X470 HVAC Ductwork and Piping

Systems
Class 1 – Introduction, Fundamentals &
Distribution Systems

Steve Taylor, PE
Taylor Engineering
Alameda, CA

2019
 Agenda

 Introductory remarks
 Grading
 Course Outline
 Fundamentals Review
 Air Distribution Systems

2
 UCBX HVAC Certificate Program

 Required Courses
• X469 HVAC System Load Calculations and Psychrometry
• X470 HVAC Ductwork and Piping Systems
• X472 HVAC System Design Considerations
• X473 HVAC Control and Energy Management Systems
 Elective Courses (three courses are required)
• X411.6 Principles of Sustainability
• X412.3 Building Systems & Technology
• X420.2 Construction & Facilities Project Management
• X479.1 Management and Supervision
• X493.1 Building Commissioning for LEED
• X494 Introduction to BIM
• X495 Introduction to LEED v.4
• X495.1 Intermediate LEED v.4
• X496 Advanced LEED v.4
• X415 HVAC Mechanical Design Codes
• X471 Refrigeration Concepts
• X475 Energy Audits of Commercial Facilities
• X478 Operation and Maintenance of Air-Conditioning Systems

3
 General

 Contact Information
• Steve: staylor@taylor-engineering.com
 Text
• None
 Slides
• Download from ftp ~ 4 hours before class
• Log in to Box at https://app.box.com/v/2019x470slides
• Username: x470@taylor-engineering.com
• Password: x470slides (case sensitive)
 Supplemental Handouts & Homework
• Download from ftp site anytime

4
 About Steve Taylor

 Principal, Taylor Engineering

 Education
• Stanford University, BS Physics, 1976
• Stanford University, MS Mechanical Engineering, 1977
 ASHRAE
• Fellow
• Standard 62 Indoor Air Quality, 8 years, chair
• Standard 90.1 Energy Standard, Chair Mechanical Subc., 21 years
• Standard 55 Thermal Comfort
• Guideline 16 Economizer Dampers, chair
• Guideline 13 Specifying Building Automation Systems, chair
• Guideline 36 Advanced Sequences of Control, founder
• TC 4.3 Ventilation, chair
• TC 1.4 Control Theory & Applications, chair
• Distinguished Lecturer
 USGBC LEED
• Indoor Environmental Quality TAG, vice chair
 UMC/IAPMO (California Mechanical Code)
• Mechanical Technical Committee, former member and ASHRAE Liaison
 CSU
• Mechanical Review Board, member

5
 Who are You?

 Consulting Engineers?
 Design/Build Engineers?
 Contractors?
 Energy/Green Building Consultants?
 Architects?
 Building Engineers?
 Other?

6
 Grading

Weighting: Attendance: 40%

Homework: 0% (voluntary)
Final: 60%

Grading: Passing: ≥70%

C: ≥70%
B: ≥80%
A: ≥90%

Grading Option: No credit

Pass/Fail
Letter Grade
Taylor Option: B-or-better: Letter Grade
C or less: Pass/Fail

Since there is no real text, you must come to class to pass this
course!
7
Course Schedule

Date Class Topic Teacher

1/2 Introduction, Fundamentals, Air Systems 1 ST
1/9 Air Systems 2 – Air Distribution System Design ST
1/16 Air Systems 3 − Fans, Noise Fundamentals ST
1/23 Air Systems 4 − Diffusers, VAV boxes, AHUs AD?
1/30 Hydronics 1 − Distribution Systems ST
2/6 Hydronics 2 − Pipe Design and Components ST
2/13 Hydronics 3 − Pumps & Expansion Tanks ST
2/20 Hydronics 4 − Chillers, Towers, Boilers ST
2/27 Test and Balance, Commissioning ST
3/6 Discussion of Take-Home Final ST

8
 Course Objective

 Learn how to design HVAC air and hydronic distribution

systems in detail
 We will cover:
• Air distribution systems (fans, ducts, etc.)
• Hydronic distribution systems (pumps, pipes, chillers, etc.)
 We will not cover
• Psychrometrics / Load Calc’s (X469)
• System Design & Selection Issues (X472)
• Controls (X473)
 Emphasis will be on practical designs
• Balance first costs with energy costs, noise and other
considerations
• Design details – how to really do it

9
 HVAC Design Truisms

Theory Application
(Science) (Art)

A good HVAC Designer

 understands fundamentals
 uses rules of thumb as check figures, not as design parameters
 has a feel for the cost impact of design decisions
 asks questions when he/she is not sure
 listens to find out the needs of his/her client, then designs systems
accordingly
 practices, so he/she does not get out of practice
 admits he/she can and will make mistakes, but always learns from them
 checks calculations (you only get one shot to do it right)
 does not believe everything...
• in equipment catalogues
• told to him/her by salespeople
• in textbooks
• taught in this class!

10
 Good Design is Finding Balance

 Costs
• Construction cost
• Annual energy cost
• Annual maintenance cost
• Replacement cost
 Performance
• Health
• Comfort
• Noise
• Environmental impact
11
Quick Fundamentals
Review
Also see Supplements
on ftp site!
Energy Content of Matter

e = KE + PE + IE
kinetic potential internal
energy energy energy

= V2/2gc+ z g/gc + Pv + u

velocity gravity pressure thermal

= V2/2gc + z g/gc + h

13
 First Law of Thermodynamics
(Conservation of Energy)

Control Volume

Work IN
Mass Flow IN Mass Flow OUT

Heat IN

∂E
PrE = 0 = − W − Q − m& in ein + m& out eout
∂t
Production Increase Work Heat Mass Mass
of Energy in in in flow in flow out
Storage
14
 Continuity
(Conservation of Matter)

Control Volume

Mass Flow IN Mass Flow OUT

∂M
PrM = 0 = − m& in + m& out
∂t
Production Increase in Mass Mass
of Matter Storage flow in flow out

15
Energy Transport by
Sensible Heating and Cooling

16
Heat Transfer in Water

17
Heat Transfer in Air (Sensible)

18
 Building Codes

 California Building
Code
• Based on
International Building
Code
 California
Mechanical Code
• Based on Uniform
Mechanical Code
 California Title-24
Part 6 Energy
Standards 19
 Ventilation Requirements

 Code
• Title-24 Energy
Standards for most
occupancies
• Mechanical Code (based
on Standard 62.1) for all
others
 Possible“Standard of
Care” & LEED
prerequisite
• ASHRAE Standard 62.1
20
 Natural Ventilation Alone?

 Codes Confusing
because they are not
integrated
 CMC (from UMC/62.1)
402.2 says No
 CBC (from IBC) 1203.1
says Yes
 Title 24 120.1(b) says
Yes
 All three have different
requirements!
 Recommend following
CMC/62.1: No
21
 Title 24 Mechanical Ventilation

Mech vent
takes larger
of two
components

No “multiple
spaces
equation” in
CA

22
Building Component of OA Rate

23
 Occupant
Density

 Quantity up to
designer, except ≥
half the exiting
density required by
the Building Code
 Table in Title 24
Energy Standards
Manual from CEC
shows airflow per
person based on
minimum and per
area
California Mechanical Code
Chapter 4 OA Rates Don’t Apply!

25
CMC Exhaust Rates do Apply!

26
 Thermal Comfort

 Physiological Factors
• Temperature, humidity,
radiation, air speed,
asymmetry…
• Clothing, activity
• ASHRAE Standard 55
Standard Environments
Dynamic Environments
80% Acceptability
 Psychological Factors

27
 Major Variables Influencing
Thermal Comfort
Environmental Personal
1. Air temperature 1. Activity
2. Humidity 2. Clothing
3. Air Velocity
4. Mean radiant temperature
5. Asymmetry

28
Common HVAC Systems
Basic HVAC System Concept

1.1 CFMS * (TR - TS) = QL + QE + QP + QS + QC

30
Single Zone System

31
Packaged Single Zone Units

32
 Typical Constant Volume Control

Fan Speed
ON OFF OFF ON

Stage 2 Stage 2

ON OFF OFF ON

Stage 1 Stage 1

heating temperature range cooling temperature range

33
Single Zone VAV Required for all CHW systems
and DX systems ≥65000 Btuh
(4-pipe fan-coil)

maximum setpoint maximum speed

Supply Air
Temperature
Setpoint Fan Speed

minimum speed

minimum setpoint

heating loop signal cooling loop signal

34
Typical Office HVAC Zoning

35
Variable Volume & Temperature
System (VVT) aka VAV Changeover

36
 VVT Limitations

 Do not mix interior and perimeter zones

 Ventilation under all load conditions
questionable
• Consider oversizing outdoor air rate
 Conservatively size bypass and do not use
barometric bypass
• Bypass should be replaced by VFD if CHW/HW
fan-coil used vs. DX
 Use pressure independent zones if duct
system is not nearly self-balancing

37
Constant Volume Reheat
Not Allowed by Title 24 even for most labs

38
Constant Volume Reheat Control

Supply CFM

Reheat Valve position

Wasted reheat energy

Heating PI Signal Cooling PI Signal

39
 Economizer Relief

 Required to prevent over-pressurizing

the building
• Doors pushed open (security issue)
• Whistling at doors and elevators
 Options (in order of first cost and
efficiency)
1. Relief dampers (aka barometric relief)
 Only works with very low RA ΔP
2. Relief fans (aka powered exhaust fans)
 Only works well with low RA ΔP
3. Return fans (aka return/relief fans)
 Works with all applications
40
Option 1: Non-powered Relief
Option 2: Relief Fan
Option 3: Return Fan
Variable Air Volume with Reheat

44
VAV Reheat Box

45
Pressure Independent VAV Box
Controls

2 cascading control loops

Damper maintains flow

T’stat resets airflow setpoint

46
Q: Why do some buildings use 3 -5
times as much energy as others?

2,500
Site #1
Boiler Input (Btu/sf)

2,000
Site #2
1,500

1,000

500

0
Mar-02 Apr-02 May-02 Jun-02 Jul-02

A: Reheat
47
Conventional VAV Control

48
“Dual Maximum” VAV Reheat Control

50
Title 24 VAV Control Requirement
for zones with DDC

51
“Dual Maximum” Logic

52
Dual Maximum Logic in Action

Start heating, At 50% Heat, start

increase DAT setpoint increasing airflow 53
 Measured flow fractions:
Yahoo campus

Warm Season All Occupied Hours Cool Season All Occupied Hours
0.15

0.15
Low Minimum Low Minimum
30% Minimum 30% Minimum
0.10

0.10
Density

Density
0.05

0.05
0.00

0.00

0 20 40 60 80 100 0 20 40 60 80 100
Flow Fraction [%] Flow Fraction [%]

54
Sort of Dual Maximum Control
(Found in some configurable controllers)

T-24

55
Sort of Dual Maximum Control
(Found in some configurable controllers)

Title 24

56
 VAV Box Dual Maximum Control
Setpoints per Title 24 (and 90.1)
 Minimum:
1. No less than larger of:
 Minimum ventilation rate for the zone
 Controller minimum
INLET DESIGN CFM
2. No more than 20% of cooling MARK
SIZE COOL MIN HEAT
maximum
VR-101 12 1035 135 260
 Heating Maximum: VR-102 10 810 90 230
1. No less than larger of: VR-103 6 210 50 50
 Minimum
 Limit stratification - ≤20°F SAT above space temperature (≤~90°F to 95°F)
2. No more than 50% of cooling maximum
 Always use Option 1 above
• Do not use code maximum just because it’s legal!
• Avoid using %-of-cooling-maximum setpoints – boxes are
usually oversized!

57
Manufacturer’s VAV box
minimums are WRONG!!

Titus Catalog

Box
Actual
MinALC
with
Controller
CFM
15
25
30
40
55
75
90
120
190
245
455

58
VAV w/ Parallel Fan-Powered
Boxes

59
Parallel Fan-Powered VAV Box

Inlet Side Top Discharge Side

60
 Parallel Fan-powered VAV Box
Control

Maximum Setpoint

Reheat Valve position

Fan On

Supply Airflow

Minimum
setpoint

Heating PI Signal Cooling PI Signal

61
VAV w/ Series Fan-Powered Boxes

63
Series Fan-Powered VAV Box

Inlet Side Top Discharge Side

64
 Series Fan-powered VAV Box
Control

Fan On continuously Maximum Setpoint

Reheat Valve position

Supply Airflow

Minimum
setpoint

Heating PI Signal Cooling PI Signal

65
 Cooling Only VAV Boxes

 When to Use
• No ventilation requirements – e.g. telecom closet
• In combination with heating boxes in large zones –
e.g. open office with cooling-only, zero-minimum
boxes in the interior and reheat boxes at the
perimeter.
• High load interior zones − e.g. kitchenette, copy
room
 When Not to Use
• Non-zero minimum required for ventilation where
low loads are possible, e.g. private interior offices

66
 VAV Reheat Box

 When to Use
• Almost everywhere
• Interior conference rooms with CO2 control
 When Not to Use
• Minimum flow for ventilation > ~30% where
low loads possible
(Note: minimum flow setpoint IS NOT maximum
heating flow setpoint)
• Heating load requires maximum heating
flow setpoint to exceed T-24 limits at ~95F

67
 Parallel Fan-Powered Box

 When to Use
• Heating load requires maximum heating
flow setpoint to exceed T-24 limits at ~95F
e.g. perimeter zone with lots of glass facing
north or with large overhang

68
 Series Fan-Powered

 When to Use
• Constant volume needed to maintain throw
– e.g. lobby sidewall diffusers.
• High ventilation rates – e.g. interior
conference rooms when using pneumatic
controls
Use Reheat with CO2 control with DDC controls

69
Single Fan Dual Duct System
Not allowed by Title 24

71
Dual Fan Dual Duct System

72
Snap Acting Dual Duct VAV Box
Control

73
 When to use DFDD vs. Reheat

 DFDD is almost always more efficient and

usually has similar first costs
• DD zones cost less than reheat, offsetting heating AHU
cost if many zones
• DD distribution costs about the same
 Piping can cost more than ductwork
 But only is practical for some buildings
• Steel structure
 Allows for cross-over of zone taps from mains
 Not practical with flat slab structure
• Generous floor-to-floor height
 Needs ~6” more space to accommodate hot duct
• Large interior zones
 Need a way to get ventilation into the building during cold weather

74
Underfloor System with UFTs

75
 UFT Control

130°F
Max Fan Speed

Design Discharge Air

Design Airflow
Fan Speed Temperature
Setpoint
Airflow
Fan Speed

Airflow
30% Design
30% Design Airflow
Fan Speed
Fan Speed
Lowest Possible
Fan Speed
(~15% Max
Fan Speed) Minimum Airflow
(due to
60°F pressurized
plenum)
Heating Loop Output Deadband Cooling Loop Output

76
The deal killer: Temperature
Degradation

77
 How to make UFAD actually work?

 Separate systems to serve envelope

heating and cooling loads
• UFAD only for interior
 See thus article for one approach:
http://www.taylor-
engineering.com/Websites/taylorenginee
ring/articles/ASHRAE_Journal_-
_Making_UFAD_Systems_Work.pdf
 UFAD still a large cost premium vs.
overhead
• Floor cost is ~$20/ft2 by itself
78
Hydronic Heat Pump System
with Dedicated Outdoor Air System (DOAS)

79
Variable Refrigerant Flow System
with Dedicated Outdoor Air System (DOAS)

80
DOAS with Flat Panel Radiant

81
DOAS with Chilled Beams

Active Chilled Beams Passive chilled beam

(OA is supplied through beam to (Radiation and
improve capacity through convection only)
induction)

82
 Radiant panel advantages &
disadvantages

 Advantages  Disadvantages
• Quiet • Extremely high Cost
• Little ceiling space • Low capacity – requires low
required space loads
• Possibly improved comfort • Slow response
• No zonal fan energy • Ceiling aesthetics
• No zonal filters/coils/fans • Chiller plant required
• Possibly lower cooling
• Limited ceiling access
energy
 Requires tepid water supply • Dewpoint control,
and waterside economizer condensation considerations
 May require increased
outdoor air; or sub-cooling
with reheat or runaround
coil at OAHU if latent
loads are high
• Possibly higher cooling and
fan energy

83
Variable Speed VAV Fan Performance with SP
setpoint reset vs. DOAS

100%
VAV
90%

80%

70%

60%
% P ow er

50%

40%

30%

20%
DOAS
10%

0%
10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
PLR
Typical Average
86
Real Data (UC Merced COB)

Actual vs. DOE-2 PLR curve

Actual vs. DOE-2 PLR curve

adjusted for oversized
design static pressure

Typical Average
87
 Chilled Beams in CA Campus
(connected to central plant)

 Costs – 300% higher!

• Chilled beams: $80/ft2 HVAC + $10/ft2 EMCS
• VAVRH: $25/ft2 HVAC + $5/ft2 EMCS
 Energy − 50% higher!
• Higher cooling energy
 no economizer, higher minimum outdoor air rate
• Higher fan energy
 Higher minimum rate, constant volume, single duct
• Higher heating energy
 Low supply air temperature for dehumidification, higher
minimum outdoor air rate
 See: https://app.box.com/TE-VAVRvsACBplusDOAS

88
In-slab Radiant+DOAS vs. VAV

89
 Other Systems & System Selection

 Take X472 next Fall

90
Questions??

91