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Tech Bulletin #3.1

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Tech Bulletin #3.1 Tech Bulletin: CAS-TB3.1-2006 What is an Allowable Duct System Leakage Specifi cation? What is an Allowable Duct System fl at oval duct leakage class to be 6. What performance and associated operating Leakage Specifi cation? It is a written the table actually shows is that for the costs. It should be further noted that specifi cation noting how much air is ac- same seal class, rectangular ducts leak at SMACNA states if the designer does not ceptable to leak from a duct system while least two-times more than round and fl at designate pressure class for duct construc- maintaining optimum occupant comfort oval, so where they are installed can have tions on the contract drawings, the basis at minimum owner expense. Leakage a signifi cant impact on the overall system of compliance is as follows: 2-inch wg reduces the amount of heated or cooled air that arrives at a work area. Th is can lead to a loss in the occupants’ comfort Table 1: Applicable Leakage Classes level, reducing productivity and increas- Duct Class ½-, 1-, or 2-inch wg 3-inch wg 4-, 6-, or 10-inch wg ing labor costs. Increasing the fan speed Seal Class CBA to off set leakage may improve occupant Sealing Applicable Transverse Joints Only Transverse Joints Joints, Seams, and all comfort, but results in increased operat- and Seams Wall Penetrations ing and maintenance costs; and sealing the ductwork during installation increases Leakage Class construction costs. No matter how you Rectangular Metal 24 12 6 examine it, leakage, or the steps required Round Metal 12 6 3 to prevent it, results in increased costs. Th e underlining goal is to determine how much leakage is too much and to specify an appropriate leakage rate that results Table 2: Leakage as Percent of Airfl ow in System in minimal leakage at minimal expense. Static Pressure (inch wg) Th e designer should carefully consider Leakage Fan Airfl ow ½12346 the following information in establishing Class (cfm prorated/sq ft) allowable leakage specifi cations. 2 15.0 24.0 38.0 Does Table 1 look familiar? It is Table 4-1 on page 4-3 in the 1985 SMACNA 48 3 10.0 16.0 25.0 HVAC Air Duct Leakage Test Manual 5 6.1 9.6 15.0 and Table 1-1 on page 1.11 in the 2005 2 7.7 12.0 19.0 SMACNA HVAC Duct Construction 24 3 5.1 8.0 13.0 Standards. Th is table is not an allowable leakage specifi cation, but is often used 5 3.1 4.8 7.5 as one. McGill AirFlow receives many 2 3.8 6.0 9.4 12.0 inquiries each year from contractors, who 12 3 2.6 4.0 6.3 8.2 are performing leak tests in the fi eld, wanting to know how to use this table to 5 1.5 2.4 3.8 4.9 test to as a leakage specifi cation. McGill 2 1.9 3.0 4.7 6.1 7.4 9.6 AirFlow often gets specifi cations stating 6 3 1.3 2.0 3.1 4.1 4.9 6.4 that the leakage class for rectangular 5 0.8 1.2 1.9 2.4 3.0 3.8 and round ductwork will be in accor- dance with the SMACNA Table 4-1 for 2 1.0 1.5 2.4 3.1 3.7 4.8 a 3-inch water gauge (wg) supply duct 3 3 0.6 1.0 1.6 2.0 2.5 3.2 system, thus allowing the rectangular duct 5 0.4 0.6 0.9 1.2 1.5 1.9 leakage class to be 12 and the round and © 2006 McGill AirFlow LLC for all ducts between the supply fan and Table 5). With the present energy cost/ helpful recommended duct seal levels variable volume control boxes and 1-inch crisis, spiral ductwork with leakage rates table noting how the seal class should wg for all other ducts of any application. of less than 1 percent may again have to be adjusted to account for duct loca- According to Table 1, this requires a seal be considered for pressures of 1-inch to tion and application. Although several class C, which means rectangular ducts 10-inch wg. duct construction types show leakage can leak up to a leakage class of 24 and Table 3 is an abridged version of classes greater than 6, the ASHRAE round ducts can leak up to a leakage class Appendix E from the SMACNA HVAC Recommended Ductwork Leakage of 12. What system can aff ord that? Duct Leak Test Manual that quantifi es the Specifi cation in Table 4 maintains a Actually, this table is very helpful in amount of leakage by pressure for each maximum allowable leakage class 6 for providing the designer with some insight duct class. Th e engineer can use this table all duct types regardless of seal class or as to the expected leakage rates for rect- to determine the expected total leakage application. Th is table is presented as an angular and round duct sealed in accor- of the system designed prior to selecting allowable leakage specifi cation but it is dance to a seal class based on operating the fan and associated costs for increased still based on SMACNA leakage classes. pressure. Th e designer can estimate how horsepower to compensate for leakage. Th e designer should consider the total much more horsepower the fan requires Th e contractor can use this table in con- ownership cost, which is the sum of the to compensate for lost energy due to junction with the capabilities of the leak fi rst cost plus the sum of the operating leakage, and hopefully material and oper- testing equipment to determine how large cost over time. What may have a lower ating costs can be compared at the design a system they can pressure leak test. fi rst cost for a rectangular system will stage and not after the system is installed. Table 4 depicts Table 7 about duct de- have much higher operating costs. Round Although specifying a higher duct class sign from the 2005 ASHRAE Handbook and fl at oval systems that have much low- does yield a lower leakage class, it is a – “Fundamentals”(refer to page 35.15, er leakage rates will end up costing much poor means to select allowable leak- Chapter 35). ASHRAE also presents a less over time since the higher operating age. Table 2 is an abridged version of duct leakage classifi cation table, similar costs of rectangular systems will continue Appendix A from the SMACNA HVAC to Table 1, which includes the seal classes to accumulate due to increased leakage. Duct Leak Test Manual comparing com- and predicted leakage classes for the ad- Unfortunately, there are no guidelines in mon prorated leakage {cubic feet per ditional duct types presented in Table 2. helping the designer to establish what minute (cfm)/square feet (sq ft) of surface ASHRAE further provides an extremely combination of construction types may area} to the “older” percent by system volume allowable leakage specifi cation. Th e percent by volume method is by Table 3: Leakage Factor (F) in cfm/100 sq ft far the more accurate means of specify- ing leakage in that at the completion Static Pressure (inch wg) of the system installation, the air test- Leakage Class ½ 1 2 3 4 6 10 ing and balancing agencies can quickly, 48 30.6 48.0 75.4 98.0 118.1 and easily, determine how close the 24 15.3 24.0 37.7 49.0 59.0 airfl ow discharged by the fan compares to the airfl ow entering the conditioned 12 7.6 12.0 18.8 24.5 29.5 space through prescribed registers. Th e 6 3.8 6.0 9.4 12.2 14.8 19.2 26.8 increased costs associated with higher 3 1.9 3.0 4.7 6.1 7.4 9.6 13.4 duct leakage are quickly realized when accounting for the increased fan horse- power required to overcome the leakage in order to obtain the designed airfl ow, a Table 4: Recommended Ductwork Leakage Specifi cation cost increase that is continually paid out Duct Type Leakage Type (cfm/100 sq ft at 1-inch wg) to the utility company. Round Metal (including metal fl exible) 3 Th e popular “old” specifi cation was 1 Flat Oval Metal 3 percent (approximately a leakage class 3) allowable leakage for medium- and Rectangular Metal 6 high-pressure systems and 5 percent Round Flexible 6 (leakage class 6 to class 12) for low-pres- Round Fibrous Glass 3 sure systems. Leakage specifi cations are Rectangular Fibrous Glass 6 less stringent today yet more complicated to fi gure out. It is a fact that spiral round and fl at oval systems did, and still can, meet or exceed ½ of 1 percent leakage Table 5: McGill AirFlow Allowable Leakage Specifi cation 1985 by volume when properly sealed under System (Static) Pressure (inch wg) Allowable Leakage (cfm/100 sq ft) seal class A. For the most part, many spiral manufacturers have softened their 0 - 0.99 3.0 positions and given in to unsubstantiated 1 - 1.99 4.6 or unqualifi ed industry claims that those 2 - 2.99 6.0 leakage specifi cations are too stringent, 3 - 3.99 7.4 too expensive, and too diffi cult to achieve; and forfeited the fact that spiral round 4 - 5.99 9.6 and fl at oval systems easily meet or exceed 6 - 10.00 13.5 the lowest published leakage class 3 (see area prorated to system total surface area Table 6: Allowable Leakage Rates allows for manageable testing of smaller Minimum Maximum sections for conformance to the percent Type of System Test Pressure5 Allowable Leakage total cfm maximum allowable leakage Fractional horsepower fan system; fan coils, rate.
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