Re-cap - Fans / Motors

Functions Provide the flow rate Q

Draw the air, overcome the resistance & maintain the flow
Types Axial (tubular axial and vane axial)
Centrifugal (BC blades, FC blades, radial blades)
Fan SP vs Q; Efficiency vs Q; Power vs Q
characteristics Free delivery vs no delivery

Fan rating table Fan size; Q; Fan SP

RPM; HP or kW

SSP SSP = SPinlet + SPoutlet

FTP FTP = SPinlet + SPoutlet if VPoutlet = VPinlet
FSP FSP = SPinlet + SPoutlet – VPinlet

System curve & fan curve System operating point (SOP) @ (Q, FSP)
AHP = Q(cfm) x FTP(“w.g.)/6356
AkW = Q(cms) x FTP(mm w.g.)/102.2 = Q (cms) x FTP (Pa) /
1000
BHP = AHP / ME
Motor HP or kW BkW = AkW / ME
SHP = BHP x kdrive loss
SkW = BkW x kdrive loss
RHP = 1.33 x SHP
RkW = 1.33 SkW
 Re-cap - Fans / Stacks
Rule of thumb 6-in and 3-out rule
10 and 50 rule
System effect loss (SEL) SEL = SEL factor x VP
Fan Laws at STP 1. Q (cfm) varies directly as fan speed (RPM)
2. TP & SP vary as the square of fan speed
3. HP varies as the cube of fan speed
1. Qnon-STP = QSTP
Fan Laws at Non-STP 2. FSPnon-STP = FSPSTP x d
3. HPnon-STP = HPSTP x d
Stack velocity Stack velocity 3,000 fpm or 15 m/s
Prevent downwash; Prevent rain drops
Stack SP loss Vertical discharge – no loss
Offset elbow k = 0.3 ; SP loss = k x VP
Offset stack k = 0.5 ; SP loss = k x VP
Stack head k = 0.25 ; SP loss = k (VPoutlet – VPinlet)
Weather cap Not recommended
Goose-neck stack Not recommended
Fans in series Overcome high SP
Fans in parallel Provide large Q
 LEV – Components & Design Parameters

LEV Component Design Parameter

Hood Airflow rate Q ; Area method or Dalla Valle equations
Q ∞ capture velocity , X2, hood opening area A except slot hood

Hood entry loss; he = f x VP

Hood static pressure; SPh = (1 + f) · VP
Duct Diameter D; Q = Duct velocity ∙ (π D2/4)
Friction loss; elbow loss; entry loss, contraction loss; expressed as k x VP

Air cleaner Pressure drop or SP loss across filter / cyclone / scrubber / EP…
Fan & motor FSP, FTP,
Motor HP or kW ∞ Q & FTP
Stack Stack loss ; discharge velocity (min. 3,000 fpm or 15 m/s)
Weather cap is not recommended
Discharge stack should not be horizontal
Discharge stack should never be downward
 SH5107
Industrial Ventilation

Tan Kia Tang

Veronica Chow
Veronica Ong
System Design

Veronica Ong
 Scope
1. LEV system design methods & procedures
• Single Hood
• Multi Hood

2. System curves & system operating point

3. LEV system design errors

4. Redesign to reduce power cost

Quick Recap – what have you learnt so far?
DISCHARGE
Qn. Is this a good
design? FAN STACK

DUCT
Qn. How the graph
AIR of SP looks like?
CLEANER
HOOD

SP +
0barg
(1atm)

Qn. How the graph of Q

- and VP looks like?
 LEV System Design - Preliminary Steps
1. Characteristics of contaminants, air stream, work practices
2. Layout of the operations, processes, workroom, building
3. Available locations for air-cleaner and fan
4. Line sketch of the LEV layout (isometrics)
- plan & elevation dimensions of hoods, branches & main, air
cleaner, fan -
locate branches with high losses close to the fan
5. Design the desired LEV system
6. Information on capture vel of all operations, required Q, entry
loss, min duct vel.
7. Information about the elevation of the plant above sea level and
temp and moisture conditions from each process.
8. Replacement air requirement & distribution
Design Drawing – Types & Views

LEV Design Drawing

1) Isometric view
2) Plan (Top) view
3) Elevation (Side) view
4) Elevation (Front) view
Drawings - Standard Symbols
LEV System Design Sample - Plan & Elevation
LEV System Design Sample - Plan & Elevation

Plan

Elevation
LEV System Design Sample : Plan & Elevation
 LEV System Design (Sample)
Isometric & Elevation

3D system plan Isometric drawing Elevation drawing

LEV System Design (Sample)
Isometric & Elevation
 Design Drawing : LEV Components

Brazing
Hood 90

Isometric Side View

Fan Inlet &

Outlet

Front view Side view

 Design Drawing : LEV Components

Bag
House

Elevation (Front) Elevation (Side)

Cleanout
Opening
 LEV System
Single Hood Double Hood

Need to balance the air flow at the junction –

blast gate design or static pressure (SP) balance
LEV System for Wood Working - Multiple Hoods

2 design methods : blast gate vs SP design

 LEV System Design – Procedure
1 Hood design
- Capture velocity, flow rate Q, hood SP
(Q will be used for determination of duct size & for the
specification of air cleaner and fan)
2 Duct segments
- duct velocity and diameter
- static pressure loss: straight duct, elbows, branch entries,
stack, etc.
3 Air flow balance at junctions: SP Balance vs Blast Gate;
Plenum duct
4 Air cleaning device: SP loss
5 Fan selection – total flow rate Q & FSP
6 Motor selection - power requirement
System & Fan Pressure Calculations (recap)

System Static Pressure (SSP)

SSP = SPoutlet – SPinlet = SPoutlet+ |SPinlet| SSP
= FTP
SSP or FTP is the pressure needed to
accelerate the air from zero velocity outside
the hood to certain velocity pressure in the
duct and to overcome the losses in energy as
the air moves through the duct system.

SSP is used to specify FSP

FSP = SPoutlet – SPinlet – VPinlet
FSP = SPoutlet + |SPinlet| - VPinlet
= FTP - VPinlet
FSP is provided in fan selection table
System & Fan Pressure Calculations

Fa
n
cu
rv
e
 Fan law summary
Correlations:
Q  RPM
SP  (RPM)2
HP  (RPM)3
Q  (HP)1/3
Q increases by about 10% for a 33% increase in HP:
Q  (1.33 HP)1/3 or 1.1 (HP)1/3

Qnon-STP = QSTP

FSPnon-STP = FSPSTP x d

HPnon-STP = HPSTP x d
 Design Calculations – Decimal Places

Parameter US unit Metric / SI unit

Length ft - no decimal m – 1 decimal
e.g. 5 ft e.g. 1.2 m
Area of duct ft2 - 3 decimal m2 - 3 decimal
e.g. 0.123 ft2 e.g. 0.123 m2
Velocity fpm – no decimal m/s – 2 decimal
e.g. 1234 fpm e.g. 12.34 m/s
Volumetric flow cfm – no decimal m3/s – 2 decimal
rate e.g. 1234 cfm e.g. 12.34 m3/s
Velocity pressure “wg – 2 decimal Pa – no decimal
e.g. 1.23 “wg e.g. 123 Pa
Static pressure “wg – 1 decimal Pa – no decimal
e.g. 1.2 “wg e.g. 123 Pa
Temperature F – no decimal C – no decimal
e.g. 70 F e.g. 21 C
Loss factors 2 decimal 2 decimal
e.g. 1.78 e.g. 1.78
LEV System Design for Single Hood

Fume Hood / Booth

 Example – One-hood LEV System
Fume Hood / Booth
Design specifications:
Metric Unit Both opening : 2 m x 1 m
Simple Hood 3m Face velocity = 0.5 m/s
Entry loss factor f = 0.5
Duct velocity = 12 m/s
4m Elbow loss factor = 0.24
Duct MOC: Galvanized metal sheet
Conditions at STP

2m 1. Determine actual duct velocity and VP

Q = V x A = 0.5 m/s x (2 m x 1m) = 1 m3/s
Cross-sectional area = 1 m3/s / 12 m/s = 0.083
2m
m2
1m
Duct radius = √(0.083 m2 / 3.1416) = 0.1629 m
Duct diameter = 2 x 0.1629 m = 0.3258 m or
326 mm
Face vel = 0.5m/s Actual duct velocity V = Q/A= 1 m3/s / {3.1416
x (0.326/2)2}= 11. 98 or 12 m/s
VP = (V / 4.043)2 =(12 / 4.043)2 = 8.8 mm w.g.
 Solution - LEV System Design : Fume Booth

2. Calculate hood static pressure

Hood static pressure SPh = VP (1 + f) = 8.8 mm w.g. ( 1 + 0.5) = 13.2 mm w.g.

3. Calculate system losses

  V0.533
Friction loss = {0.0155 ---------} x VP x L = 0.0952 x 8.8 mm w.g. x (2 m + 4 m) = 5.0 mm w.g.
Q0.612
Elbow loss = kelbow x VP = 0.24 x 8.8 mm w.g. = 2.1 mm w.g. (per elbow)
 
Stack friction loss = k x VP = 0.0952 x 8.8 mm w.g. x 3 m = 2.51 mm w.g.
 

  Note : if not @STP,

remember to multiply Note : same VP since the duct,
the losses by d, the elbows and stack are of same
density correction factor diameter.
 Solution - LEV System Design : Fume Booth

4. Calculate fan static pressure

 
Fan inlet SP = SPh + Friction loss + elbow loss = 13.2 + 5.0 + 2.1 = 20.3 mm w.g.

Fan outlet SP = stack friction loss = 2.51 mm w.g.

  For one elbow.
Fan TP = SPoutlet + |SPinlet|= 20.3 + 2.51 = 22.81 mm w.g.
 
Fan SP = Fan TP – VPinlet = 22.81 - 8.8 = 14.0 mm w.g.

5. Calculate fan power

Q(cms) x FTP(mm w.g.) x d 1 m3/s x 22.81 mm w.g. x 1

AkW = --------------------------------------- = --------------------------------------- = 0.22 kW
102.2 102.2
  or 220 W / 746 = 0.3 HP
 
 Solution - LEV System Design : Fume Booth
Desired Q = 1 m3/s ; Desired FSP = 14 mm w.g.
SP α Q2
SP2 = SP1 x Q22/ Q12= 14 x Q22 / 1.02 = 14 x Q22
Q 0.25 0.5 0.75 1 1.25 1.5
SP 0.875 3.5 7.875 14 21.875 31.5

Note: You could generate a

system curve by calculating
friction losses at many flow
rates and plotting the results.
Or you could use the
Fan SP correlation SP α Q2
mm w.g.
SOP
Q = 1 cms
@ 14 mm w. g.

Q cms
LEV System Design for Single Hood

Grinding Hood with Fabric Collector

SI Unit
 Example - LEV System Design
Grinding Hood with Fabric Collector
SI Unit f

Simple Hood L= 9.1m

140mm diam
a L=5m b d e
c

Grinding 120mm diam

Hood L= 0.3m
140mm diam

Required specifications for hood design:

Grinding hood
Minimum duct velocity along a-b (V) = 20.0 m/s (light grinding)
Required airflow Q = 0.250 m3/s
he = 0.65 VP
SP drop across Fabric collector = 500Pa
Duct MOC: Galvanized metal sheet
Conditions at STP
Grinding Hood Specifications

22cms
18cms
 Solution - LEV System Design
Grinding Hood with Fabric Collector
1 Determine actual duct velocity and VP
Q=VxA  
d = 120 mm 3. Loss for 5 m of straight duct (ab)
A = 3.1416 x (120 mm/2)2 = 11309 mm2 = k (no. of VP/m) x VP x L
= { 0.0155 x V 0.533 / Q 0.612 } x VP x L
Actual duct velocity 22.10.533
V=Q/A = 0.0155 -------------- x 294 Pa x 5 m
= 0.25 cms / 11309 mm2 0.250.612
= 22.1 m/s
V = 1.29  VP = 0.188 x 294 x 5
VP = (22.1 m/s / 1.29)2 = 293.5 or 294 Pa = 277 Pa

4. SP drop across Fabric collector (bc)

2 Calculate hood SP
SP drop = 500 Pa
SPh = VP + he
= VP + 0.65 VP Note:
= 1.65 x 294 Pa If not given, use SPloss = k x Vfilter x d
= 484 Pa
ΔP = ΔPf + ΔPd = k1 v + k2 v w (dirty)
 Solution - LEV System Design Grinding Hood with Fabric Collector
5. Duct velocity and VP in cd 8. SP at fan inlet d (total loss from a to d)
Q=VxA SPi = -(2 + 3 + 4 + 6 + 7)
Duct diameter 140 mm = -(484 + 277 + 500 + 236 + 8) Pa
A = 3.1416 x (140 mm/2)2 = 15394 mm2 = -1505 Pa
Actual duct velocity 9. SP at fan outlet (SP loss for 3.1 m
stack ef)
V = 0.25 cms / 15394 mm2 = 16.24 m/s
SPo = +{ 0.0155 x V 0.533 / Q 0.612 } x VP x L
V = 1.29  VP Recalculate VP = { 0.0155 x 16.240.533 / 0.250.612 } x 159 Pa
VP = (16.24 m/s / 1.29) 2 because diameter
x 3.1 m
changes
= 158.5 Pa or 159 Pa = 0.16 x 159 x 3.1
= 79 Pa
6. Hood SP at c 10. Calculate FTP and FSP
SPh = VP + he = VP + 0.49 VP FTP = SPo + |SPi |
= 79 + 1505
= 1.49 x 159 Pa = 236 Pa f of Flanged entry = 1584 Pa
loss
7. Loss for 0.3 m of straight duct (cd) FSP = SPo + SPi – VPi
= { 0.0155 x V 0.533 / Q 0.612 } x VP x L = 79 + 1505 – 159
={0.0155 x16.240.533/0.250.612}x159 Pax0.3m = 1425 Pa
= 0.16 x 159 x 0.3
= 8 Pa
Solution - LEV System Design : Grinding Hood with Fabric Collector

SOP
Q = 0.25 cms
FSP = 1425 Pa
SOP
FSP = 1425 Pa
SP ∞ Q2
FSP = 1425 x Q2 / 0.252
Q = 0.25 cms
 Re-cap : System Curve & Fan Curve
use Q & FSP to select fan RPM
use Q & FSP to plot system curve

3000
System Curve
Fan Curve
2500

System Operating Point

2000 Q = 0.25 cms
FSP = 1425 Pa
FSP Pa

1500
SP ∞ Q2
1000
FSP = 1425 x Q2 / 0.252

500

0
0 0.1 0.2 0.3 0.4 0.5
Q cms
LEV System Design for Single Hood

Grinding Hood with Fabric Collector

US Unit
 Example – LEV System Design
Grinding Hood with Fabric Collector
10’

US Unit 10’ d
wheel
4.5” d

a 15’ b d e
c
fan
A
4” d
1’
fabric 4.5” d
collector
Grinding hood design
Q = 390 cfm
V = 4,500 fpm Calculate hood SP and losses in duct
he = 0.65 VP SPh = VP + he = VP + 0.65 VP
Determine actual velocity and VP: = 1.65 x 1.24”
d=4“ = 2.05” wg
A = 3.1416 x (2/12)2 = 0.0873 ft2
Loss for 15 ft of straight duct (ab)
Actual duct velocity = { 0.0307 x V 0.533 / Q 0.612 } x VP x 15’
Q=VxA = { 0.0307 x 4467 0.533 / 390 0.612 } x 1.24” x 15’
V = Q / A = 390 cfm / 0.0873 ft = 4467 fpm = 1.30” wg
V = 4005  VP
VP = (4470 / 4005)2 = 1.24” wg Fabric collector (bc)
SP drop = 2.0” wg
 
 Solution – LEV System Design
Grinding Hood
Duct velocity and VP in cd
Duct diameter 4.5” SP at fan inlet d (total loss from a to d)
A = 0.1104 ft2 SPi = 2.05” + 1.30” + 2.0” + 1.16” + 0.05”
Actual velocity = 6.56“ wg
V=Q/A  
= 390 cfm / 0.1104 ft2 = 3531 fpm SP at fan outlet (SP loss for 10’ stack ef)
VP = (3531 / 4005)2 = 0.78” wg SPo= { 0.0307 x V 0.533 / Q 0.612 } x VP x 10’
= { 0.0307 x 3531 0.533 / 390 0.612 } x 0.78” x 10’
Hood SP at c = 0.48” wg
SPh = VP + he  
= VP + 0.49 VP Calculate FTP & FSP
FTP = SPo + SPi
= 1.49 x 0.78”
= 6.56” + 0.48”
= 1.16” wg
= 7.04” wg

Loss for 1 ft of straight duct (cd)

= { 0.0307 x V 0.533 / Q 0.612 } x VP x 1’ FSP = SPo + SPi – VPi
= { 0.0307 x 3531 0.533 / 390 0.612 } x 0.78” x 1’ = 6.56” + 0.48” – 0.78”
= 0.05” wg = 6.26” wg
 
 Plotting System Characteristic Curve

FSP = 6.26” w.g.

Q = 390 cfm

SP ∞ Q2
SP2 = SP1 x (Q2/Q1)2
SP “w.g.

= 6.26 x (Q2/390)2

Q cfm
 Solution : LEV System Design : Grinding Hood
System Curve
16
System Curve
14

12

10
Q = 390 cfm
8
FSP = 6.26” w.g. FSP = 6.26” w.g
6
SP ∞ Q2
4 FSP = 6.26 x Q2 / 3902

0
0 100 200 300 400 500 600 700

Q = 390 cfm
LEV System Design for Grinding – Single Hood

SP VP TP
 Work Sheet for LEV System Design
– ACGIH Industrial Ventilation Manual
LEV System Design for Single Hood

Welding Bench (Slot Hood)

 Example – Single Hood Welding Bench Design

US Unit
Compound Hood
1 Determine actual duct velocity and VP
Q = 1050 cfm; A slot = 4”/12 x 3’ = 1 ft2
Vslot = Q/A = 1050 / 1 = 1050 fpm
VPslot = (1050 / 4005 )2 = 0.07” w.g.

Duct diameter = 8.5”

A duct = 3.1416 x (4.25 / 12)2 = 0.3941 ft2
V duct = 1050 / 0.3941 = 2664 fpm
VP duct = (2664 / 4005 )2 = 0.44” w.g.

2. Calculate hood static pressure

SPh = {VP slot + 1.78 VP slot} + {VP duct + 0.25 VP
duct}
= (0.07 + 1.78 x 0.07) + (0.44 + 0.25 x 0.44)
= 0.75” w.g.
V0.533
Friction loss (no. of VP / ft) = 0.0307 -------------
Q0.612
= 0.029 VP/ft

Total friction loss = 0.029 x 0.44 x (25 + 7)ft x R x d

= 0.41”w.g.
3. Calculate system losses 4. Calculate Fan SP
Elbow loss = k x VP x d FSP = SPoutlet – SPinlet – VPinlet
= 0.12 x 0.44 = 1.21 + 0.10 – 0.44
= 0.053”w.g. = 1.31 – 0.44
= 0.87”w.g.
Stack loss = 0.029 x 0.44 x 8’
= 0.10 “w.g. FTP = SPoutlet – SPinlet
= 1.21 + 0.10
SP in = - (0.75 + 0.41 + 0.053) = 1.31”w.g.
= - 1.21”w.g.

SP out = 0.10”w.g. 5. Calculate Fan Power

AHP = Q x FTP x d / 6356
= 1050 x 1.31 / 6356
= 0.22 HP
 System & Fan Curves

SOP

SOP • FSP ∞ Q2
Q = 1,050 cfm
FSP = 0.87”w.g. • FSP = 0.87 x Q2 / 1,0502

The operating point shows that the fan will deliver 1050 cfm of air at 0.87”of water
FSP.
The brake HP (0.25 HP) can be determined by moving up from the operating point
to the brake HP curve, then reading the brake HP on the right vertical axis.
LEV System Design for Multiple Hoods
 LEV System Design Methods (for Multiple Hoods)
ELEVATION PLAN

Blast gate

SP balance

Plenum
 LEV System Design Methods (for Multiple Hoods)
1 Blast Gate Design
• System designed to achieve desired flowrate
and SP loss of the governing branch (greatest
resistance/SP loss)
• Utilizes dampers or blast gates in each branch
to regulate air flow
• Designed as flexible system

2 SP Balance Design
• Balance SP at desired flowrate in each branch
by adjusting the duct sizing, layout, fittings etc
• Designed as fixed/inflexible system

3 Plenum Design (not suitable for dusty

environment)
• Consist of large enclosure (ie. Plenum)
• Branches connect to plenum having about same
SP to cause airflow
• May utilise dampers/covers to regulate flow at
each branch
• Designed as flexible system
LEV System Design for Multiple hoods

Blast Gate Design

 Blast Gate Design

1. Size branches and main to give the required velocity

2. Calculate the loss in the duct run with the greatest
resistance or SP (usually furthest from fan) - governing
3. Select fan to provide the required Max Q & Highest SP
4. Use dampers or blast gates in runs to regulate
airflow
 Blast Gate Design
Advantages & Disadvantages

Advantages
1.Design calculation is shorter
2.Flexibility for changes without redesign
3.Correction of exhaust rates is easier

Disadvantages
4.Field balancing is required
5.Unauthorized tampering
6.Accumulation of dust and pockets of flammable gases
Types of dampers
Blast Gate Method – Balancing with Damper
 Example : Blast Gate Method

Determine: E
1. Q1, Q2, Q3 AB-15 ft BC-15 ft CD-15 ft DE-20 ft
Governing
2. Hood SP at hood #1 branch
6 inches
diameter
9 inches
diameter
12 inches
diameter
12 inches
diameter

3. Friction loss 1A A 45˚ B C D

4. Elbow loss at A
Fan
5. Friction loss AB Hood 1
Q1=500 cfm
Hood 2
Q2=700 cfm
Hood 3
Q3=900 cfm

6. Friction loss BC 1A-10 ft

2B-12 ft
7. Friction loss CD 6 inches
diameter 7 inches
diameter
8. Friction loss DE
9. SP inlet =2+3+4+5+6+7
10. SP outlet = 8  Size branch ducts and main duct to
11. Fan TP = 9 + 10 achieve min duct velocity
12. Fan SP = 11 - VPinlet  Use dampers to control air flow in 2B
13. Air HP or kW and 3C
 Blast Gate Balancing - Step-by-step Procedure

1. Open all dampers & measure Q at each outlet.

2. Adjust outlets to give the desired Q starting with the one

handling the highest Q & progressing toward the lowest.

3. Recheck all Q & make final adjustments.

4. Lock the dampers & mark their locations.

5. Recheck total Q by pitot tube traverse, record Q & SP.

 Example: Blast Gate Balancing
Designed flow rates 1800 cfm
Hood 3
400 cfm
Hood 1
500 cfm

Hood 2 Hood 4
600 cfm 300 cfm

Commissioning with dampers fully open 1800 cfm

Hood 3
500 cfm
Hood 1
400 cfm

Hood 2 Hood 4
300 cfm 600 cfm
 Example: Blast Gate Balancing
1800 cfm
With dampers fully open
Hood 3
500 cfm
Hood 1
400 cfm

Hood 2 Hood 4
300 cfm 600 cfm

Adjust damper 4 to give 300 cfm Field balancing to

Adjust damper 3 to give 400 cfm achieve desired
Adjust damper 1 to give 500 sfm
flowrates
Adjust damper 2 to give 600 cfm
1800 cfm
Hood 3
400 cfm
Hood 1
500 cfm

Hood 2 Hood 4
600 cfm 300 cfm
LEV System Design for Multiple hoods

Static Pressure Balance (SP) Design

 SP Balance Design
1 Calculate the SP loss in each run
2 Balance SP at each junction by sizing the duct,
fittings & adjusting the flow
3 Select fan to provide the required Q and SP
 Static Pressure Balance
- Advantages & Disadvantages
Advantages
1. Hood exhaust rates not easily changed
2. No balancing required after installation
3. Dust settling / plugging problems are reduced

Disadvantages
4. Design calculation more time consuming
5. Less flexibility for changes or redesign of
ductwork
SP Balance Method
 SP Balance at Junction : Criteria
The Static Pressure (SP) at the junction for each branch must be the
same when the system is in operation. If not, correction of Q or re-
sizing of duct is required.

SP Difference Suggested Procedure

< 5% May ignore, use governing or higher SP &
continue the design

< = 20% increase flow rate in non-governing (lower

SP) duct
Qcorrected = Qdesign(SPgoverning/SPdesign)1/2

> 20% Re-size duct work OR provide additional SP

loss
 Example : SP Balance at Junction
The designed air flow rates in duct 1 and 2 are Q1 = 800 cfm and
Q2 = 600 cfm respectively. The designed SP at the junction are
indicated below.
SP 1 = 1.00”w.g.
1 3
SPhigher/ SPlower
= 1.00”w.g. / 0.90”w.g. 2
= 1.11 or 11% SP 2 = 0.90”w.g.

As SP2 is less than SP1, more air will be flowing into duct 2 than
the designed flow rate when the system is in operation.

Q corrected = Q design x√ (SP higher / SP lower)

= 600 cfm x √ (1.00” / 0.90”)
= 633 cfm
Q3 = Q1 + Q2 corrected
= 800 + 633 or 1,433 cfm
LEV System Design for Multiple hoods

Example : SP Design for 2 Hoods

 Example : SP Balance Design
LEV System Design for Grinding & Buffing
US Unit

A Determine hood design

Surface grinder
V = 3,500 fpm minimum
Q = 300 cfm
he = 0.25 VP
 
Buffing & polishing
V = 4,500 fpm for branch
Q = 740 cfm (assume good
enclosure)
he = 0.40 VP using tapered
takeoff

All elbows
  are 4-piece, 2 D centerline radius. 
What design is required for such a system?
US Unit Example : SP Balance Design
LEV System Design for Grinding & Buffing

stack
20’

Isometric
fan
30° 10’
Balance at
90° 50’
10’ junction
10’

90°
60°
10’
10’

90°

4’ 90°
6’

Surface grinder
Buffing & polishing
 
 Solution – SP Balance Design
B. Select branch of greatest resistance C. Calculate losses in branch (surface grinder)
Start at branch furthest from the fan, Loss for 74 ft (4’ + 10’ + 50’ + 10’) of straight
greatest resistance. To size duct for duct
surface grinder: = { 0.0307 x V 0.533 / Q 0.612 } x VP x 74’
Q=VxA = { 0.0307 x 3440 0.533 / 300 0.612 } x 0.74” x 74’
= 3.93” wg
A = 300 cfm / 3,500 fpm = 0.0857 ft2
SP Loss occurring at elbows (2-90 degree
A = 3.1416 x d2 / 4 elbows)
d = 4 “ (round off to the nearest duct = 0.24 VP x 2 = 0.24 x 0.74” x 2
diameter) = 0.36” wg
A = 0.0873 ft2 1-60 degree elbow, SP loss
Actual duct velocity = 0.24 VP x 2/3 = 0.24 x 0.74” x 0.67
V=Q/A = 0.12” wg
Total elbow loss = 0.36 + 0.12 = 0.48” wg
= 300 cfm / 0.0873 ft2
 
= 3.,440 fpm Loss at branch entry (30 degree entry)
V = 4005  VP = 0.18 VP = 0.18 x 0.74”
VP = 0.74” wg = 0.13” wg
SPh = VP + he  
= VP + 0.25 VP Total loss for branch:
= 1.25 x 0.74 = 0.93” + 3.93” + 0.48” + 0.13”
= 0.93” wg = 5.46” wg
 Solution – SP Balance Design > 20% Resize duct
D. Calculate losses in branch (buffing & E Determine if branches are in balance
polishing) Ratio of branch SP loss = 5.46” / 3.59” = 1.52
Size duct for buffing & polishing Balance by raising SP loss in buffing &
A = Q / V = 740 cfm / 4,500 fpm = 0.164 ft2 polishing. This can be accomplished by
reducing the duct size to 5” which will
Round off duct diameter to 5.5”;A= 0.1650 ft2
increase the duct velocity and the loss that
Actual velocity V=740 cfm/0.1650 ft2 occurs.
= 4480 fpm Recalculate the loss buffing and polishing:
VP = (4480 / 4005)2 = 1.25” wg A = 0.1364 ft2
 SPh = VP + he Q=VxA
V = 740 cfm / 0.1364 ft2 = 5425 fpm
= VP + 0.40 VP = 1.40 x 1.25” = 1.75” wg
VP = 1.83” wg
SP loss for 26’ (6’ + 10’ + 10’) of straight duct SPh = VP + 0.4 VP = 1.4 x 1.83” = 2.56”
= { 0.0307 x V 0.533 / Q 0.612 } x VP x 26’ Straight duct loss
= {0.0307 x 4480 0.533/740 0.612 }x1.25”x 26’ = { 0.0307 x V 0.533 / Q 0.612 } x VP x 26’
= 1.24” wg = { 0.0307 x 5425 0.533 / 740 0.612 }x 1.83” x 26’
Loss occurring at elbows (2-90 degree = 2.50” wg
elbows) = 0.24 VP x 2 = 0.24 x 1.25” x 2 = 0.6” Elbow loss (2-90 degree elbows)
wg = 0.24 VP x 2 = 0.24 x 1.83” x 2 = 1.20” wg
Total loss for branch: 1.75” + 1.24” + 0.6” Total loss for branch:
= 2.56” + 2.50” + 1.20”
= 3.59” wg
= 6.26” wg (recalculated using 5”duct)
 
 Solution – SPN Balance Design
F Determine ratio of branch SP loss = H Calculate losses from junction to fan
6.26”/ 5.46” = 1.15 (15% difference) (from 10’ duct, 7.5” diameter)
Since this is within 5-20%, balance system Q
for system by increasing flow in branch with SP loss = { 0.0307 x V 0.533 / Q 0.612 } x VP x 10’
lower resistance. = { 0.0307 x 3445 0.533 / 1060 0.612 } x 0.74” x
Q corrected = Q calculated x  (SP larger / 10’
SP smaller) = 0.25” wg
 
= 300 cfm x  (6.26 / 5.46)
I Total loss on inlet of fan (SPi)
= 320 cfm
= 6.26” + 0.25”
The governing SP is the SP of the branch = 6.51” wg
with greater resistance i.e. 6.26” wg  
G Determine main duct size: J Calculate loss at fan outlet (SPo) (from 20’
Total flow= 320 cfm + 740 cfm= 1060 cfm stack)
To maintain duct velocity at 3500 fpm: SPo = { 0.0307 x V 0.533 / Q 0.612 } x VP x 20’
A = Q / V = 1060 / 3500 = 0.303 ft2 = { 0.0307 x 3445 0.533 / 1060 0.612 } x 0.74”
Using nearest duct size of 7.5” diameter (A = 0.49” wg
= 0.3068 ft2)  
K Calculate FSP
Actual velocity V = Q / A = 1060 / 0.3068 =
FSP = SPo + SPi – VPi
3455 fpm
= 0.49” + 6.51” – 0.74”
VP = 0.74” wg
= 6.26” wg
 
Solution – SP Balance Design : System Curve
Total flow Q = 320 cfm + 740 cfm = 1060 cfm
FSP = SPo + SPi – Vpi = 0.49” + 6.51” – 0.74” = 6.26” wg

FSP ∞ Q2
FSP = 6.26”w.g. x Q2 / 1,0602

FSP = 6.26” wg
Q = 1060 cfm
 SP Balance : Corrections for Velocity Changes

1 3
2

By definition:
VPr = (Q1/Q3)VP1 + (Q2/Q3)VP2
VPr : resultant velocity pressure
If VP3 > VPr
there is an increase in VP or loss in SP.
SP3 = SP1 – (VP3 - VPr)
If VPr > VP3
there is a static pressure gain, many designers ignore
this gain to be on conservative side
 Example : Balance Method - VP adjustment

1 3
2
Duct Dia” Area Q cfm V fpm VP” SP”
No w.g. w.g.
1 10” 0.545 1935 3550 0.79 -2.11
2 4” 0.087 340 3890 0.94 -2.11
Main 3 10” 0.545 2275 4170 1.08 ------

VPr = (Q1/Q3)VP1 + (Q2/Q3)VP2

= (1935 / 2275) x 0.79 + (340 / 2275) x 0.94
= 0.81” w.g.

VP3 (1.08” w.g.) > VPr (0.81” w.g.)

SP3 = SP1 – (VP3 – VPr)

= -2.11 – (1.08 – 0.81)
LEV System Design for Multiple hoods

Plenum Design
 Plenum System

 This method is similar to the Blast

Gate method.

 Duct branches dump air into a large

chamber with a fixed SP supplied
by the fan.

 Airflow rates in the branches are

regulated with blast gates or other
flow control devices.

 The plenum velocity is low and

cannot maintain the transport
velocity required for dust, so
cleanout should be installed.
 Plenum System Applications

Cooked food stalls

Oven

Vehicle tailpipe
exhaust

Open surface tank

Restaurant
 Plenum Exhaust System - Advantages & Disadvantages

Advantages
1. Branch ducts can be added, removed or relocated
2. Branch ducts can be closed off & the flow rate in the entire system is
reduced
3. Plenum acts as a settling chamber – primary separator

Disadvantages
4. Stick and linty materials e.g. buffing dust tend to clog the chamber
5. Not for explosive dusts e.g. Al, Mg, Ti, grain dust
 Example : Plenum System Design

A tapered round hood (included angle 60 degrees, entry loss factor f

= 0.08) is connected to a plenum chamber (box) by a 24-cm diameter
flexible duct (a = 0.0186, b = 0.604, c = 0.639). The total length of the
duct is 5 m with a 90-degree stamped elbow (elbow loss factor k =
0.15, see line sketch below). The required duct velocity is 10 m/s.
Determine the required static pressure (SP) at the plenum. Assume
STP.
to exhaust
fan

1m
Plenum
box

4m

circular
tapered
hood
 Solution
Q=VxA
= 10 m/s x 3.1416 x (0.24 m / 2)2
= 0.45 m3/s
 
to exhaust
V = 4.043 x √ VP fan

Metric unit
1m
VP = (10 / 4.043)2 Plenum
box
= 6.1178 mm w.g.
 

SI unit 4m
VP = (10 / 1.29)2
= 60 Pa
circular
tapered
Hood static pressure SPh hood

= VP + f x VP
= (1 + f) VP
= (1 + 0.08) x 6.1178 mm w.g.
= 6.6072 mm w.g. or 65 Pa
 
 continue …Solution
Friction loss at duct=
a Vb
F = ------ x L x VP
Qc to exhaust
fan
= 0.0186 x (100.604 / 0.450.639) x 5 m x 6.1178 mm w.g.
= 0.0186 x (4.0179 / 0.6004) x 5 x 6.1178
1m
= 0.1245 x 5 x 6.1178 Plenum
box
= 3.8075 mm w.g. or 37 Pa
 

Elbow loss = k x VP 4m

= 0.15 x 6.1178
= 0.9177 mm w.g. or 9 Pa
  circular
tapered
Static pressure at the plenum hood

= -(6.6072 + 3.8075 + 0.9177)

= -11.3324 mm w.g.  Or -106 Pa
Or -0.45 “w.g.
LEV System Design
What Can Go Wrong?
Fan & System Matched
What Can Go Wrong ?
- Wrong Fan
What can go wrong?
- Wrong System
 What can go wrong?
- Both Fan & System Wrong
Increase Air Flow by Increasing Fan Speed
Increase Air Flow by Reducing System Resistance
LEV Redesign / Modification
to Save Power Cost
Typical LEV System
Re-design to Save Power Cost
Separate LEV Systems to Reduce Power Cost
 Exercise
LEV System Design - Location of Air Cleaner & Fan

Which one is a good, acceptable or bad layout?

 Solution
LEV System Design – Location of Air Cleaner & Fan
 Exercise
LEV System Design – Duct layout

Poor duct layout with 90deg

entry to main duct Resulting build up in the duct
 Exercise
LEV System Design – Duct layout

Pigging
 Exercise
LEV System Design – Flexible bellow

Absorb
vibration
(bellow must
withstand
max |SP|)
The End
 Re-cap : System Design

Three key parameters:

1. Q
2. SPin
3. SPout SPout = duct /stack loss

Q
SPin = SPh + friction loss + elbow loss + Air cleaner SP loss +
Friction other dynamic losses
Friction loss
loss
Elbow
loss SP loss
Elbow
loss
SPh = he + VP

Q
 Re-cap : System Design

Fan – Use ISPiI & SPo to determine FTP & FSP

SSP = SPo + ISPiI
FTP = SPo + ISPiI if VPo = Vpi
FSP = SPo + ISPiI – VPi

Motor – Use Q & FTP to determine motor power or kW

AkW = Q (cms) x FTP (Pa) / 1,000
BkW = AkW / ME
SkW = BkW x kdl
RkW > 1.33 x SkW
 Re-cap : Systme Curve & Fan Curve
use Q & FSP to select fan RPM
use Q & FSP to plot system curve

3000
System Curve
Fan Curve
2500

System Operating Point

2000
Q = 0.25 cms
FSP = 1425 Pa
FSP Pa

1500
SP ∞ Q2
1000 FSP = 1425 x Q2 / 0.252

500

0
0 0.1 0.2 0.3 0.4 0.5
Q cms
Re-cap : LEV Design Drawing

LEV Design Drawing

1) Isometric view
2) Plan (Top) view
3) Elevation (Side) view
4) Elevation (Front) view
 Re-cap : LEV System Design Methods

1. Blast Gate Design – adjust the damper to

balance the air flow at junction during
operation

2. SP Balance Design – balance the SP at the

junction at the design stage

3. Plenum design – connect branch ducts to a

plenum chamber and control the air flow by
dampers
 Re-cap : SP Balance Method

SP Suggested Procedure
Difference
< 5% May ignore, use governing or higher SP & continue the
design

< = 20% Increase flow rate in non-governing (lower SP) duct

Qcorrected = Qdesign (SPgoverning/SPdesign)1/2

> 20% Re-size duct work OR provide additional SP loss

Re-cap : LEV System Design Errors
Re-cap : 2 Ways to Increase Air Flow Rate Q