Duct Leakage Testing

Ken Helfers, TSI Inc.

© 2011, TSI Incorporated

 Agenda
• Need for duct leakage testing
• Duct leakage testing standards and regulations
• Performing duct leakage testing

© 2011, TSI Incorporated

 Why Test Ducts for
L k
Leakage?
?

• Conserve energy
– 10-30% of heated/cooled air lost through ductwork
– Leaky supply ducts don’t delivery air where needed
– Leaky return ducts add load

© 2011, TSI Incorporated

 Why Test Ducts for
L k
Leakage?
?
• Indoor Air Quality
– Leaky returns can pull in air from uncontrolled
spaces,
p causingg
• Humidity problems
• Contaminants

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 System Leakage
• IAQ
IAQ, Comfort,
Comfort Energy issues caused by
leakage from HVAC System
• System Leakage = Duct Leakage +
Equipment Leakage
+ Accessory
y Leakage
g
• Scope of presentation = Duct leakage
– Does not include:
• Leakage through Equipment (See ASHRAE 193)
• Leakage through Accessories
– Commercial & industrial systems
• Similar concepts for residential
© 2011, TSI Incorporated
 Why Test Ducts for
L k
Leakage?
?
• Requirements
R i t
– US
• SMACNA HVAC Air Duct Leakage g Test manual,, First edition,, 1985
• ASHRAE 90.1 (Proposed)
• Project specifications
• California Title 24  residential testing required if ahu/furnace in
garage or ducts in non-conditioned space (attic)
– Europe
• BS EN 12237:2003 – Circular Ductwork
• BS EN 1507:2006 – Rectangular Ductwork
• DW/143 (HVAC—A practical guide to Ductwork leakage testing)
• Eurovent 2/2 (Air leakage rate in sheet metal air distribution systems)

© 2011, TSI Incorporated

 Where Does Duct Leakage
O
Occur?
?
• Transverse Joint
– Duct-to-duct, -branch,
-tap, etc.
• Longitudinal
g Seam
– Joining of 2 edges in
direction of airflow
• Penetration
– Rod, wire, tubing, etc.
• Sealing not required:
– Spiral seams
– Screws & fasteners
– Damper rods

© 2011, TSI Incorporated

 Where Does Duct Leakage
O
Occur?
?

• Higher-pressure ductwork
– ASHRAE 90 90.1
1 recommends only testing ductwork rated >3 in H2O
– Don’t test flex duct

© 2011, TSI Incorporated

 How to Test Duct Leakage
(B i )
(Basic)
• Identify ductwork section to be tested
– Calculated surface area
• Seal ductwork
• Pressurize ductwork to specified level
• Measure flow required to maintain duct
pressure
• Compare to standards

© 2011, TSI Incorporated

 Duct Leakage
Measurements
• % of Flow requirements
– Problem: Disregards size of ductwork & static pressure
– i.e. 1% of flow on 3900 cfm system
y = 39 cfm.
If 1300 ft2 duct area = 3 cfm leakage / 100 ft2
300 ft2 duct area = 13 cfm leakage / 100 ft2
• Test pressure requirements
– Problem: Test pressure higher than duct design
– i.e. testing system designed for 2 in H2O operation at 10 in
H2 O
• Need
N d tto consider
id
– Surface area of ductwork
• Type of ductwork (round, rectangular)
– Static pressure

© 2011, TSI Incorporated

 US Duct Leakage Testing
R
Requirements
i t - (SMACNA)

Duct Class ½-, 1-, 2-inwg 3-inwg 4-, 6-, 10-inwg

Seal Class C B A
Transverse
a sve se Joints,
Jo s, Sea
Seamss
S li
Sealing T
Transverse
Joints and and All Wall
Applicable Joints Only
Seams Penetrations
Leakage Class (CL) – CFM Leakage per 100 ft2 @ 1 in H2O
Rectangular
24 12 6
Metal
Round Metal 12 6 3

F=CL* P0.65
• F = Max Leakage (cfm/100 ft2)
• CL = Leakage Class (from table above)
• P = Pressure (in H2O)
© 2011, TSI Incorporated
Prior to Field Testing

© 2011, TSI Incorporated

 Prior to Field Testing

1) Duct System Designer:

Include on Design/Contract Drawing:

• Specify
S if Duct
D tPPressure Cl
Classification
ifi ti

© 2011, TSI Incorporated

 US Duct Leakage Testing
R
Requirements
i t - (SMACNA)

Duct Class ½-, 1-, 2-inwg 3-inwg 4-, 6-, 10-inwg

Seal Class C B A
Transverse
a sve se Joints,
Jo s, Sea
Seamss
S li
Sealing T
Transverse
Joints and and All Wall
Applicable Joints Only
Seams Penetrations
Leakage Class (CL) – CFM Leakage per 100 ft2 @ 1 in H2O
Rectangular
24 12 6
Metal
Round Metal 12 6 3

F=CL* P0.65
• F = Max Leakage (cfm/100 ft2)
• CL = Leakage Class (from table above)
• P = Pressure (in H2O)
© 2011, TSI Incorporated
 Duct Leakage Equation

F = CL P .65

Where F = Leakage [CFM] / 100 ft2

duct
CL = Duct Leakage Classification
P = Duct Static Pressure [[“w
w.g.]
g]

© 2011, TSI Incorporated

© 2011, TSI Incorporated
 Prior to Field Testing
1) Duct System Designer:
Include on Design/Contract Drawing:
• Test (or not) as installed? Depends on design
intent/requirements
• If Test: Specify on Dwgs
• Portion of ductwork, or whole system?
• Positive Pressure? Negative?
• P id method
Provide th d d
details
t il

© 2011, TSI Incorporated

 Prior to Field Testing
Quote from HVAC AIR DUCT LEAKAGE TEST
MANUAL (SMACNA):

“WHERE NO SPECIFIC DUCT PRESSURE

CLASS DESIGNATIONS ARE PROVIDED BY
THE DESIGNER THE 1” WATER GAGE
PRESSURE CLASS IS THE BASIS OF
COMPLIANCE…

© 2011, TSI Incorporated

 Prior to Field Testing

… EXCEPT WHEN THE DUCT IS VARIABLE

VOLUME: ALL VARIABLE VOLUME DUCT
UPSTREAM OF VAV BOXES HAS A 2” W.G.
BASIS OF COMPLIANCE WHEN THE
DESIGNER DOES NOT GIVE A PRESSURE
CLASS.”

– from SMACNA HVAC AIR DUCT LEAKAGE

TEST MANUAL, 1985
© 2011, TSI Incorporated
 Prior to Field Testing
2) Testing Agency: Prepare paperwork

• Test plan

• Test
T t reportt form
f

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 Prior to Field Testing
3) Testing Agency: Prepare the site
• Plan/Coordinate with construction/installation
contractors
• Blanking materials
• Equipment
• Select according to Test Requirements
• Consider
• System Flowrate
• Leakage Classification
• Flow Capacity of Test System

© 2011, TSI Incorporated

 Prior to Field Testing
• Equipment Details:
– Must use instruments that have been calibrated
within the p
past 12 months
– Calibration certificates traceable to NIST

– Consider
C Test S
System capabilities:
• Ability to Log data and download with Time/Date stamp
vs using liquid-inclined and U-tube manometers
vs.

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 Prior to Field Testing

• Contingency planning
(Designer: Put plans in contract drawing/specs)

– If duct leak test FAILS – then what?

REMEDIATE!

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 Prior to Field Testing
• REMEDIATION Plan
– Seal the leaks

– Wait for seals to cure

– Re-test
Re test
• Re-test failed section only?
gg need to test more sections?
• Does section failure trigger

SPECIFY!
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 Test Procedure

1) Select Duct Section for Testing

2) Measure and Calculate Duct Surface Area

3)) Seal All Openings

p g ((except
p one))

© 2011, TSI Incorporated

© 2011, TSI Incorporated
 Test Apparatus
Duct Leakage Test System consists of:
1) Blower with speed control (VFD) to
generate range of pressure/flow
2) Flow measuring devices
- Flow Grid/Flow Station (High Flow)
- Orifice Plate (Low Flow)
3) P
Pressure iinstruments
t t ((manometers)
t )
4) Accessories to attach to duct system
5) Optional item (smoke generator)
© 2011, TSI Incorporated
 Test System:
C
Considerations
id i
• Maximize: Flow Range
– Limits duct section size/Leakage Rate
• Maximize: Pressure Range
– High Pressure Blower to cover duct classes
• ½” to 10” w.g.
g
• Maximize: Instrument Measurement Accuracy
– Flow: 2.5% of reading
– Pressure: 1% of reading

© 2011, TSI Incorporated

Test System Considerations
• Instrumentation:
– Traceable to National Standards (NIST)
– Logging capability – SIMPLIFY!
• Time/Date Stamp on each data set
• Calculates Flows
• Calculates Leakage rate based on duct ft2 input
• Indicates PASS/FAIL status according to selectable
defined leakage classifications
• Report generation and validation

© 2011, TSI Incorporated

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© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
© 2011, TSI Incorporated
 Summary

• Leaky ductwork is costly

• There are Standards and Test Procedures

• Designer: Be Specific with specs and

i t ti
instructions

• Choose
Ch th
the right
i ht T
Testt E
Equipment
i t
© 2011, TSI Incorporated
 Contacts
• Ken Helfers, TSI Inc. • Siva Iyer, TSI Inc.
• Ken.helfers@tsi.com • siva.iyer@tsi.com
• 502
502-897-0945
897 0945 • 651
651-765-3721
765 3721

© 2011, TSI Incorporated

 Appendix

© 2011, TSI Incorporated

 European Duct Leakage
R
Requirements
i t - Round
R d Ducts
D t

Static Pressure Limit Maximum Air leakage

Duct Pressure Positive Negative Air Velocity limts
Class Pa Pa m/s l/s/m2
Low pressure
500 500 10 0.027*pt0.65
– Class A
Medium
pressure – 1000 750 20 0.009*pt0.65
Class B
High pressure
2000 750 40 pt0.65
0.003*p
0.003
– Class
Cl C

• Pt = test pressure

© 2011, TSI Incorporated

 European Duct Leakage
Requirements - Rectangular
Ducts
Static Pressure Limit (ps) Pa Air
Positive at pressure Leakage
Air Tightness class Limit
Class Negative 1 2 3 l/s/m2
Low pressure – 500 400 NA NA
0.027*pt0.65
Class A
Medium pressure 750 400 1000 2000
0.009*pt0.65
– Class B
High pressure – 750 400 1000 2000
pt0.65
0 003*p
0.003
Class C

• Pt = test pressure
© 2011, TSI Incorporated
Comparison of SMACNA & EU
L k
Leakage Requirements
R i t

© 2011, TSI Incorporated

 Comparison
EU Standards SMACNA Standard
Standard / Actual Required Suggested if:
Conversions • Air Temp <40F or
>100F
• Elevation
El ti >1500 ffeett
• Duct static <-20 in H2O
or >+20 in H2O

© 2011, TSI Incorporated

 Comparison
EU Standards SMACNA Standard
Report Requirements Specified in Standards Defers to project
• Site details specifications. Suggests:
• Date • Site Details
• Location
L ti • Date
D t
• Test equipment • Location
• Personnel & • Personnel &
witnesses witnesses
• Ductwork installer & • Duct section tested
manufacturer
• Duct design
operating pressure
• Required Air
Tightness Class

© 2011, TSI Incorporated

 Comparison
EU Standards SMACNA Standard
Report Requirements Specified in Standards Defers to project
• Measurements specifications. Suggests:
• Duct surface area • Measurements
• Test
T t pressure • Duct
D t surface
f area
• Leakage rate • Test pressure
• Pressurizing time • Leakage rate
• Calculated • Calculated
• Leakage factor • Max Air Leakage
• Air Leakage Limit allowed
• Pass/fail result • Pass/fail result

© 2011, TSI Incorporated