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Microsoft PowerPoint - modera-new How is Duct Sealing Emerging as
an Energy Efficiency Technology
Mark Modera
Carrier-Aeroseal, LBNL
ACEEE Emerging Technologies Meeting
October 14
th
2004
San Francisco, CA Presentation Outline
Current Events in Duct Sealing
ASHRAE Standard 152
California 2005 Energy Efficiency Standards
Aeroseal
What is Aeroseal?
How is it Sold?
Diagnostic Results
Sealing Results
New Technology
Future Directions
Duct Sealing in Commercial Buildings
Utilities and Duct Sealing Current Events: ASHRAE Standard 152
Published March 2004
- Duct Leakage and Fan
Flow Test Procedures
s
- Design Efficiency
Calculations (Capacity and
Peak Demand)
- Seasonal Efficiency
Calculations (Energy
Savings) Current Events: ASHRAE Standard 152
Duct Leakage Testing
Procedures for
Duct Blaster Test
With and Without a
Blower Door
Duct Leakage at
Normal Operating
Pressures
HVAC Fan Flow Testing
Duct Blaster Technique
Flow Plate Technique Current Events: ASHRAE Standard 152
Calculation Procedures
Design and Seasonal
Efficiency for Air and
Hydronic Systems
Impacts of Leakage,
Location, Insulation,
Climate
Impacts of Air Flow and
Equipment Interactions Who Uses ASHRAE 152?
Energy Star Program
Duct Investor
Energy Codes
California Title-24
Energy Utilities?
Program Design
Program Evaluation
Interactions with HVAC Equipment ASHRAE 152 in Energy Star
Duct Investor ASHRAE 152 and System Performance
Sealing and Super-Insulation in Sunbelt
Duct Improvement Savings in California CZ-13
0%
5%
10%
15%
20%
25%
30%
35%
40%
Heating, design
Heating,
seasonal
Cooling, design
Cooling,
seasonal
4/4 R4.2
11/11 R38
4/4 R38 ASHRAE 152 and System Performance
Two-Stage Equipment in Sunbelt
Very Sensitive to Duct Leakage and Conduction Losses
Attic Ducts in Atlanta
0
2
4
6
8
10
12
14
0
10
20
30
40
% leakage
SEER
12 SEER 1-s
15 SEER 2-s ASHRAE 152 and System Performance
Two-Stage Equipment in Sunbelt
Very Sensitive to Duct Leakage and Conduction Losses
Attic Ducts in Atlanta
0%
10%
20%
30%
40%
50%
Unsealed 2-Speed
15 SEER vs.
Unsealed 12-SEER
2-Speed/Sealed
vs. Unsealed 12-
SEER
2-Speed/Sealed
vs. Unsealed 2-
Speed 15-SEER
E
n
e
r
gy
S
a
v
i
ngs ASHRAE 152 and System Performance
Two-Stage Equipment in Frostbelt
LESS Sensitive to Duct Leakage and Conduction Losses
Basement Ducts in Chicago
0%
10%
20%
30%
40%
Unsealed 2-Speed
15 SEER vs.
Unsealed 12-SEER
2-Speed/Sealed
vs. Unsealed 12-
SEER
2-Speed/Sealed
vs. Unsealed 2-
Speed 15-SEER
E
n
er
g
y
S
avi
n
g
s 2005 California Energy Efficiency Code
Part of Base Case Design in New Construction
Savings must be replaced if sealing is not
performed
Has viability of alternatives changed?
Verified Sealing at Duct or HVAC Equipment
Replacement starting in 2005
Third-Party Testing
Residential and Light Commercial
Depends upon Permit Process What is Aeroseal?
A technology that seals duct leaks from the inside
more than
12,000
systems sealed to date
A business system that includes
Diagnostic Tools
and Protocols
A computer-driven technician-feedback and utility-
feedback system driven by
HVAC dealers
A
Quality Assurance
system that requires internet
uploading of all diagnostic and sealing data What is Aeroseal? What is Aeroseal?
History
California Utilities (CIEE), EPRI, DOE and EPA fund Duct
Research at Lawrence Berkeley National Laboratory (LBNL)
1994
research yields Aerosol Sealing Technology Patent
1997
Aeroseal receives exclusive license
1999
- First applications by HVAC dealers
2001
Aeroseal purchased by Carrier Corporation
2003
Carrier-Aeroseal obtains license for Large
Commercial Buildings and FASTER technology from LBNL What is Aeroseal?
Sealing Documentation What is Aeroseal?
FAQs
Does not coat
the ducts
Vinyl polymer is
safe
No lingering odors
or off-gassing
Lasts
10+ years What is Aeroseal?
FAQs
Seals holes up to
3/8
across
Sealant remains
rubbery
Need not clean
before sealing
Cleaning after sealing generally does
not hurt seals What is Aeroseal?
FAQs
Does not coat
the ducts
Vinyl polymer is
safe
No lingering odors
or off-gassing
Lasts
10+ years How is Aeroseal Sold?
Existing Residences
At HVAC Equipment Replacement
Comfort, Energy, Capacity and IAQ
Stand Alone Sealing - Diagnostics
New Residences
Efficiency, Energy Star and Quality Control
Light Commercial
Energy Savings and Peak Reduction
Large Commercial
Fan Power Savings How is Aeroseal Sold?
Comfort
Customer Satisfaction with HVAC System
0%
10%
20%
30%
40%
50%
60%
70%
80%
90%
NOT AT ALL
NOT VERY
SOMEWHAT
VERY
Before
Aeroseal
After
Aeroseal How is Aeroseal Sold?
Energy
S E E R L o s s D u e to A tt ic D u c t L e a ka g e
(F r e s n o , C A ) 2 -s p e e d im p a c ts
-7 .0
-6 .0
-5 .0
-4 .0
-3 .0
-2 .0
-1 .0
0 .0
0%
1 0%
2 0%
3 0 %
4 0 %
50 %
60 %
O ve ra ll D u c t L e a ka g e
Loss
of
SEE
R
10 S E E R
12 S E E R
14 S E E R How is Aeroseal Sold?
Capacity
C ap ac ity L oss D ue to A ttic D u ct L e ak age
(Fre s no, C A )
-3.0
-2.5
-2.0
-1.5
-1.0
-0.5
0.0
0%
10%
20%
30%
40%
50%
60%
Overall Du ct Leakage
C
h
a
n
ge
i
n
C
a
pa
c
i
t
y
[
T
on
s
]
5-ton
4-ton
3-ton How is Aeroseal Sold?
IAQ
Sunbelt
- Uncontrolled Return Air, Excess Humidity Aeroseal Diagnostic Process
Perform duct leakage test
Measure room airflow
Measure register temperature
Evaluate return air performance
Visually inspect ductwork
Test for combustion safety Combustion Safety Diagnostic Data
Percentage of Homes with <3Pa in Combustion
Zone
0%
2%
4%
6%
8%
10%
12%
14%
16%
Sacramento
A (994)
Sacramento
B (1048)
Sacramento
C (120)
Bakersfield
(14)
Illinois (20) Register Flow Diagnostic Data
T o ta l R e g is te r F lo wra te s
0
5 0
1 0 0
1 5 0
2 0 0
2 5 0
3 0 0
3 5 0
S a c ra m e n to
A (2 1 5 9 )
S a c ra m e n to
B (1 8 9 8 )
S a c ra m e n to
C (5 5 6 )
B a k e rs fie ld
(4 7 )
Illin o is (4 2 )
Flow [cfm/ton] Residential Thermal Diagnostic Data
Registers with >25% Thermal Loss
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
Sacramento
A (525)
Sacramento
B (960)
Sacramento
C (374)
Bakersfield
(32)
Illinois (26)
Number of Registers Residential Duct Leakage Data Residential Duct Leakage Data
Pre-Sealing Duct Leakage
0
100
200
300
400
500
600
700
800
900
Sacramento
A (443)
Sacramento
B (279)
Sacramento
C (110)
Bakersfield
NEW (1231)
Illinois
(1065)
Leakage [cfm@25Pa] Residential Leak Sealing
Fraction of Leakage Sealed
0
10
20
30
40
50
60
70
80
90
100
Sacramento
A (781)
Sacramento
B (513)
Sacramento
C (556)
Bakersfield
NEW (1223)
Illinois
(1060)
Sealed [%] New Aeroseal Injection Technology
New Nozzle Patent
Smaller particles
No dilution needed
No 220V heaters needed
Narrow Spray Angle
Direct Injection in Ducts and Shafts
New Sealing Control
Weather Optimized Injection
Adjustment for Flow, Temperature, Humidity
Performance
3-10 times faster sealing New Aeroseal Injection Technology New Technology Performance
High Pressure vs. Old Injection
0.0
200.0
400.0
600.0
800.0
1000.0
1200.0
Fraction Sealed
[% *10]
Injection Time
[minutes]
Average Seal Rate
[cfm/h]
HP Injection (16)
Old Injector (995) Light Commercial Duct Sealing
Southern California Sealing Program Average Initial Leakage
(400 systems) 36%
of fan flow Average Final Leakage 6%
of fan flow 152 vs. Measured Savings:
Light Commercial
Savings from Sealing 46% Total Leakage to 2%
(Sacramento CA)
0%
5%
10%
15%
20%
25%
30%
35%
40%
S1 (ave.)
S2 (ave.)
S1 (peak)
S2 (peak)
Measured Control 1
Measured Control 2
ASHRAE Std. 152 Estimate Aerosealing Commercial Ducts Aerosealing Large Commercial Ducts Aerosealing Large Commercial Ducts
Case Study
78,000 ft
2
office building
O.88
cfm/ft2
14%
leakage according to Test and Balance report
13,300
cfm@25
leakage encountered
87%
sealed