DUE eee Rr) A practical guide to — Ductwork Leakage Testing aa aC Cae Fist published 1983 iG rr fog Frances en) HEATING AND VENTILATING CONTRACTORS’ ASSOCIATION Esca House, 34 Palace Court, London W2 4JG ‘Telephone: (020) 7313 4900 Fax: (020) 7727 9268 e-mail: contact @hvca.org.uk web: www-hvca.org, COPYRIGHT © 2000 by the Heating and Ventilating Contos’ Association Al rights reserved (Revised) 2000 ISBN: 0-903783-30-4DW/143 Ductwork Leakage Testing A practic CONTENTS Page Acknowledgements. Cautions: Preface esfrafns PART ONE Practical guide to leakage testing 46 Example of complete test sheet 7 Hints on leakage te: PART TWO Ductwork classification and air leakage 10 Appendix A: Air leakage from ductwork 11-13 Appendix B: Air leakage testing procedure 13-16 ACKNOWLEDGEMENTS ‘The HVCA records its appreciation and thanks to the persons and organisations who have freely contributed to this work, and in particular to the members of the Drafting Panel. Original DW/143 Drafting Panel 1983 Ductwork Group Technical Sub-Committee 2000 JH. G. Gardner (Chairman) . Poppleton (Chairman) K. Angood C. Collins H. Brierley S. V. Howard H. Brocklehurst, B, James P. Doyle J.B, Murray K. Waldron C. Robertson K. Wheatley G. P. Keller (Secretary, Ductwork Group) J. M. Paynton (Former Secretary, Ductwork Group) R. J. Miller (Former Secretary, Ductwork Group) Front cover photograph by kind permission of Commtech Limited FINANCIAL CAUTION It is essential to realise that except where it is mandatory in Class C ductwork in DW/144 this document is not an endorsement of the routine testing of ducts but purely a guide to outline the procedures, necessary for testing ducts for conformity with air leakage fimi When proper methods of assembly and sealing of ducts are used a visual inspection will suffice for the Verification of a well engineered construction, WHERE NOT MANDATORY, DUCT LEAKAGE TESTING IS GENERALLY AN UNJUSTIFIED SUBSTANTIAL EXPENSE.DW/143 Ductwork Leakage Testing 4 practical guide PREFACE Edgar Poppleton Chairman, Technical Sub-Committee Ductwork Group, 2000 uctwork Specification DW/142, published by the HVCA in 1982, provided for the first time in a long series of such publications for leakage limits over the whole range of air pressures covered by the specification and (where required) a test procedure to establish conformity. Although leakage testing of high-pressure ductwork Il mandatory in DW/144 (as was the case in previous ductwork specifications issued by HVCA) the leakage testing of ductwork designed to operate at low and medium pressures is required only where so specified in individual job specifications. With the retention of three pressure classifications in DW/144 it is hoped that the designer, having control over performance standards, will find leakage testing an unnecessary contract expense with regard to low and medium pressure ductwork see note Financial Caution (page 2). Ductwork contractors faced with a job calling for leakage testing should take this requirement very seriously and satisfy themselves as the job progresses that the required leakage rate or rates are within the limits set by the designer or the client. The cost of making good an installation that has been found on completion to have in this respect can be very expensive, DW/144 specifies leakage limits for the ductwork alone, because the ductwork contractor has no control over the leakage characteristics of the various components which go to make up the whole of the air distribution system, Where a job specification calls for a leakage limit for the whole system, it will be for the designer or client to ensure that the leakage rates of the components are also within the required limits. Edgar Poppleton Chairman, ‘Technical Sub-Committee Ductwork Group, 2000DW/143 Ductwork Leakage Testing 4 py Part One A practical guide to ductwork leakage testing 1 General ith regard to air leakage, the responsibili- for ensuring the achievement of a satis- factory job is divided between the drawing office, the factory and the ductwork installers on site, Tt is essential that there is full co- operation between them, 2 The drawing office 2.1 Establish with the client or his represent- atives the class of ductwork called for in the job specification, i Class A: up to 500 Pa positive Class B: up to 1000 Pa positive Class C: up to 2000 Pa positive 2.2 Establish with the client or their represent- ative that the required leakage rate or rates are for the ductwork alone (eg excluding dampers, fire dampers, air handling units, fans, coils, attenuators, terminal boxes) unless, by prior agreement, the casings for any such items have been manufac- tured/sealed, by the supplier, to the required standard of DW/144, Additionally, establish the type of gasket material required in relation to the pressure class/velocity of the system. Note:- Specific gasket material may be required in locations such as clean rooms, hospitals ete, Ifa leakage limit is laid down for the whole system, it will be for the client or the design- er to ensure that the leakage characteristics of the components are acceptable, 2.3 Agree with the client or designer the test pressure for each section of the installation (Note that whilst duct construction specifica 24 25 27 tion is related to the highest test class of the uct installation itis important that each duct test zone should only be tested to a pressure to cover the mean working pressure of that particular section of ducting ~ see A.9(b). Decide on the best way to isolate the installation into test zones. When doing so, the drawing office should bear in mind the test pressures called for, the allowable air losses, the work sequence on site and the capacity of the test equipment. Arrange for the supply of suitable blanking medium, e.g. heavy-duty polythene sheet ‘Make sure that all test points and blanking devices can be reached with the minimum of difficulty after the ductwork has been installed. Ensure that a reading can be obtained, by planning test sections to have a permitted leakage of approximately 25 per cent less than the total volume generated by the test rig at the pressure required for each section. Provide the ductwork installers with details of the test zones, duct operating pressures and test pressures; and indicate the nature of the blanking devices, gasket material and sealant to be used. Prepare test sheets giving the information called for on the sample test sheet shown on page 7, ‘This information should indicate the test content, the surface area of the ductwork to be tested, and the permitted leakage of each section to be tested (this leakage is to be expressed in litres per second per square metre of the ductwork surface area). The factory Take care to make components with a good fit to minimise the use of sealant. A poor fit cannot be remedied by the use of more sealant — it will not work.3.3 3.4 3.5 3.6 3.7 4A 4.2 43 44 Dre rerio aes Seal all longitudinal seams, laps, cross joints, rivets and duct penetrations generally, in accordance with the requirements of DW/144. Make sure that sealant is properly applied to the ends of all lock forms and other types of longitudinal seam, and to the corners and junctions between those seams and the cross joints. ‘Take special care to have as small a clearance as possible where there are penetrations of the duct, as for example, damper spindles. Fit and seal branch connections carefully, as required by DW/144. ‘To be sure of minimum leakage, special care must be taken in the fitting and sealing of access doors and panels ete. ‘To avoid the danger of breaking the seals, the ductwork when ready to despatch to site must be handled and loaded carefully. Site work For full details of procedure see Fig. 1 on Pages 8 and 9 and Appendix B Pages 14 and 15 . Understand the proper use of the test rig, It is expensive precision equipment. The instructions must be read carefully and the equipment handled in a responsible manner. Make sure that the right type of test rig is available for the job. A rig suitable for high- pressure leakage testing is seldom suitable or economic for testing low- or medium- pres- sure ductwork, and vice versa. Note that leakage testing is always done under positive pressure even when the duct- work is to operate under negative pressure. Before installation, inspect all duct sections to make sure that factory applied sealants have not been damaged in transit. Make good where any damage is noticed. Tere 4.5 Ensure the correct gasket material has been supplied and the application is in accor~ dance with the manufacturer's instructions. Check with the drawings and specifications where sealants are to be used on the cross joints, and apply the sealants as necessary. (Use only as much sealant as will do the job = too much sealant is as bad as too little.) 4.6 Pay special attention to the sealing of joints that will be difficult to reach after installation of the ductwork. 4.7. Fix the blanking plates or other types of tem- porary seal in the positions shown by the draw- ing office, (Ensure that the blanking material is accessible for subsequent removal.) 4.8 At the earliest opportunity agree with the client or their representative on a progressive testing programme. 4.9. Before presentation to the client or their rep- resentative, it is essential that a preliminary test is carried out on each section of the work at the earliest opportunity to ensure that the ductwork has been correctly manufactured and site sealant correctly applied 4.40 If these preliminary tests show that the leak- age is over the limit, then: 4.10.1 Look for any obvious places where there may be leaks, for example, an open access door or missing or punctured polythene blanks. Simple methods of locating any leakage are: a) by listening for them; b) by feeling for them especially with a wet hand; ©) by applying soapy water over the seams or joints; 4) by (with the agreement of the client) using a smoke pellet. NOTE When smoke pellets are used, the smoke should be intro- duced downstream of the test rig and not on its intake side.DW/143 Ductwork Leakage Testing A practic y 4.40.2 Reseal or correct where you have found the leakage source(s). Manufacturing faults should be reported to the factory immediately. 4.10.3 Repeat the test after allowing enough time for the sealant to cure. (Remember that sealants take longer to cure in cold weather. Read the sealant manufacturer's instructions.) 11 When satisfied with the results of the preliminary tests then:~ i 4.11.1 On successful completion of the | test, offer the section to the client or their representative for formal acceptance and signature on the test sheet; 4.44.2. A permanent record of tests must be retained. 4,12 As tests are satisfactorily completed, remove all blanking-off devices.DW/143 Ductwork Leakage Test 5 Example of a completed test sheet Based on ductwork shown on pages 8 and 9 ‘Test No. General Name of job... N@%: Building Ref. 44a Block 2 Project. Part 1 — Physical details Section of ductwork to be tested 4a Sure. Drawing Number. 2433/1 . . . Pressure Classification. (488 ,0" — _{PROMDED BY DESIGNERS) Test static pressure..£5OO PBAME cus _etee Des mer rma, Leakage factor Surface area of duct under test .SO S6are metres, ‘Maximum permitted leakage. 28 (108/266, mime ae se Part 2 - Test particulars a Duct static pressure reading..2990 pascal b Manufacturer and type of flow measuring device..7: AR, Led, 100 Test Ry Range of measurement of flow measuring deviee 0%, £00 iea/se,.. OM MORE d_ Reading of flow measuring device ...26.3 48 Interpreted air flow leakage rate...£8 W@5/26E..... f Duration of test (normally 15 minutes).£2. Monies Date of test 22:00 Cartied out by ZMHeY. OMe” Printed Name, 74. OTHER, Printed Name A AWIDEOR,. Ld. AB Consutants and Company 42% and Company .? ‘Area millimetres ‘square metres 3100 F 54.40 2500 13.93 144PED re ee ora Fig.1 Hints on Ductwork Leakage Testing Take special care 2500. with inaccessible 500 joints | 600 x 650 800% 750, Ne = f 300 x 300 300 $95 FLEX 415, _ Keep length to a minimum and make sure that both nd connections ae correctly" sealed and that the flexible TEST RIG . ‘doct ite has no leaks. To be connected and operated in accordance with the apparatus | instructions. In general, site on firm level base and ensure gauges are topped up with correct fluid ‘In order to avoid ‘and zeroed prior to commencing incorrect readings Fitcorrect flow _ test. Inclined manometer to read. Bl ‘of duct pressure measuring device. _ leakage rate or pressure drop | the tube from the ——— | which can be converted to leakage || vertical manometer rate by reference to graph. should be connected lreetly to the uetwork under test. | omy | SEQUENCE OF TEST | 1. Prepare test sheet. 2. Connect and adjust test rig to correct pressure. 3. Read off leakage rate. 4, Reseal if necessary (allow time to cure). WARNING Parenter eaey » Taka care not to over pressuriea 6, Switch off and allow to zero. ‘system under test 7. Reapply test pressure and check reading. 8. Record details on test sheet and obtain signature.Prey er ger ores) ‘The dimensions on this ductwork are used In an example on page 7 3. Feel ‘over joints can help to locate leaks. 4. Sosp and Water — paint over joints and look for bubbles . ‘5. Smoke Pellet — placed inside ductwork (obtain permission for use) DRG No. 20435/12CUR rrr ger er rece Bl Part Two 6 This section, apart from Appendix ‘B’, is extracted from DW/144 — Specification for Sheet Metal Ductwork, and for ease of refer- ence the numbering as in DW/144 has been retained. The leakage limits for EUROVENT classifications A, B and C, as set out in their document 2/2 (Air Leakage in Ductwork) have been adopted for the low pressure, medium pressure and high pressure Class C classifi tions. Ductwork classification and leakage 6.1. Classification and air leakage limits Ductwork classification and air leakage limits are set out in Table 1. The leakage factors used in Table 1 for Classes A, B and C are the same as those for the classes similarly designated in the CEN Document Pr EN12237/Pr EN1507. 6.3 Leakage at various pressures; and other relationships Applying the limits specified in Table 1, Appendix A (Table 17) sets out the permitted leakage at each of a series of pressures up to a maximum for each class. Included in that appendix is a graphical presentation of the pressure/leakage relationship (see fig 178). Appendix A, also gives details of the basis 6.4 Air leakage testing Air leakage testing of low and medium pres- sure ductwork is not mandatory under the specification DW/144. Air leakage testing of high pressure ductwork is mandatory under the specification DW/144 and for details of testing procedure refer to Part 1 of this guide for the leakage limits specified in Table 1. Table 1 Ductwork Classification and Air Leakage Limits z ‘Stati pressure limit x Ar leakage limits ! Maman at] ya perce por square Positive | Negative | ____etre of det surface area 2 3 4 5 Pa Pa mis 500 300 10 0.027 x poss 1000 750 20 0.009 x poss 2000 750 40 0,003 x pss Where p is the differential, pressure in pascals,APPENDIX A Ai leakage from ductwork A.1 Introduction Leakage from ducted air distribution systems is an important consideration in the design and operation of ventilation and air condi- tioning systems. A ductwork system that has limited air leakage, within defined limits, will ensure that the design characteristics of the system can be maintained. It will also ensure that energy and operational costs are main- tained at optimum levels. Ductwork constructed and installed in accor- dance with DW/144 should minimise a level of air leakage that is appropriate to the oper- ating static air pressure in the system. However, it is recognised that the environ- ment in which systems are installed is not always conducive to achieving a predictable level of quality in terms of system air leakage and it is therefore accepted that designers ‘may sometimes require the systems to be test- ed in part or in total. It should be recognised that the testing of duct systems adds a signif- icant cost to the installation and incurs some extra time within the programme (See 4.1 and 6.4 of DW/144 re mandatory testing). A.2 Duct pressure Ductwork constructed to DW/144 will be ‘manufactured to a structural standard that is compatible with the system operating pressure. ‘There are three classes of duct construction to correspond with the three pressure classifications: Class A Low pressure ducts suitable for a maximum positive operating pressure of 500 Pascals and a maximum negative pressure of -500 Pascals. Class B Medium pressure ducts suitable for a maxi- mum positive operating pressure of 1000 Pascals and a maximum negative pressure of Pep re eee eer) As Ad ~750 Pascals. Class C High pressure ducts suitable for a maximum positive operating pressure of 2000 Pascals and a maximum negative pressure of ~750 Pascals, Leakage from ductwork Leakage from sheet metal air ducts occurs at the seams and joints and is therefore propor- tional to the total surface area of the ductwork in the system. The level of leakage is similar- ly related to the air pressure in the duct sys- tem and whilst there is no precise formula for calculating the level of air loss it is generally accepted that leakage will increase in propor- tion to pressure to the power of 0.65. The effect of air leakage from high pres- sure/velocity ductwork is critical in terms of system performance, energy consumption and the risk of high frequency noise associat- ed with leakage, These problems are less critical with medium pressure/velocity systems, but should be considered. Low pressure/velocity ducts present the lowest risk in terms of the effect of leakage on the effective operation of the system, ‘System leakage loss As there is no direct relationship between the volume of air conveyed and the surface area of the ductwork system required to match the building configuration itis difficult to express air leakage as a percentage of total air vol- ume. Similarly, the operating pressure will vary throughout the system and as leakage is relat- ed to pressure the calculations are complex. However, it is generally accepted that in typ- ical good quality systems the leakage from each class of duct under operating conditions will be in the region of: Class A low pressure 6% Class B_ medium pressure 3% Class C high pressure 2%| DW/143 Ductwork Leakage Test A.5 Specifying air leakage testing Respecting both the cost and programme implications associated with testing ducts for leakage, the designer may, for example indi- cate that a particular system is tested as follows: a) High pressure ducts ~ all tested. b) Medium pressure ducts — 10% of the ductwork shall be selected at random and tested. ©) Low pressure ~ untested. Table 17 Air leakage rates ‘Maximum leakage of ductwork ‘Siac | Cow presure | Medium-pressure | High-presoure rescue Class A Class B Cass C ferential Bel 7 z 3 7 Se eeaiegeondakem 100, 0.54 0.18 200, 084 0.28 110 037 132 0.44 1.53 051 0.58 0.19 0.64 021 0.69 023 075 025 0.80 027 1100 029 1200 030 1300 032 1400 0.33 1500 035 1600 036 1700 038 1800 039 1900 0.40 2000 | 0.42 Note: Recommended ‘mean’ test pressures are highlighted in bold type with the actual selection being left to the test ‘operator. AT In the case where a random testis selected for ‘medium pressure ducts the following clause is, suggested for inclusion by the designer. The designer shall select at random a maxi- ‘mum of 10% of the duct system to be tested for air leakage. The duct shall be tested at the pressure recommended in Table 17 of DW/144 for the classification for the section of the ductwork that is to be tested. The tests shall be carried out as the work pro- ceeds and prior to the application of thermal insulation. In the event of test failure of the randomly selected section, the designer shall have the right to select two further sections at random for testing. Where successive failures are identified there shall be a right to require the contractor to apply remedial attention to the complete ductwork system. The contractor shall provide documented evidence of the calculations used to arrive at the allowable loss for the section to be tested and the client, or his agent, shall witness and sign the results of the test Special cases There may be situations on a project where circumstances dictate that special considera- tion be given to containing air losses, e.g. a Jong run of ductwork may incur a dispropor- tionate level of air loss In cases such as this example the designer can specify an improved standard of airtightness, i.e. 80% of allowable loss for Class *B’ ducts. The designer should not specify a Class °C” test at Class ‘C’ pressure for a Class “B’ duct. Suggested range of testing (See cautionary note on page 2 of this guide) * High pressure ducts 100% test ‘* Medium pressure ducts see AS * Low pressure ducts Untested ‘+ Exposed extract systems — Untested * Ceiling void extract systems Untested * Secondary ducts from VA or fan coil units -Untested * Flexible ducts UntestedDW/143 Ductwork Leakage Testing 4 * Final connections and branches to grilles and diffusers Untested A.8 Testing of plant items Items of inline plant (eg. Figs. 168 to 175) will not normally be included in the air leakage test. The ductwork contractor may. include such items in the test if the equipment has a cettificate of conformity for the pressure class and air leakage classification for the system under test, A.9 Designer's calculations The designer can calculate with reasonable accuracy the predicted total loss from a sys- tem by: a) Calculating the operating pressure in each section of the system. b) Calculating the surface area of the ductwork in each corresponding pressure section. ©) Calculating the allowable loss at the operating pressure for each section of the system (see Table 17 for allowable leak- age figures). A.10 Variable pressures in systems Designers can achieve significant cost savings. by matching operating pressures throughout the system to constructional standards and appropriate air leakage testing, e.g. the prac- tice of specifying construction standards for whole duct systems based on fan discharge pressures may incur unnecessary costs on a Project. For example, some large systems could well be classified for leakage limits as follow: Plant room risers Class C Main floor distribution Class B Low pressure outlets. Class. A Appendix B Air leakage testing Procedure General Section 6 (page 10) of this specification deals, with the performance requirements of duct- work in respect of air leakage, and Table 17 (Appendix A) tabulates the limits of leakage applicable to each class of ductwork. Appendix B is solely concerned with recom ‘mendations for the testing procedure. B.2 Extent of ductwork to be tested B.2.1. The procedure set out in this section is limited to the ductwork and those items of in-line plant equipment that are manufactured/sealed to the crite- ria set out in Table 1 (also see Appendix A.8). B.2.2 The extent of the ductwork to be tested and the method of selection (where not included in the job spec~ ification) should be determined in collaboration between the designer and the ductwork contractor with consideration having been given to the recommendations outlined in “Appendix A. B.2.3 Fit blanking devices in accordance with the drawing office guidance notes (Part 1, Section 2). To enable a blank to be cut out after the testing is completed, access may be required adjacent to each blank. B.2.4 Alternatively, rigid removable blanking plates can be used, although this involves remaking Joints,Pe re eee emery] 178 Permitted leakage at various pressures ‘Leakage in litres per second per square metre duct surface area 10 1900 2000 1800 1000 120013001400 15001600 00 900 Pressure difference in pascals 40 5060700 300B.3 Testing to be completed before insulation, etc. Testing shall be satisfactorily completed before insulation or enclosure of the duct- work and before terminal units (if any) are fitted, Ba Re-testing procedure where B.4.2 1 The air leakage rate for any section shall not be in excess of the permit- ted rate for that section. If a first test produces leakage in excess of the permitted maximum, the section shall be resealed and retested until a leakage not greater than the permit- ted maximum for that section is achieved, If atthe time of witnessing the test it is apparent that excessive additional sealing of searhs or joints has been done in order to meet the required leakage level, the section of duct- ‘work under test shall not be counted as part of the tested ductwork, except where the whole of the duct- work is required to be tested. imum area to be tested ‘The section of ductwork to be tested shall have an area large enough to enable the test rig to register a measurable leakage. DW/143 Ductwork Leakage Testing 4 practic B.6 Test pressures and leakage rates ‘The maximum permissible leakage rates for the full range of pressures are given in Table 17, The recommended test pressures for the various classes of ductwork are set out in Table 2, and unless otherwise specified, the choice of test pressure shall be at the discre- tion of Bz B74 B.7.2 8.7.3 B84 the test operator. Test rig ‘The accuracy of the test rig shall be within: + 10 per cent of the indicated flow rate, or 0.4 litres per second, whichever is the greater; and + 5 per cent at the indicated static pressure in the duct under test. The test rig shall be inspected by the user before use on site, and shall have a calibration certificate, chart or graph dated not earlier than one year before the test for which it is used. ‘A schematic arrangement of an air leakage test is given in Fig. 2. Procedure ‘The section of ductwork to be test- cd for air leakage shall be sealed. Main ducts should be provided Table 2 Recommended maximum test pressures (with leakage rates) ‘Maximum leakage of ductwork c Static T == yressure Low-pressure | Medium-pressure | High-pressure differential ClassA | Class B ise i Dey 3 Pa Litres per second per square metre. 200 ost | 400 132 | oa 800 \ 0.69 1200 1500Cre re eee eee with flanged joints to enable blanking plates to be fitted, while sinall open ends may be sealed with polythene or inflatable bags, which should be left in position until final connections are made. B.8.2 On low-pressure systems, final grille spigots made as a second fix operation shall be excluded from the test. The joint shall, where practica- ble, be checked by external visual examination. B.8.3 Sufficient time shall be allowed between installation and leakage testing for sealants to cure. B.8.4 Special care must be exercised in ‘making all joints which fall outside the scope of the testing procedure, i.e., joints between tested sections of ductwork and between ductwork and items of in-line equipment not included in the test. B.8.5 Due notice of tests shall be given, so that arrangements for witnessing the tests can be made. B.9 Testing sequence The recommended sequence of testing is as follows. Fig. 2 Schematic B94 B.9.2 B.9.3 B.9.4 B.9.7 Complete Part 1 of the Test Sheet. Connect test rig to section of duct- work to be tested. Adjust test rig until the static pres- sure differential is obtained. Check that the measured leakage is within the permitted rate. (No addi- tion shall be made to the permissible leakage rate for access doors, access panels or dampers where these are included in the ductwork.) Maintain the test for fifteen minutes and check that the leakage rate has not increased. Reduce pressure in section to zero by switching off the fan; then imme- diately re-apply test pressure to establish that the air leakage rate is not greater than the previous read- ing. Record details on Part 2 of the Test Sheet and complete, including wit- nessing leakage test sheet A example of a suitable Test Sheet is given on page 7. ngement of an air leakage test Flow messing device Blanking place {ray be fost on epee the fam) it under est Doct test pressure gauge —>| Inclined gauge Bleed valve (not necessary Of tvarate speed fanused)(HVCA) Heating and Ventilating Contractors’ Association Esca House 34 Palace Court London W2 4JG Tel: 020 7313 4900 Fax: 020 7727 9268 e-mail contact @hyca.org.uk web site www.hyca.org.uk eT ete re eng eco CORY CNT UE EC) ated Penrith Cumb PLD a 01768 860405 Fax: 01768 860401