NJ AIHA CIH Review Industrial Ventilation
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1 NJ AIHA CIH Review Industrial Ventilation Thomas Block, CIH MPH American Industrial Hygiene Association, New Jersey Section, Inc.
2 Course Objectives At the end of this session, you should: 1. Be familiar with the industrial ventilation topics you may encounter on the ABIH CIH Exam 2. Identify your strengths & areas for improvement 3. Identify additional resources to prepare for the exam Page 2 Summer Review Course: Industrial Ventilation
3 Properties of Air Ventilation Reference Values Temperature 70 o F For Absolute Rankine = o F+ 460 Pressure in Hg 1 inch Hg = 13.6 inch H 2 O Density lbs/ft 3 MW ~ 29 Page 3 Summer Review Course: Industrial Ventilation
4 Principles Air moves because of pressure differences Fans create pressure differences Air flows from higher to lower pressure Air assumed to be incompressible Pressures in system < 3% (12 inches of water) Flow assumed to be turbulent (Reynolds Number) Page 4 Summer Review Course: Industrial Ventilation
5 Reynolds Number (N Re ) A dimensionless parameter used to characterize fluid flow Ratio of the inertial force which is causing gas movement to the viscous force which is restricting movement N Re = L * v * p µ Where: L = Linear dimensions (duct diameter) v = Fluid velocity p = Fluid density µ = Fluid viscosity Page 5 Summer Review Course: Industrial Ventilation
6 Airflow Patterns in a Duct Laminar Flow Classification of Gas Flow Types Turbulent Flow Type Gas Flow Laminar Transitional Turbulent Reynolds Number < 2,000 2,000 10,000 > 10,000 Page 6 Summer Review Course: Industrial Ventilation
7 Conservation of Energy Bernoulli s Equation Total Energy in = Total Energy out Units: (inches of water) Two types of energy Potential: (Static Pressure SP) Kinetic: (Velocity Pressure VP) Total Pressure (TP) = VP + SP SP and VP are mutually convertible Potential Energy to Kinetic Energy Page 7 Summer Review Course: Industrial Ventilation
8 Duct Pressures Static Pressure: the pressure exerted in all directions Value can be negative or positive, depending upon position in the ventilation system Example: Tire pressure Velocity pressure: directional pressure Velocity pressure is always positive Example: Wind Page 8 Summer Review Course: Industrial Ventilation
9 Static Pressure NOTE: The static pressure should be positive with the fan downstream of the manometer, negative with the fan upstream of the manometer Page 9 Summer Review Course: Industrial Ventilation
10 Velocity Pressure Page 10 Summer Review Course: Industrial Ventilation
11 Total Pressure Page 11 Summer Review Course: Industrial Ventilation
12 Pressure Relationships Page 12 Summer Review Course: Industrial Ventilation
13 Pressure Upstream and Downstream of the Fan Page 13 Summer Review Course: Industrial Ventilation
14 Conservation of Mass Page 14 Summer Review Course: Industrial Ventilation
15 5 Components of a Local Exhaust 1. Hood 2. Duct System Locate as close to source as possible Have the necessary capture or control velocities for contaminants Necessary transport velocity 3500 fpm for most industrial dusts Proper size Maintain Q and transport velocity Consider friction loss Page 15 Summer Review Course: Industrial Ventilation
16 Components of a Local Exhaust System 3. Air cleaner Selection Criteria Removal and/or destruction of contaminants to achieve required efficiencies Consider contaminant characteristics & pressure loss to the system 4. Fan Selection Criteria Achieve desired flow Q (cfm) Maintain required capture, control and duct velocities to counteract system resistance (i.e., SP losses on the suction side & exhaust side losses) Page 16 Summer Review Course: Industrial Ventilation
17 5 Components of a Local Exhaust 5. Exhaust Stack System Must be high enough to avoid gas re-entrainment Must be 6 10 feet above the highest part of the roof Must have vibration isolation Page 17 Summer Review Course: Industrial Ventilation
18 Exhaust Stack Design Considerations: Actual vs. Effective height Resistance (SP) Prevailing wind speed & direction (wind rose) Roof obstructions ASHRAE Fundamentals Chapter 16 Page 18 Summer Review Course: Industrial Ventilation
19 ASHRAE Airflow Around Buildings Airflow around buildings affects: Safety Processes & Operations Building environmental factors Scaling Height (R) R = B s B l 0.33 Where: B s = smaller of upwind building dimensions B l = larger of upwind building dimensions Page 19 Summer Review Course: Industrial Ventilation
20 Hoods Suction openings that provide points of entry into the local exhaust system Three Hood Types: 1. Exterior hoods Draws air away from the contaminant source but does not surround the source at the point of release Round or rectangular openings Page 20 Summer Review Course: Industrial Ventilation
21 Hoods 2. Receiving Hoods designed to take advantage of natural movement of contaminant from its source Canopy hoods over hot processes Capture hoods for grinders 3. Enclosing hoods glove box provides complete enclosure, booth hoods have one side open for access Page 21 Summer Review Course: Industrial Ventilation
22 Hood Capture Velocity The air velocity at any point in front of the hood or at the hood opening necessary to overcome opposing air currents and draw the contaminant into the hood Air drawn into a hood (all directions) by lower SP At approximately one-hood-diameter away from the hood entrance, the gas velocities are often <10% of the velocity at the hood entrance High terminal make-up air velocities at the hood opening necessitates higher capture velocities Suction is less efficient than blowing Page 22 Summer Review Course: Industrial Ventilation
23 Theoretical Point Source Suction Surface Area of Sphere: A = 4πX 2 Required Airflow (CFM) Q = V (10X 2 + A) Page 23 Summer Review Course: Industrial Ventilation
24 Chapter 3: ACGIH Industrial Ventilation Handbook Page 24 Summer Review Course: Industrial Ventilation
25 Chapter 3: ACGIH Industrial Ventilation Handbook Page 25 Summer Review Course: Industrial Ventilation
26 Chapter 3: ACGIH Industrial Ventilation Handbook Page 26 Summer Review Course: Industrial Ventilation
27 Capture Velocity Considerations Source: Chapter 3, ACGIH Industrial Ventilation Handbook Methods to Reduce Hood Airflow Flanges: Surface placed parallel to hood face to prevent unwanted airflow from behind hood Baffles: Surface placed to prevent unwanted airflow from the front or sides of a hood Push-Pull systems Page 27 Summer Review Course: Industrial Ventilation
28 Transport Velocity The minimum velocity that will transport captured particles in a duct with little settling Recommended Transport Velocities Pollutant Type Recommended Transport Velocity (ft/min) Gaseous gases ~1,000 2,000 Light particulate loading ~3,000 3,500 Normal particulate loading ~3,500 4,500 Page 28 Summer Review Course: Industrial Ventilation
29 Losses of Energy or Pressure Friction Loss: The static pressure loss in a system caused by the friction between moving air and the duct wall, expressed as: Inches w.g./100 feet Fractions of VP/100 feet of duct Varies directly with: Duct length Interior roughness of duct Square of velocity (v 2 ) Varies inversely with duct diameter Page 29 Summer Review Course: Industrial Ventilation
30 Losses of Energy or Pressure Dynamic Loss: A loss due to turbulence due to the change in direction or velocity in a duct or hood Hood Entry Loss (h e ) turbulence losses due to air entry into a hood or duct Coefficient of Entry (C e ) efficiency of conversion of hood SP to velocity pressure Page 30 Summer Review Course: Industrial Ventilation
31 Losses of Energy or Pressure Acceleration Loss: A loss of energy required to accelerate air from zero velocity to a given velocity This is always positive and equal to 1 VP Combination Loss: A loss occurring as a result of friction and dynamic losses that occurs in elbows, contractions, expansions, branch entries, and air cleaners Page 31 Summer Review Course: Industrial Ventilation
32 Hood Static Pressure (SP h ) The static pressure required to accelerate air at rest into the hood and up to the duct velocity (1 VP) and the hood entry loss (Duct VP + h e loss) Expressed in terms of SP: SP h = VP (inches water) + he (inches water) Expressed in terms of VP: SP h = acceleration loss + hood entry loss = 1 VP + Fd(VP) Where Fd(VP) is hood entry loss factor Page 32 Summer Review Course: Industrial Ventilation
33 Hood Entry Loss (h e ) The loss of pressure (inches of water) when air enters a duct through a hood. The majority of the loss usually is associated with a vena contracta formed in the duct Varies with the type of opening Always expressed in absolute terms he = SP h + VP d SP h = hood static pressure, inches W.C. VP h = hood velocity pressure, inches W.C. = Overall hood entry loss, inches W.C. h e Page 33 Summer Review Course: Industrial Ventilation
34 Vena Contracta An area of air convergence upon entering a duct As air passes through the vena contracta, its velocity increases. After passing through the vena contracta, the airflow expands and some of the velocity pressure converts to static pressure. The hood static pressure and entry loss are related to the size of the vena contracta. The hood geometry determines the size of the vena contracta by influencing how smoothly airflow enters the hood (circular vs. square) Page 34 Summer Review Course: Industrial Ventilation
35 Coefficient of Entry (C e ) A measure of the efficiency of a hood s ability to convert static pressure to velocity pressure; the ratio of actual to ideal flow C e = actual flow rate / theoretical flow rate OR C e = (VP) 1/2 / (SP) 1/2 All are expressed in positive terms (absolute value) Page 35 Summer Review Course: Industrial Ventilation
36 Hood Entry Loss Factors (F d )* for Several Duct Designs *h e = F d (VP) Page 36 Summer Review Course: Industrial Ventilation
37 Friction Losses Ducts and Elbows Friction in straight ducts Round ducts preferred Rectangular use equivalent diameter Elbows have friction & turbulence loss Long radius elbows have less loss Turbulence occurs in contractions and expansions Page 37 Summer Review Course: Industrial Ventilation
38 Friction Losses Ducts and Elbows To calculate air flow pressure drop in typical HVAC ducting, use friction charts Chart shows the friction pressure loss in terms of inches of water/100 feet of duct equivalent For elbows, use charts that express losses or resistance as a fraction of VP or to equivalent length of straight duct Page 38 Summer Review Course: Industrial Ventilation
39 Other Losses in System Design Branch duct entry Air cleaners Stacks Use reference data Page 39 Summer Review Course: Industrial Ventilation
40 Static Pressure Measurements U Tube manometer Simplest; usually filled with water or oil Magnehelic gauge aneroid gauge Measurement locations Hoods: 3 duct diameters downstream from plain or flanged hood Ducts: Location where airflow parallel to duct wall Page 40 Summer Review Course: Industrial Ventilation
41 Velocity Pressure Measurement Pitot Tube: Consists of two concentric tubes One detects Total Pressure (TP) The other detects Static Pressure (SP) Generally not used at velocities < 600 FPM (0.02 inches water VP) Standard type does not require calibration, but S-type does Page 41 Summer Review Course: Industrial Ventilation
42 Velocity Pressure Measurement Pitot-Traverse used for an accurate velocity profile Location must have uniform flow At least 7.5 duct diameters downstream from major turbulence 2.5 duct diameters upstream from disturbance or stack For round ducts, concentric areas of equal area with a specific number of points Ducts < 6 diameter, 6 points per traverse Ducts 6 48 diameter, 10 points per traverse Ducts > 48 diameter, 20 points per traverse Page 42 Summer Review Course: Industrial Ventilation
43 Pitot Tube Measurement Page 43 Summer Review Course: Industrial Ventilation
44 Velocity Pressure Measurement Swinging Vane Anemometer Different scales, up to 10,000 fpm Frequent calibration required, not good with high dust loading Hot wire thermoanemometer 10 8,000 fpm Fragile; do not use in dusty or combustible environments Rotating Vane 200 2,000 fpm Frequent calibration required; not good with high dust loading Page 44 Summer Review Course: Industrial Ventilation
45 Local Exhaust System Measurement Velocity Pressure Total Pressure Page 45 Summer Review Course: Industrial Ventilation
46 Addendum to Previous Slide The labels on the previous slide are incorrect: The first manometer reads velocity pressure (leg in the air stream); should read w.c. (velocity can never be a negative number) The second manometer reads static pressure The third manometer reads total pressure One manometer leg reads velocity pressure The other manometer at the duct wall reads static pressure Since TP = VP + SP, then the total pressure of the system is w.c. Page 46 Summer Review Course: Industrial Ventilation
47 Static Pressure Measurement Page 47 Summer Review Course: Industrial Ventilation
48 Fans Must provide required flow and static pressure Types 1. Axial (window fan) Flow parallel to fan shaft (propeller); not used in local exhaust ventilation systems 2. Centrifugal Flow perpendicular to axis of rotation; industrial ventilation use Page 48 Summer Review Course: Industrial Ventilation
49 1. Radial Types of Centrifugal Fans Classified by impeller blade shape Most common; least sensitive to particulate laden gas streams Can handle high static pressures 2. Backward curve For low particulate loads; higher efficiency but accumulates solids 3. Forward curve Used for heating & AC systems Minimal use in industrial ventilation Page 49 Summer Review Course: Industrial Ventilation
50 Fan Law Basics Static pressure rise across fan increases rapidly as fan speed is increased Relationship between gas flow rate (Q) and fan motor current is not linear; the non-linear characteristic of the relationship is indicated by the brake horsepower curve The fan motor current is directly proportional to the brake horsepower Page 50 Summer Review Course: Industrial Ventilation
51 Fan Law #1 1. As the speed increases (rpm), the airflow rate increases (Q) Q 2 = Q 1 (rpm 2 /rpm 1 ) Where: Q 1 = baseline airflow rate, CFM Q 2 = new airflow rate, CFM Rpm 1 = baseline fan wheel rotational speed, revolutions per minute Rpm 2 = new fan wheel rotational speed, revolutions per minute Page 51 Summer Review Course: Industrial Ventilation
52 Fan Law #2 2. Fan static pressure is proportional to rpm 2 Where: Fan SP 2 = Fan SP 1 (rpm 2 /rpm 1 ) 2 Fan SP 1 = baseline fan static pressure, in. W.C. Fan SP 2 = new fan static pressure, in. W.C. Rpm 1 = baseline fan wheel rotational speed, revolutions per minute Rpm 2 = new fan wheel rotational speed, revolutions per minute Page 52 Summer Review Course: Industrial Ventilation
53 Fan Static Pressure The air stream moving through the fan experiences a static pressure rise due to the mechanical energy expended Static pressure at the outlet is always higher than the static pressure at the inlet Fan ΔSP 2 = SP fan outlet - SP fan inlet - Vp fan inlet SP fan outlet = static pressure at fan outlet, in W.C. SP fan inlet = static pressure at fan inlet, in W.C. Vp fan inlet = velocity pressure at fan outlet, in W.C. Page 53 Summer Review Course: Industrial Ventilation
54 Static Pressure Rise Across a Fan Page 54 Summer Review Course: Industrial Ventilation
55 Brake Horsepower (bhp) The actual horsepower required to move air through a ventilation system against a fixed total pressure plus losses in the fan Fan bhp = ahp * (1/efficiency) Where: ahp = air horsepower or theoretical hp required to drive a fan with no losses (100% efficient) eff = fan mechanical efficiency Page 55 Summer Review Course: Industrial Ventilation
56 Brake Horsepower BHP = I * E * 1.73 * Eff * P.F./746 Where: BHP = Brake horsepower (total power consumed by fan) I = Fan motor current, amperes E = Voltage applied, volts Eff = Efficiency, expressed as a decimal P.F. = Power factor (phase relationship between current and voltage waveforms) Page 56 Summer Review Course: Industrial Ventilation
57 Where: Q = flow (cfm) TP = total pressure Brake Horsepower BHP = Q(TP)/(6362)ME ME = mechanical advantage of fan (usually ) Page 57 Summer Review Course: Industrial Ventilation
58 Fan Law #3 3. Brake horsepower is related to the cube of the fan speed BHP 2 = BHP 1 (rpm 2 /rpm 1 ) 3 Where: Fan BHP 1 = baseline brake horsepower Fan BHP 2 = new brake horsepower Rpm 1 = baseline fan wheel rotational speed, revolutions per minute Rpm 2 = new fan wheel rotational speed, revolutions per minute Page 58 Summer Review Course: Industrial Ventilation
59 General Ventilation Dilution ventilation is a form of exposure control that involves providing enough air in the workplace to dilute the concentration of airborne contaminants to acceptable levels Page 59 Summer Review Course: Industrial Ventilation
60 Appropriate when: Dilution Ventilation Emission sources contain materials of relatively low hazard, as assessed by the toxicity, dose rate, and low individual susceptibility Emission sources are primarily vapors or gases or small, respirable-size aerosols not likely to settle Emissions occur uniformly Emissions are widely dispersed Page 60 Summer Review Course: Industrial Ventilation
61 Dilution Ventilation A simple case assumes: Perfect mixing of air in the room Constant generation rate of contaminant(s) Example: Dip tank emissions Page 61 Summer Review Course: Industrial Ventilation
62 Box Model General Exhaust Ventilation C = concentration as a function of time (ppm) G = contaminant generation rate (constant) Q = ventilation rate (cfm) V = room volume (ft 3 ) Page 62 Summer Review Course: Industrial Ventilation
63 General Exhaust Ventilation To estimate the flowrate needed to achieve TLV assuming constant emission and constant room ventilation rates Q = 403 * SG * ER * K * 10 6 MW * TLV Where: C = contaminant concentration (ppm) SG = specific gravity ER = emission rate (pints/minute) K = mixing factor (3 10) MW = molecular weight (gm/gm-mol) Q = ventilation rate (cfm) TLV = desired value and/or TLV (ppm) Page 63 Summer Review Course: Industrial Ventilation
64 General Exhaust Ventilation To calculate for transient concentrations (releases): Purging: Decreases from an initial concentration with zero generation OR C t = C 0 * e tq/kv C t = C 0 * e -t Nchanges Where: T = time (minutes) Q = ventilation rate (cfm) K = mixing factor V = room volume (ft 3 ) N changes = number of air changes per hour Page 64 Summer Review Course: Industrial Ventilation
65 Purge Example Find the purge time required to safely enter a room 12.5 x 10 x 8 with an initial contaminant concentration of 3000 ppm. Assume the ventilation rate is 500 cfm, a mixing factor of 3, the TLV is 100 ppm. Answer: minutes Page 65 Summer Review Course: Industrial Ventilation
66 General Exhaust Ventilation Accumulating example concentrations increase from initial with a generation rate > 0 Or C = G/Q(1-e Nt/60 ) * 10 6 C = G/Q(1-e Qt/V ) * 10 6 Where: C = contaminant concentration (ppm) N = number of air changes per hour G = vapor generation rate (mg/min) T = time (minutes) Q = ventilation rate (cfm) ** effective (Q/K) Page 66 Summer Review Course: Industrial Ventilation
67 Accumulation and Purge Combined Page 67 Summer Review Course: Industrial Ventilation
68 Biological Safety Cabinets Page 68 Summer Review Course: Industrial Ventilation
69 Laminar Flow Hoods (Non Protective) Page 69 Summer Review Course: Industrial Ventilation
70 Fume Hood Acceptance Testing ASHRAE establishes a procedure to assess containment (leakage rate) of laboratory fume hoods Assumes proper laboratory design (low terminal supply air velocity at hood opening, hoods installed away from windows & heavy traffic areas) Establishes qualitative & quantitative criteria to assess hood performance Qualitative: Smoke reflux at opening (small & large source) Quantitative: Face velocity, tracer gas concentration at hood opening Considers sash movement effect for VAV exhaust systems Page 70 Summer Review Course: Industrial Ventilation
71 ASHRAE Acceptance Criteria Typical Acceptance Criteria expressed as: Where: AM = as manufactured AI = as installed AU = as used 4.0 AM/AI/AU = release rate of SF6, lpm 0.05 = acceptable control (leakage) level, ppm Page 71 Summer Review Course: Industrial Ventilation
72 Additional References ACGIH. Industrial Ventilation: A Manual of Recommended Practice ASHRAE Fume Hood Test Method National Science Foundation Standard 49 (Biosafety Cabinet) Page 72 Summer Review Course: Industrial Ventilation
73 Thank You! Tom Block Page 73 Summer Review Course: Industrial Ventilation
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