Critical analysis of the condensation of water vapor at external surface of the duct

In this paper, the effects of contraction of the insulation of the air duct of heating, ventilation, and air conditioning (HVAC) system is investigated. The compression of the insulation contracts it at joint, turn and other points of the duct. The energy loss and the condensation resulted from this contraction are also estimated. A mathematical model is developed to simulate the effects of this contraction on the heat gain, supply air temperature and external surface temperature of the duct. The simulation uses preliminary data obtained from an HVAC system installed in a pharmaceutical company while varying the operating conditions. The results reveal that insulation thickness should be kept greater than 30 mm and the volume flow rate of the selected air distribution system should be lower than 1.4m 3 /s to subside condensation on the external surface of the duct. Additionally, the optimum insulation thickness was determined by considering natural gas as an energy source and fiberglass as an insulation material. The optimum insulation thickness determined for different duct sizes varies from 28 to 45 mm, which is greater than the critical insulation thickness. Therefore, the chances of condensation on the external surface of the duct could be avoided at an optimum insulation thickness. Moreover, the effect of pressure loss coefficient of the duct fitting of air distribution system is estimated. The electricity consumption in air handling unit (AHU) decreases from 2.1 to 1.5 kW by decreasing the pressure loss coefficient from 1.5 to 0.5.