TESTINGFORDUCTLEAKAGE

Gaylon Richardson Engineered Air Balance Co., Inc. Spring, Texas

WhatShouldBeSpecified
AssociatedAirBalance CouncilAABCStandard TypeofSystem Minimum Test 17 Pressure1,7 0.50WC (125 pa) Maximum Allowable Leakage k 2% ASHRAE2012DuctConstructionChapter SystemsandEquipmentHandbook System Condition Operating System During Construction 1.00WC (250pa) 2% TestPressure1,7 in.wc(Pa) Operating Pressure 0 5(125) 0.5 Allowable System Leakage k 5% 5%

1.Fractionalhorsepowerfan systems;fancoils,small exhaust/supply / pp yfans, ,andresidential systems 2.Smallsystems;splitDXsystems usuallysystemsunder2000CFM (940l/s),andresidentialsystems

1

Testpressureshouldnotexceedthepressureratingoftheduct.

7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthepossibility

of ffan f shut h toff ffexists i t either ith i inVAVsystems t ori insystems t with ithsmoke/fire k /fi damper d control. t l

WhatShouldBeSpecified
AssociatedAirBalance C Council ilAABCStandard S d d TypeofSystem Minimum TestPressure
17 1,7

ASHRAE2012DuctConstructionChapter S Systems and dE Equipment i H Handbook db k System Condition Operating System Operating System During g Construction TestPressure Allowable 1,7,in.wc System y (Pa) Leakage Not Addressed Operating Pressure 2.0( (500) ) 5% 5%

Maximum Allowable Leakage 2%

3.VAVandCAVboxesand associateddownstream ductwork2 4.Singlezone,multizone,

1.00WC (250pa) 2.00WC (500pa)

2%

returnducts,andexhaust ductsystems y
1

Testpressureshouldnotexceedthepressureratingoftheduct.

7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthepossibilityoffanshutoff

existseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol control.

WhatShouldBeSpecified
AssociatedAirBalance CouncilAABCStandard ASHRAE2012DuctConstructionChapter SystemsandEquipmentHandbook

TypeofSystem

Minimum Test Pressure1,7 3.00 3 00WC (745pa)

Maximum Allowable Leakage 1%

System Condition Operating O ti System During Construction

TestPressure1,7, in.wc(Pa) N tAdd Not Addressed d NotAddressed

Allowable System Leakage

5.Allconstant 5 t tvolume l d ducts t inchasesandconcealed spaces,mainreturnducts onVAV8 andCAV8 systems

1

Testpressureshouldnotexceedthepressureratingoftheduct.

7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthe

possibilityoffanshutoffexistseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol. 8 Itisassumedthattheprimaryairdamperislocatedattheboxinlet inlet.Ifinsteadthisdamperisatthebox outlet,thentheboxshouldbeincludedintheupstreamleakagetesting.

WhatShouldBeSpecified AssociatedAirBalance
CouncilAABCStandard TypeofSystem Minimum Test Pressure1,7 4.00WC (995pa) Maximum Allowable Leakage g 1%

ASHRAE2012DuctConstructionChapter SystemsandEquipmentHandbook System Condition Operating System During Construction TestPressure1,7, in.wc(Pa) Operating Pressure UpstreamBox: 4.0 (1000) Downstream Box:1.0(250) Allowable System Leakage g 5% 5%

6.SupplyductsforVAV8 and CAV8 systems

VAVandCAVterminal boxestestedwith upstreamductwork

1

Testpressureshould T h ldnotexceed dthe h pressurerating i of fthe h d duct. 7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthe possibilityoffanshutoffexistseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol. 8 Itisassumedthattheprimaryairdamperislocatedattheterminalboxinlet.Ifinsteadthisdamperis at tthe th terminal t i lbox b outlet, tl t then th the th terminal t i lbox b should h ldbe b included i l d din i the th upstream t leakage l k testing. t ti

WhatShouldBeSpecified
AssociatedAirBalance C Council ilAABCStandard S d d ASHRAE2012DuctConstructionChapter S Systems and dE Equipment i H Handbook db k

Type yp ofSystem y

Minimum Test Pressure1,7 6.00WC (1495pa) )

Maximum Allowable Leakage 1%

System y Condition Operating S t System During Construction

TestPressure1,7, in.wc(Pa) Operating P Pressure 6.0(1500) Operating O ti Pressure 6.0(1500)

Allowable System Leakage 5% 5% 5% 5%

7.Dualductsystems,both h tduct hot d tand dcold ldd duct t

8.High 8 Hi hpressureinduction i d ti system

6.00 6 00WC5 (1495pa)

0 5% 0.5%

Operating O ti System During Construction

Testpressureshouldnotexceedthepressureratingoftheduct. 5 Largeinductionsystemsmayhavehigherpressurerequirements,i.e.,10WC(2490pa) 7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthe ibilit f f h t ff i t ith i VAV t i t ith k /fi d t l

WhatShouldBeSpecified
AssociatedAirBalance C Council ilAABCStandard St d d TypeofSystem Minimum Test Pressure1,7 6.00WC6 (1495pa) Maximum Allowable Leakage 0.5% ASHRAE2012DuctConstructionChapter S t Systems and dE Equipment i tH Handbook db k System Condition Operating System During i Construction 4.00WC (995pa) ( p ) 0% Operating System y During Construction
1

TestPressure1,7, in.wc(Pa) NotAddressed NotAddressed dd d NotAddressed NotAddressed

Allowable System Leakage

9.Manifoldedexhaustsystems

Exhaustsystemsforlabs withairvalves
10.Grease ductsystems

Testpressureshouldnotexceedthepressureratingoftheduct. 6 Largemanifoldexhaustsystemsmayhavehigherpressurerequirements,i.e.,10WC(2490pa) 7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthe possibilityoffanshutoffexistseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol.

WhatShouldBeSpecified
AssociatedAirBalance CouncilAABCStandard TypeofSystem Minimum Test Pressure1,7 Not Addressed Maximum Allowable Leakage g ASHRAE2012DuctConstructionChapter SystemsandEquipmentHandbook System Condition Operating System During Construction TestPressure1,7, in.WC(Pa) Operating Pressure Downstream box:3.0(750) Upstreambox: 1.0(250) Allowable System Leakage g 5% 5%

11.VAV8 andCAV8 return systems

Testp pressureshouldnotexceedthep pressurerating goftheduct.

7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthe

possibilityoffanshutoffexistseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol. 8 Itisassumedthattheprimaryairdamperislocatedattheterminalboxinlet.Ifinsteadthisdamperis attheterminalboxoutlet, ,thentheterminalboxshouldbeincludedintheupstream p leakage g testing. g

WhatShouldBeSpecified
AssociatedAirBalance CouncilAABCStandard ASHRAE2012DuctConstructionChapter SystemsandEquipmentHandbook

TypeofSystem

Minimum Maximum Test Allowable Pressure Leakage

1,7

System Condition

TestPressure Allowabl 1,7,in.WC eSystem ( ) (Pa) Leakage

Operating Pressure 4.0(1000) 5% 5%

12.Chilledbeamprimary 2.00 WC 1%

supply

(500 pa)

Operating System During Construction

Testpressureshouldnotexceedthepressureratingoftheduct duct. 7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthe possibilityoffanshutoffexistseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol.

WhatShouldBeSpecified
AssociatedAirBalance ASHRAE2012DuctConstructionChapterSystems CouncilAABCStandard andEquipmentHandbook

TypeofSystem

Minimu Maximum mTest Allowable Pressure Leakage

1,7

System Condition

Test Pressure1,7, in wc(Pa) in. Operating Pressure 3.0(750) Operating Pressure 3.0(750)

Allowable System Leakage 2% 2% 2% 2%

13.Supplyandreturn ductworklocatedoutdoors

3.00 WC4 (745pa)

1%

Operating System During Construction

14.Exhaustductwork 14 ocatedindoors

2.00 2 00 WC(500 pa)

2%

Operating System During Construction

Testpressureshouldnotexceedthepressureratingoftheduct.

7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthepossibilityof

fanshutoffexistseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol.

WhatShouldBeSpecified
Associated A i t dAir Ai Balance B l CouncilAABCStandard TypeofSystem Minimum Test Pressure1,7 Maximum Allowable Leakage ASHRAE2012D Duct t C Construction t ti Ch Chapter t SystemsandEquipmentHandbook System Condition TestPressure1,7, in.wc(Pa) Allowable System Leakage

10.0 10 0WC (2500pa) 15.Airhandlingunits 1% Sitetest by Manufacturer

Specified design pressure Operating Pressure 2.0(500)

Testpressureshouldnotexceedthepressureratingoftheduct. 7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureifthe possibilityoffanshutoffexistseitherinVAVsystemsorinsystemswithsmoke/firedampercontrol.

WhatShouldBeSpecified
AssociatedAirBalance ASHRAE2012DuctConstructionChapter CouncilAABCStandard SystemsandEquipmentHandbook
TypeofSystem Minimum Test Pressure1,7 Maximum Allowable Leakage System Condition TestPressure
1,7,in.wc(Pa)

Allowable System Leakage

16.Multizonesupply systems;Multizone returnsystems; Multizoneexhaust systems

1

Item4 above 2.00WC (500Pa)

2%

Operating System During Construction

Operating Pressure 2.0(500)

5% 5%

Testpressureshouldnotexceedthepressureratingoftheduct. 7Itisrecommendedthatthepressureratingoftheductbeequaltothefanshutoffpressureif possibility yoffanshutoffexistseitherinVAVsystems y orinsystems y withsmoke/fire / damper p thep control.

WhatShouldBeSpecified
ForAirHandlingUnits(AHU)withtotalstaticpressures(TSP)below 4WCIwouldsuggestthetestrequirementbe2xTSPnottoexceed 10WC S 10WC. Suggestpanel ld deflection fl i b betested dd during i the h AHU pressuretest. Instrumentationusedtomeasurethepressureacrosstheorifice tubemusthave.01WCresolution.

DeflectionTesting
DeflectionlimitofL/250shallbedemonstrated.Measurements shallbetakenatmidpointofLusingdialindicatorsreadingin 1/1000 h M 1/1000ths. Mounting i of fdial di lindicators i di shall h llbe b independent i d d of fthe h unitcasing.Multiplemeasurementsshallbemade.Dialindicator shallbemountedatmidpointofLontheseams.Lisdefinedas theheightofthelargestpanelonthesidesoftheAHU,widthofthe largestpanelacrossthetopoftheAHU,andthesmallerofwidthor heightofthelargestpanelfortheendsoftheAHU.Theseare knownasthegoverningpanels.

DeflectionTesting
Measurementsshallbespacedalongthesides,ends,andtopat midpointandquarterpointsoftheunit.Spacingshallbeadjusted tofall f llonthe h nearestfl flangeorpanel lj joint. i Any A side, id toporend dof f unitoflessthanfivefeetshallrequireonlyonemeasurementatthe center.Inordertoreducethenumberofpressurecycles,itis recommendedthatmultipledialindicatorsbeusedatthe measurementpoints.

IssuesofSealingDucttoaLeakageClassandSealClass
Case1:PriortoSMACNAHVACAirDuctLeakageTestManual,1985two id i lphases identical h of faresearch h b building ildi werebuilt b il by b different diff contractors. TheAHUsystemsweredualduct.Phase1bycontractorArequired increasingtheRPMandloadingthe125HPmotors(156amps)tomaintain thestaticpressureattheendofthesystem. system Phase2bycontractorB requireddecreasingtheRPMwhichloweredtheampdraw(92amps)to maintainthestaticpressureattheendofthesystem.

IssuesofSealingDucttoaLeakageClassandSealClass
Case2:Twoidenticaltenstoryofficebuildingswerebuiltbythesame contractors.Theoutsideair(OSA)andtoiletexhaustductrisersinthe shaftweretobesealedtosealclassAandleakageclass6. 6 Theductswere identicalsizesandhadthesamerateddesignairflow.Thespecification requiredapressuretestof3.0andleakagetonotexceed2%.BuildingA ductsealingbyteamApassedonthefirsttestineachduct.BuildingB ductsealingbyteamBfailedmanytimesandfinallypassedafter3weeks ofextrasealing.

IssuesofSealingDucttoaLeakageClassandSealClass
Case3:A96x96mainexhaustductwasdesignedfor180,000CFM.The sealclasswasAandtheleakageclasswas6.Thespecificationsrequired 1%leakageat6WC 6 WC.Thecontractortestedseveralsectionsoftheduct andfoundtheleakagetobebetween8%to15%.Theductwasinstalledin aninterstitialspaceandthetopoftheductranbetweenthebeams.An investigationdeterminedtheductsealantwasonlyappliedtothesides andnotthetopandbottom.

IssuesofSealingDucttoaLeakageClassandSealClass
Case4:Connectionofplenumboxestodiffusers.Onahardducted systemthediffuserswereconnectedtoplenumboxes.Thediffusers wereinstalled i ll dwith i hzip i screwsoneach hside. id Our O testing i found f d15% leakage.Theplenumboxeshadtobedisconnectedfromthebranch ductandthediffuserandplenumremovedtoproperlysealthe connection.Afterthediffusersandplenumboxeswerereinstalled noleakagewasdetected.

ReportingDuctLeakage
JobNumber JobName DescriptionofDuctTested PerformedBy B andWitnesses Equipmenttagordesignationoftheprimarymover DesignCFMofTestSection TestEquipmentOrificeSizeandCalibrationDate RequiredSPActualSP AllowableLeakage g inCFMDeterminedby y%ofDuctBeing gTested ActualLeakageCFM Pass/Fail Date

AnticipatedCost
Thesecostsarebasedontheassumptionthatbuildingsare designedontheaverageof1CFM/Ft2 andthecost is approximately$2.00/ Ft2
TypeofSystemFromWhat ShouldbeSpecifiedAbove Maximum AABCStandards ASHRAE2012Duct CFM Cost/Year=Leak % ConstructionChapter Cost/Year=Leak %x xCFMx$2.00 CFMx$2.00 2000 1570 25000 $80 $62.80 $1000 00 $1000.00 $200 $157.00 $2500 00 $2500.00

1.&2.SmallSystems (multiples) 3.TerminalBox Downstream Ductwork(multiples) 4.SystemsBelow 2 4 2WC,MZ, MZ VAV,CAV

AnticipatedCost
TypeofSystemFromWhatShould Maximum beSpecifiedAbove CFM AABC Standards Cost/Year= Leak %xCFMx $2.00 ASHRAE2012Duct Construction ChapterCost/Year= Leak %xCFMx $2.00 $5000 $8000 $15000 $ $10000 $20000 N tAdd Not Addressed d $10000

5.DuctsinChases 6.VAVandCAVSupplyDucts 7.DualDuctSystems y 8.HighPressureInduction 9.ManifoldExhaustSystem 10 Grease 10. G D Ducts t 11.VAV&CAVReturnSystems

50000 80000 150000 100000 200000 10000 100000

$1000 $1600 $3000 $ $1000 $2000 $0 $1000used1%

AnticipatedCost
TypeofSystemFromWhat ShouldbeSpecifiedAbove Maximum AABCStandard ASHRAE2012Duct CFM Cost/Year=Leak % Construction xCFMx$2.00 ChapterCost/Year =Leak %xCFMx $2.00 20000 30000 200000 150000 25000 $200used.5% $0used0% $4000used1% $3000 $1000 used2% $2000 $3000 $8000 $3000 $2500

12.ChilledBeam 13.Supply&Returnlocated Outdoors 14.ExhaustDuctwork 15.AHUs 16.MultizoneSystems

AnticipatedCost
The$2.00perCFMcamefromanestimatedvaluewhenTC5.2was analyzingterminalboxleakage.ThesamecostperCFMwasfound tobe b truei ina7400ft f 2office ffi with i h5rooftop f single i l zoneunits. i ResearchbuildingoperatorshavestatedtheircostperCFMranges between$4.00to$8.00perCFMdependingonhowmany100% OSAsystemsareservingthebuildingandhowmanyspaceshave highairchangerates.

WhatDoesASHRAEStandard90.1Addendumcq add
6.4.4.2DuctworkandPlenumLeakage 6.4.4.2.1DuctSealing.Ductworkandallplenumswithpressureclass ratingsshallbeconstructedtosealclassA,asrequiredtomeetthe requirementsofsection6.4.4.2.2,andwasstandardindustry practice(seeInformativeAppendixE)......Allconnectionsshallbe sealed,includingbutnotlimitedtospinins,taps,otherbranch connections,accessdoors,accesspanels,andductconnectionsto equipment. q p Sealing gthatwouldvoidp productlistings g isnotrequired. q Spirallockseemsneednotbesealed.Allductpressureclassratings shallbedesignatedinthedesigndocuments.

WhatDoesASHRAEStandard90.1Addendumcq add
6.4.4.2.2DuctLeakageTests.Ductworkthatisdesignedtooperateat staticpressuresinexcessof3in.wcandallductworklocated outdoorsshallbeleaktestedaccordingtoindustry acceptedtest procedures(seeInformativeAppendix p pp E). ) Representative p sections totalingnolessthan25%ofthetotalinstalledductareafor designatedpressureclassshallbetested.Allsectionsshallbe selectedbythebuildingownerorthedesignatedrepresentativeof thebuildingowner.Positivepressureleakagetestingisacceptable fornegativepressureductwork.Themaximumpermittedduct leakageshallbeLmax =CL P0.65 ,whereLmax =maximum maximumpermitted leakageCFM/100ft2 ductsurfacearea.CL=for,ductleakageclass, CFM/100ft2 ductsurfaceareaat1in.wc.P=testpressure,which shallbeequaltothedesignductpressureclassrating rating,in in.wc

Summary
Ihaveseenonseveralprojectssampleleakagetestingofthe ductworkspecifiedandthesealingofthesampleducttobebetter thantheremainingductwork.Iwouldsuggestthat100%ofthe ductworkbetested. TosaveenergyIwouldsuggestthatductworkabove3WCbe testedattheductratedpressureandnotexceed1%leakage. The Th duct d trated t dpressureshould h ldbe b what h tthe th rated t dfan f system t shut h t offpressurewouldbeifadamperfailed.Thestaticpressuresetting forthelimitswitchesmustbesetbelowthemaximumtest pressureof fthe th duct. d t Tonotpressuretestductworkandassumethesealantwillbe appliedproperlyhassavedmoneyonthefrontendbutcostthe ownerdearlythroughoutthelifeofthesystem.

QUESTIONS

IT COULD BE WORSE