HVAC Piping system

HVAC Piping system

• Refrigerant pipe
• Suction line (Gas line)
• Discharge line (Liquid Line)
• Chilled water pipe
• Evoporation circuit (Close loop)
• Condensing circuit (Open Loop)
Refrigerant pipe
Refrigerant Pipe
Refrigerant pipe
• Suction pipe,
• Liquid pipe,
• Hot Gas by pass pipe
• All these pipe design shall size based on 1F° pressure drop at design
capacity.
• The actual line size should provide no more than a 2 to 3°F (1.1 to 1.7°C)
pressure drop. The actual pressure drop in PSI (kPa) will depend on the
refrigerant.
Suction line must
• Make sure return oil from the evaporator to the compressor at
minimum system capacity
• Prevent oil draining from an active evaporator to an inactive
evaporator.
• Minimize line sweating from condensation
• Prevent unnecessary heat gain into refrigerant system
Liquid line must
• Make sure no forming of flash gas (expending) before the expansion
valve or metering device.
• No heat gain into the refrigerant.
Design Considerations
• Provide practical line size to minimum pressure drop:- Pressure drop
will result in thermal decrease in thermal capacity
• Increase power requirement.
• Protect compressors by
• a. Preventing excessive lubricating oil from being trapped in the system.
• b. Minimizing the loss of lubricating oil from the compressor at all times.
• c. Preventing liquid refrigerant from entering the compressor during
operation and shutdown
• d. Minimize the accumulation of liquid refrigerant in the compressor
crankcase
• e.Return oil to compressor at the same rate at which it leave.
Refrigerant line Velocities
• Discharge line (from compressor outlet to condenser inlet) 2000-
3500fpm
• Liquid line(From condenser to the metering devices) 100-300fpm
to minimize liquid hammer
• Suction line(From evaporator outlet to compressor inlet (900-
4000fpm)
R410a maximum pressure drop Example
• Maximum Allowable Pressure Drop,
• A high efficiency R−410A unit operating at 10°F subcooling and 115°F (390
psi) condensing temperature, find the maximum allowable pressure drop in
the liquid line.

Refer to the pressure/ temperature chart @ 115° F condensing temperature

minus 10°F subcooling equals to 105°F sub−cooled liquid temperature (340
psi – this is the pressure below which subcooled liquid will begin to form
flash gas),
390 psi condensing pressure minus 340 psi subcooled pressure equals 50 psi.
The maximum allowable pressure drop is 50 psi
Given 10Ton Evaporator 10 ton condenser
unit with 10F subcool at 125F, Length of line
94 FT
• Given Pressure drop cannot exit 35Pa
From the chart: Select the ¾”OD pipe with
pressure drop 2.5psi/100ft

2 nos 90 degree elbow @3/4”=equiv length

1.3ft( refer table valve and fitting)

• Total equiv length= 3+40+53+(2x1.3)=98.6ft

• Total friction loss= 98.6/100x2.5psi=2.46psi

• Lift loss R410a=0.43psi/foot x 40ft=17.2psi

• Filter drier= 1psi (From manufacturer)

Total pressure loss=Total friction loss+lift loss+

filter dryer
• Total losses= 2.46+17.2+1=20.63Psi
Thank you
Presentation overview
• Introduction to air duct design
• Factors need to be consider
• Classification of duct systems
• Method of duct sizing
• Gavalnized sheets material classifications and usage.
• System air duct ventilation and air pressure sizing.
Air Duct Design
Air Duct Design:-Factors to consider
•Available Space
•Sound Level
•Friction Loss
•First Cost
•Heat gain and loss,leakage losses
Classification of Duct systems
Duct Velocities
• Low Velocity • High Velocity
• Main 1000-2400FPM • Main 2500-4500FPM
• Branches 600-1600FPM • Branches 2000-4000FPM

Air Outlets

Low Pressure Outlets High Pressure Terminls

Static Pressure 0.1-0.5” Static Pressure 1.0”-3.0”
Construction:-Conventional Ductwork Construction:-Spiral Conduit
Duct Sizing Methods
3 methods available
•Velocity Reduction
•Equal Friction
•Static Regain
Method of Ductwork Sizing
3 methods available
• Velocity Reduction:=Arbitrary reduction in velocity, Sized by V=Q/A

• Equal Friction:=Same Friction loss per foot of duct

• Static Regain:=Size duct that increase in Static Pressure offsets friction

loss velocity pressure in next duct section,Velocity Head hv=[V/4000]2
• Hv=Velocity head in inches water, V= velocity in feet per minute

• whenever there is an enlargement in the cross-sectional area of the duct, the velocity of
air decreases, and the velocity pressure is converted into static pressure. The increase in
static pressure due to a decrease in velocity pressure is known as static regain
Static Regain

Δpv = pv,1 - pv,2 = Δps = ps,2 - ps,1

Pt,1 = Pt,2
Method of Ductwork Sizing
Methods Pro Con
Velocity Reduction Simple Not standard
Not completely balance
Normally noise not the controlling
factor
Friction Method Simple Considerable dampening required
Static Regain Low System pressure Larger duct size
Lower energy consumption Increase capital cost
Less noise issue in take off Try and error method
HVAC air conditioning and air ventilation
• Classified as low velocity categories
• Equal Friction method most frequent use.
• We Explore on the Equal Friction method.

• Recap: Equal Friction: = Same Friction loss per foot of duct

Aspect Ratio
Define as ratio of Width Vs High
of the rectangular duct.
Generally maximum (Y:X)= 1:5
Y

X
Aspect Ratio
• Increasing the aspect ratio,
• increases both the installed cost
• Increase the operating cost of the system.
• Usually small rectangular duct with an aspect ratio closer to 1to be
use:-Reasons
1. Other benefits include low friction drop,
2. Low weight of metal, and lower insulation
3. Lower installation costs.
Example: Duct cross sectional area 4ft2 with
100ft length
• Duct can fabricate 2’ x 2’ (Aspect ration 1:1) or 1’x 4’(Aspect ratio 1:4)
• 2’x 2’ perimeter 8 ft, material required= 8 x100ft= 800ft
• 1’x4’perimeter 10ft, material required= 10 x 100ft= 1000ft.
• As Aspect ratio 1:1 increase to 1:4, the surface area and insulation
requirement increase by 40%
Friction Chart
In any duct section thru which air is flowing, there is a
continuous loss of pressure. This loss is called duct
friction loss and depends on the following:
1. Air velocity
2. Duct size
3. Interior surface roughness
4. Duct length Varying any one of these four factors
influences the friction loss in the ductwork.
The relationship of these factors is illustrated in the
following equation:
Simplification done by Duct
calculator
Most Popular Method
• Equal Friction method:-This method is far superior than Velocity
reduction because requires less balancing for symmetrical duct
layouts
A B C D E
Say Blower Fan 7200CFM
A B 40’ C 30’ D 30’ E

Duct Section B-C C-D D-E

Quantity CFM 7200 4800 2400
Velocity-FPM 1800 1600 1350
Rect Duct Area 4.0 2.89 1.78
Rect Duct Size 36 x 16 26 x16 16 x16
Equiv.Round Duct 25.8 22 17
Friction Rate/100ft 0.18 0.18 0.18
Velocity reduction method

V=Q/A
Say Blower Fan 7200CFM,
Usually by choosing maximum recommended velocity
A B 40’ C 30’ D 30’ E

Abitrarily velocity Abitrarily velocity

say V=1800fpm reduce to V=1300fpm reduce to V=800fpm

Duct Section B-C C-D D-E

Quantity CFM 7200 4800 2400
Velocity-FPM 1800 1300 800

Rect.Duct Area 4 3.7 3

Rect Duct Size 36 x16 34 x16 28 x16
Equiv.Round Duct 25.8 25.1 22.9
Friction Rate/100ft 0.18 0.1 0.045
Friction/sec 0.07 0.03 0.01
0.045 0.1 0.18
Galvanize Sheet Material
Duct Sheet Metal Thickness –SMACNA Guide
Duct Sheet Metal Thickness
Thank you
Duct Ventilation Static
Total Pressure
• TP = SP + VP
• VP = (V)2 /(4005) 2
• Air Distribution
• Velocity Recommendation
Air Travel Velocity
Two types of air transmission systems used for air conditioning applications.
• Conventional or low velocity
• High velocity systems.
• Guideline
Commercial comfort air conditioning .
-Low velocity – up to 2500 fpm.
- For Factory application : comfort air conditioning between 2200 and 2500 fpm
Normally between 1200 and 2200 fpm.
-High velocity – above 2500 fpm.
-Factory High velocity – 2500 to 5000 fpm.
Normally, return air systems for both low and high velocity supply air systems are designed as low velocity
systems.
The velocity range for commercial and factory comfort application is as follows:
1. Commercial comfort air conditioning – low velocity up to 2000 fpm. Normally between 1500 and 1800 fpm.
2. Factory comfort air conditioning – low velocity up to 2500 fpm. Normally between 1800 and 2200 fpm
Pressure Air distribution systems
• three pressure categories;
• low, medium and high.
• These divisions have the same pressure ranges as Class I, II and III fans
as indicated:
• 1. Low pressure – up to 3 3/4 in. wg – Class I fan
• 2. Medium pressure –3 3/4 to 6 3/4 in . wg – Class II fan
• 3. High pressure – 6 3/4 to 12 1/4 in. wg – Class III fan
The design of a low velocity supply air system
• Three following methods:
• 1. Velocity reduction
• 2. Equal friction
• 3. Static regain

The equal friction method is recommended for return and exhaust air
systems.
Note :
Pressure drop characteristics for the ducts and fittings are derived from ASHRAE 1997 Fundamentals Chapter 32 pp 32.01-32.49.
Density of std. Air (r) 1.2 kg/m3
Kinematic viscosity (n) 1.6E-05 m²/s
Rectangular ducts De = 1.30(ab)0.625/(a+b)0.25
Reynolds Number Re = DhV/1000n
Friction factor f' = 0.11[(e/Dh)+(68/Re)]0.25 If f'<0.018: l = 0.85f'+0.0028 , Else l = f'
Friction Loss (pa) DPf = (1000lL/Dh)*(rV²/2)

Total Tot
Duct Air Flow Rate Duct Dimension Straight Equivalent Length For Elbow Eqv. al
Equip. Ref. Area Served System Sect. Insul Width Height Length Eqv. Len Qty Total Eqv. Length A V Dh De Re e f' l DPf Friction
No. (L/S) (m3/s) (mm) (mm) (m) (m) (nos) Len. (m) (m) (m2) (m/s) (mm) (m) (mm) (Pa/m) Loss (Pa)

AHU 16-2 Ruang Legar A/C Supply Air 1 5663 5.66 int. 730 730 2 5.1 1 5.1 7.1 0.53 10.62 730.00 0.80 4.8E+05 0.9 2.1E-02 2.1E-02 1.96 13.94
2 5663 5.66 int. 1000 600 6.6 7 1 7 13.6 0.60 9.43 750.00 0.84 4.4E+05 0.9 2.1E-02 2.1E-02 1.50 20.43
ARAS 1 3 3775.4 3.78 ext. 800 600 11.6 5.6 2 11.2 22.8 0.48 7.88 685.71 0.76 3.4E+05 0.09 1.5E-02 1.5E-02 0.84 19.09
4 3067.5 3.07 ext. 750 600 2.4 5.3 0 0 2.4 0.45 6.82 666.67 0.73 2.8E+05 0.09 1.5E-02 1.6E-02 0.66 1.59
5 2831.5 2.83 ext. 700 600 7 4.9 0 0 7 0.42 6.74 646.15 0.71 2.7E+05 0.09 1.5E-02 1.6E-02 0.67 4.70
6 2595.6 2.6 ext. 600 600 2.4 4.2 0 0 2.4 0.36 7.22 600.00 0.66 2.7E+05 0.09 1.6E-02 1.6E-02 0.84 2.01
7 2359.6 2.36 ext. 600 550 2.5 4.2 0 0 2.5 0.33 7.15 573.91 0.63 2.6E+05 0.09 1.6E-02 1.6E-02 0.87 2.17

8 1887.7 1.89 ext. 600 500 6.3 4.2 0 0 6.3 0.30 6.30 545.45 0.60 2.1E+05 0.09 1.6E-02 1.7E-02 0.73 4.58
9 1651.7 1.65 ext. 600 400 5 4.2 0 0 5 0.24 6.88 480.00 0.53 2.1E+05 0.09 1.7E-02 1.7E-02 1.00 4.99
10 1179.8 1.18 ext. 600 300 5.5 4.2 0 5.5 0.18 6.56 400.00 0.46 1.6E+05 0.09 1.7E-02 1.8E-02 1.14 6.27
11 943.84 0.94 ext. 600 250 3.1 4.2 0 3.1 0.15 6.27 352.94 0.41 1.4E+05 0.09 1.8E-02 1.8E-02 1.21 3.76
12 471.92 0.47 ext. 400 250 2.7 2.8 0 2.7 0.10 4.70 307.69 0.34 9.0E+04 0.09 2.0E-02 2.0E-02 0.85 2.30
13 235.96 0.24 ext. 250 250 2.1 1.8 0 2.1 0.06 3.84 250.00 0.27 6.0E+04 0.09 2.2E-02 2.2E-02 0.77 1.61
14 117.98 0.12 ext. 200 150 2.3 1.4 1 1.4 3.7 0.03 4.00 171.43 0.19 4.3E+04 0.09 2.4E-02 2.4E-02 1.32 4.89

A/C Return Air 1 5663 5.66 ext. 1200 600 5.5 8.4 1 8.4 13.9 0.72 7.86 800.00 0.91 3.9E+05 0.09 1.4E-02 1.5E-02 0.69 9.63

Max. Ducting Friction Loss ( Pa) 101.95

 8. Outdoor Unit Installation
Example of on-site exhaust air duct installation:

➢Ensure efficient ventilation

➢Discharge speed=4.5-5m/s
➢Suction speed≤1.6m/s

➢ Exhaust air duct

➢ High static pressure
setting of outdoor
fan motor.

➢Water drain processing

Grille open rate > 70%, louver tilting angle < 20 °

111
P2,V2,A2,
M2 50pa

1.366m
coil M1=Q1

V3,A3

P1,V1,A1

1.35m
0.72m
• Q=AV, M=þAV
•QαVαA
• If given Area has been reduced by half net free area ie
(louvre application)
• Ie 2 x A2=A1
• Q also reduce by half; so
• At point 2, M2=Q2 = Q1/2 =2.25 m3/s
• When flow rate Q reduces by half, velocity also
reduces by half V2= V1/2 = 2.31m/s
• At the point of louvre,the minor losses
• ^P= (£ x V22 x §AIR ) /2 Pa
• ^P= (5 x 2.312 x 1.2)/2 =6.93 Pa -----(2)
• Pressure losses across the 90º bend at static of 50 Pa
~0.25 inWg (refer to duct design equivalent length
55/100 x 0.17 ~0.093 inWg = 18.7 Pa-------(3)
• Total Pressure losses => P2
• P2= 50Pa-18.7Pa-6.93Pa
• =24.37Pa
For perfact gas per unit gas (Isothermal process)
• P1V´=M1 R ^T1----------(4)
• P 2V´=M2 R ^T2---------(5)
• Work done per unit volume
• W= M R T Loge (P1/P2)
• (P1V1) / P2 V2 =(50 x 4.5)/ (24.37x 2.31)
=225/56.29
• % losses in efficiency
(225-56.29)/225 x 100%
75% losses in efficiency
Component or Fitting Minor Loss Coefficient
-ξ-

Grilles, 0.7 ratio free area to total surface 3

Grilles, 0.6 ratio free area to total surface 4

Grilles, 0.5 ratio free area to total surface 6

Grilles, 0.4 ratio free area to total surface 10

Grilles, 0.3 ratio free area to total surface 20

Grilles, 0.2 ratio free area to total surface 50

 Minor Loss (Pa, N/m2)
Flow Minor Loss Resistance Coefficient - ξ
Velocity
(m/ 1 2 3 4 5 6 7 8 9 10
s)
2 2.4 4.8 7.3 9.7 12.1 14.5 16.9 19.4 21.8 24.2
2.5 3.8 7.6 11.3 15.1 18.9 22.7 26.5 30.3 34.0 37.8
3 5.4 10.9 16.3 21.8 27.2 32.7 38.1 43.6 49.0 54.5
3.5 7.4 14.8 22.2 29.6 37.1 44.5 51.9 59.3 66.7 74.1
4 9.7 19.4 29.0 38.7 48.4 58.1 67.8 77.4 87.1 96.8
4.5 12.3 24.5 36.8 49.0 61.3 73.5 85.8 98.0 110 122
5 15.1 30.3 45.4 60.5 75.6 90.8 105 121 136 151
5.5 18.3 36.6 54.9 73.2 91.5 109 128 146 164 183
6 21.8 43.6 65.3 87.1 108 130 152 174 196 217
6.5 25.6 51.1 76.7 102 127 153 178 204 230 255
7 29.6 59.3 88.9 118 148 177 207 237 266 296
7.5 34.0 68.1 102 136 170 204 238 272 306 340
8 38.7 77.4 116 154 193 232 271 309 348 387
8.5 43.7 87.4 131 174 218 262 306 349 393 437
9 49.0 98.0 147 196 245 294 343 392 441 490
9.5 54.6 109 163 218 273 327 382 436 491 546
10 60.5 121 181 242 302 363 423 484 544 605
10.5 66.7 133 200 266 333 400 466 533 600 667
11 73.2 146 219 292 366 439 512 585 658 732
11.5 80.0 160 240 320 400 480 560 640 720 800
12 87.1 174 261 348 435 522 609 697 784 871
12.5 94.5 189 283 378 472 567 661 756 850 945
P2,V2,A2,
M2 50pa

1.366m
coil M1=Q1

V3,A3

P1,V1,A1

1.35m
0.72m
2.Mollier diagram

Evaporating pressure
2.40Mpa

Condensing temp
35℃
Super heat 3 degrees

Condensation pressure
0.75Mpa

260kJ/Kg 430kJ/Kg 463kJ/Kg

Louver net free area estimation
In order for the unit to operate in normal condition, P2 shall ≥ 2/3 of
original P1
• For isothermal process
• PṾ= ṀRT(Ṁ= mass flow rate kg/s)
• P is proportional to Ṁ, where Ṁ= ῤ Q = ῤ x A x V (ῤ= density of air =
1.2 kg/m3)
• PαA αV
• At P2 , P2= 2/3 P1
• P2= 2/3 x 50Pa =33.33Pa
• P1/A1 = P2/A2,
• A2= P2 x A1/P2
• Where A1=original air discharge(1.35x0.72=0.972m2),P1= Original
EXP=50Pa.
• =>A2= 33 x (0.972 m2)/ 50= 0.631 m2
• Area losses due to blockage = A1-A2
• 0.972- 0.641 m2= 0.33 m2
• % area losses= 0.33/0.972 x100%= 35%
• i.e net free area remaining is 65%
• Since the net free area is 65%, then the louver angle
is tan β= 84/200
• β = 22 degree measured from the horizontal
 Discharge net
free area example