method

3.3.1 In this method Initial velocity is selected on a similar basis as given in 2.25 earlier.

3.3.2 In all subsequent sections the velocity is reduced by 5 to 7.5%.

3.3.3 This method is only suitable when a designer has a lot of design experience otherwise
it may result in uneven friction.

3.3.4 Hence, this method is not considered very suitable and is not discussed further.

DUCT DESIGN Page 2

 HVAC DESIGN GUIDE

3.4 Velocity Regain Method

3.4.1 This method gives the most uniform pressure loss which can be kept within required
limits.

3.4.2 This is very suitable when several long branches are taken out from the same AHU and
the length of branches is unequal.

3.4.3 In this method the total friction loss in the longest run of the duct is fixed arbitrarily to
stay within available friction losses.

3.4.4 Further the velocity in duct is reduced after each section. This reduction in velocity
results in regain of static pressure. This the total friction loss can be decided in
advance.

3.4.5 Charts are given in Carrier Handbook which indicates the regain necessary to stay
within the overall pressure drop limit.

3.4.6 Since all branches whether or long and short have equal pressure drop, the air
quantity in each branch remains as per design and avoids too much use of dampers to
balance the system.

3.4.7 This is a good method but requires much longer time to design.

3.4.8 This may be adopted where there is a possibility of too much pressure drop in ducts or
when there are may unequal branches.

4. Fundamentals of duct design

4.1 Several basic fundamental principles should be borne in mind, to achieve a sound and
economical duct design. These are outlined below :

4.2 When the air leaves the air handling unit (AHU) fan outlet it has certain velocity and
momentum. If this momentum is under-stood and harnessed properly it will result in
optimum duct design with minimum friction losses.

4.3 When the air leaves the outlet of a centrifugal fan, it tends to travel in straight line. Its
turning momentum is in the same direction as the turn of vector forces.

4.4 Therefore, if the duct is also turned in this direction there will be least resistance to
turning. In all other direction there will be undesirable losses.

4.5 The other principle is that if the air is allowed to travel straight from outlet for a
distance equal to 4 times the larger outlet size, then it will lose all its turning
momentum.

4.6 Once the turning momentum is lost, then the air stream can be turned in any desired
direction.

DUCT DESIGN Page 3

 HVAC DESIGN GUIDE

4.7 The taper piece in ducts at the reduction in duct size should be in the ratio of 4.1 i.e.
the length of taper piece should be 4 times the amount of reduction eg. If the
reduction is 6” (150mm) then the duct length be should 6x4 = 24” (600 mm).

4.8 If the width of a bend is more than 24” (600 mm) then turning vanes must be
provided in such bends. The distance between vanes starting from small turning radius
should be approx. 15%, 30% & 55% of the duct width.

4.9 Grille collars should not be provided in a taper piece.

4.10 A Splitter damper should be provided wherever a duct branches in two parts.

4.11 Only one duct size should be changed at any one time. Both sizes should not be not
changed together eg.

- Good Practice = 48x18 - Reduce to Say 36x18

- Bad Practice = 48x18 - Reduce to say 40x15

4.12 The thickness of the sheet metal or Gauges of sheet should be in accordance with
relevant ISI or SMACNA (USA) standards.

5. Sizing of Ducts

5.1 The ducts have to be sized to suit the available space.

5.2 Hence, the available space should be clearly evaluated and if necessary discussed will
the architects or interior designer.

5.3 Usually in a corridor there is both the limitation of width and height. Therefore, the
size of duct should be such that it can be accommodated in given space.

5.4 In a open hall situation, the major restriction is of height and not the width, hence
height available for ducts should be confirmed from the interior designer.

5.5 If the whole hall has ceiling at one height then the supply air outlets can be :

5.5.1 Slot diffusers.

5.5.2 Square or round diffusers.

5.6 The return air outlets can be either as above or can be continuous linear grilles at the
periphery.

5.7 Where the ceiling is at two levels or where the ducts are running in the corridor then
the air should be thrown from side wall grilles.

5.8 The return can be taken from the same surface as the supply grille or it can be taken
from near the windows or walls at the other end.

6. Economics of Duct Costing

6.1 The cost of ducts depends on the amount of duct sheets which are used, which is
dependent on the perimeters of the duct.

DUCT DESIGN Page 4

 HVAC DESIGN GUIDE

6.2 The following facts must be considered.

6.2.1 A circular duct has the least perimeter for a given area and have least cost.

6.2.2 Next in terms of smaller perimeter is a square duct.

6.2.3 The rectangular duct has much higher perimeter then circular or square duct for the
same area and it keeps increasing as the aspect ratio (i.e. ratio of length to height)
increases.

6.3 The above becomes clear from the following example.

CFM Duct Dia/Sizing Perimeter Area Increase in % Area

Sq.ft./ft.Length

6.3.1 8000 30” 7.85 --

6.3.2 8000 26”x27” Square 8.8 12
6.3.3 8000 38 x 20 Rectangle 9.7 23
6.3.4 8000 54 x 15 Rectangle 11.5 46
72 x 12 Rectangle 14 78

6.4 The above example clearly illustrates how the material and hence cost of duct
increases with aspect ratio.

6.5 Ideally round ducts should be preferred, but this is not always possible due to
limitation of height.

6.6 Hence, round duct are used where there is sufficient height or where there is no false
ceiling and ducts are left exposed, because circular ducts are aesthetically more
pleasing to eye, then square or rectangular ducts.

6.7 In case of rectangular ducts effort should be made to keep aspect rate as low as
possible to keep the cost down.

6.8 Further in subsequent pieces the size should be changed to constantly keep the aspect
ratio closer to square duct.

6.9 It must be remembered that the reduction in duct cost also result in reduction in cost
of insulation material and as such results in overall saving.

7. Insulation of Ducts

7.1 It is desirable to provided insulation on ducts to :

7.1.1 Prevent condensation in AC duct.
7.1.2 Reduce temperature rise/fall of air in AC/Heating ducts.

7.2 The desirable thickness of insulation on Ducts is.

7.2.1 Ducts in conditioned space where or where supply - Fibreglass - 25 mm
ducts are surrounded by return air Close cell rubber – 9mm

DUCT DESIGN Page 5

 HVAC DESIGN GUIDE

7.2.2 Ducting not in conditioned space - Fibreglass - 50 mm

(not surrounded by return air) Close cell rubber – 13mm

8. Acoustic Lining

8.1 It is necessary to dampen the air noise as it leaves the Air handling unit and strike
against metal surface of the ducts.

8.2 This noise is reduced by providing lining of acoustic material in the ducts.

8.3 The Acoustic lining usually consists of heavy density fiberglass wool blankets or board
of 25 mm (1”) thickness for a length of 4-5 mm. where possible . If 4.5 m is not
possible then minimum 3.0 m length should be covered with lining

8.4 In case of sound/TV studies or other low noise application, it is desirable to provide
acoustic lining throughout the length of both supply and return ducts after finding out
the requirement.

8.5 It may also be necessary or desirable to provide 50 mm thick lining in supply ducts and
25 mm return duct for very low noise application.

8.6 Separate calculations are required for this purpose which cannot be covered in this
general data.

9. Grilles/Diffusers

9.1 Grilles are usually provided on the side face where the false ceiling is at two levels.

9.2 If the false ceiling is at one level their ceiling type diffusers are provided.

9.3 The sizing of some types of grilles and diffusers are given later on.

9.4 Usually supply air grilles/diffusers are provided with volume control dampers to adjust
the air flow between various outlet.

10. Typical Detail

Some typical details of Fan connection & taper piece are given in B-31-T 1.

x.x.x.x.x

DUCT DESIGN Page 6