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ASSIGNMENT

OF PLFD

AIR CONDITIONING IN GARMENT/OTHER INDUSTRIES Machines give off heat. For example, workers who use garment presses or die casting equipment are always near hot machines and materials. If the factory does not have good ventilation or a cooling system, the air around these machines can become dangerously hot. The best way to protect workers from too much heat is to keep the air inside the factory cool. If the outside air is very hot and humid, air conditioning may be the only way to keep the factory cool enough inside to be safe for all workers. The whole factory does not have to be air conditioned. Cooled air can be blown through ducts to the spot where each worker sits or stands. Most factory buildings can be kept cool with a good ventilation system, plenty of air space, insulation, and shade.

AIR CONDITIONING Air conditioning includes both the cooling and heating of air. It also cleans the air and controls the moisture level. An air conditioner is able to cool a building because it removes heat from the indoor air and transfers it outdoors. A chemical refrigerant in the system absorbs the unwanted heat and pumps it through a system of piping to the outside coil. The fan, located in the outside unit, blows outside air over the hot coil, transferring heat from the refrigerant to the outdoor air.

Basic Operations Most air conditioning systems have five mechanical components: 1. Compressor 2. Condenser 3. Expansion Device 4. Evaporator

1. Compressor:

The compressor (which is controlled by the thermostat) is the "heart" of the system. The compressor acts as the pump, causing the refrigerant to flow through the system. Its job is to draw in a low-pressure, low-temperature, refrigerant in a gaseous state and by compressing this gas, raise the pressure and temperature of the refrigerant. This high-pressure, high-temperature gas then flows to the condenser coil.

2. Condenser:

The condenser coil is a series of piping with a fan that draws outside air across the coil. As the refrigerant passes through the condenser coil and the cooler outside air passes across the coil, the air absorbs heat from the refrigerant which causes the refrigerant to condense from a gas to a liquid state. The high-pressure, high-temperature liquid then reaches the expansion valve.

3. Expansion Device:

The expansion valve is the "brain" of the system. By sensing the temperature of the evaporator, or cooling coil, it allows liquid to pass through a very small orifice, which causes the refrigerant to expand to a low-pressure, lowtemperature gas. This "cold" refrigerant flows to the evaporator coil.

4. Evaporator: The evaporator coil is a series of piping connected to a furnace or air handler that blows indoor air across it, causing the coil to absorb heat from the air. The cooled air is then delivered to the house through ducting. The refrigerant then flows back to the compressor where the cycle starts over again.

APPLICATION OF REFRIGERATION AND AIR CONDITIONING The largest application of refrigeration is for air conditioning. In addition, refrigeration embraces industrial refrigeration including the processing and preservation of food, removing heat from substances in chemical, petroleum and petrochemical plants, and numerous special applications such as those in the manufacturing and construction industries. In a similar manner, air conditioning embraces more than cooling. The comfort air conditioning is the process of treating air to control simultaneously its temperature humidity, cleanliness, and distribution to meet the comfort requirements of the occupants of the conditioned space. Air conditioning, therefore, includes entire heating operation as well as regulation of velocity, thermal radiation, and quality of air, including removal of foreign particles and vapours. Some applications of refrigeration and air conditioning are as follows : 1. Air Conditioning of Residential and Official Buildings Most of the air conditioning units are devoted for comfort air conditioning that is meant to provide comfortable conditions for people. Air conditioning of building is required in all climates. In the summer, living/working spaces have to be cooled and in the winter the same have to be heated. Even in places where temperature remains normal, cooling of the building is required to remove the heat generated internally by people, lights, mechanical and electrical equipment. Further in these

buildings, for the comfort, humidity and cleanliness of air has to be maintained. In hospitals and other medical buildings, conditions on cleanliness and humidity are more stringent. There ventilation requirements often specify the use of 100 percent outdoor air, and humidity limits. 2. Industrial Air Conditioning The term industrial air conditioning refers to providing at least a partial measure of comfort for workers in hostile environments and controlling air conditions so that they are favorable to processing some objects or materials. Some examples of industrial air conditioning are the following: Spot Heating

In a cold weather it may be more practical to warm a confined zone where a worker is located. One such approach is through the use of an infrared heater. When its surfaces are heated to a high temperature by means of a burner or by electricity, they radiate heat to the affected area. Spot Cooling

If a specific area has to be cooled, it will be unwise to cool entire room or factory. In this case, conditions may be kept tolerable for workers by directing a stream of cool air onto occupied areas.

3. Environmental Laboratories The role of air conditioning may vary from one laboratory to the other. In one laboratory, a very low temperature, say 40oC must be maintained to test certain equipment at low temperatures, and in another, a high temperature and humidity may be required to study behaviour of animals in tropical climates.

4. Printing In printing industries, control of humidity is a must. In some printing processes the paper is run through several different passes, and air conditioning must be maintained to provide proper registration. If the humidity is not properly maintained the problems of static electricity, curling or buckling of paper or the failure of the ink to dry arise.

5. Textiles Like paper, textiles are sensitive to changes in humidity and to a lesser extent changes in temperature. In modern textile plants, yarn moves at very high speeds and any changes in flexibility and strength of the yarn because of the change in humidity and temperature will thus affect the production.

6. Precision Parts and Clean Rooms In manufacturing of precision metal parts air conditioning helps to (a) keep the temperature uniform so that the metal will not expand and contract, (b) maintain humidity so that rust is prevented and (c) filter the air to minimize dust.

7. Photographic Products Raw photographic materials deteriorate fast in high humidity and temperatures. Other materials used in coating film also require a careful control of temperature. Therefore, photographic-products industry is a large user of refrigeration and air conditioning.

8. Computer Rooms In computer rooms, air conditioning controls temperature, humidity and cleanliness of the air. Some electronic components operate in a faulty manner if they become too hot. One means of preventing such localized high temperature is to maintain the air temperature in the computer room in the range of 20 to 23 0C. The electronic components in the computer functions favourably at even lower temperatures, but this temperature is a compromise with the lowest comfortable temperature for occupants. A relative humidity of about 65% is maintained for comfort condition. 9. Air Conditioning of Vehicles For comfortable journey, planes, trains, ships, buses are air conditioned. In many of these vehicles the major contributor to the cooling load is the heat from solar radiation and in case of public transportation, heat from people. 10. Food Storage and Distribution Many meats, fish, fruits and vegetables are perishable and their storage life can be extended by refrigeration. Fruits, many vegetables and processed meat, such as sausages, are stored at temperatures just slightly above freezing to prolong their life. Other meats, fish, vegetables and fruits are frozen for many months at low temperatures until they are defrosted and cooked by consumer.

TYPES OF AIR CONDITIONING SYSTEMS USED IN INDUSTRIES 1. HVAC SYSTEM

Heating, Ventilating, and Air Conditioning (HVAC) equipment perform heating and/or cooling for residential, commercial or industrial buildings. The HVAC system may also be responsible for providing fresh outdoor air to dilute interior airborne contaminants such as odours from occupants, volatile organic compounds (VOCs) emitted from interior furnishings, chemicals used

for cleaning, etc. A properly designed system will provide a comfortable indoor environment year round when properly maintained.

An air conditioner cools and dehumidifies the air as is passes over a cold coil surface. The indoor coil is an air-to-liquid heat exchanger with rows of tubes that pass the liquid through the coil. Finned surfaces connected to these tubes increase the overall surface area of the cold surface thereby increasing the heat transfer characteristics between the air passing over the coil and liquid passing through the coil. The type of liquid used depends on the system selected. Direct-expansion (DX) equipment uses refrigerant as the liquid medium. Chilled-water (CW) can also be used as a liquid medium. When the required temperature of a chilled water system is near the freezing point of water, freeze protection is added in the form of glycols or salts. Regardless of

the liquid medium used, the liquid is delivered to the cooling coil at a cold temperature. In the case of direct expansion equipment, the air passing over the indoor cooling coil heats the cold liquid refrigerant. Heating the refrigerant causes boiling and transforms the refrigerant from a cold liquid to a warm gas. This warm gas (or vapour) is pumped from the cooling coil to the compressor through a copper tube (suction line to the compressor) where the warm gas is compressed. In some cases, an accumulator is placed between the cooling coil and the compressor to capture unused liquid refrigerant and ensures that only vapour enters the compressor. The compression process increases the pressure of the refrigerant vapour and significantly increases the temperature of the vapour. The compressor pumps the vapour through another heat exchanger (outdoor condenser) where heat is rejected and the hot gas is condensed to a warm high pressure liquid. This warm high pressure liquid is pumped through a smaller copper tube (liquid line) to a filter (or filter/dryer) and then on to an expansion device where the high pressure liquid is reduced to a cold, low pressure liquid. The cold liquid enters the indoor cooling coil and the process repeats. As this liquid passes through the indoor cooling coil on the inside of the heat exchanger, two things happen to the air that passes over the coils surface on the outside of the heat exchanger. The airs temperature is lowered (sensible cooling) and moisture in the air is removed (latent cooling) if the indoor air dew point is higher than the temperature of the coils surface. The total cooling (capacity) of an AC system is the sum of the sensible and latent cooling. Many factors influence the cooling capacity of a DX air conditioner. Total cooling is inversely proportional to outdoor temperature. As the outdoor temperature increases the total capacity is reduced. Air flow over the indoor cooling coil also affects the coils capacity and is directly proportional to the total capacity of an AC system. As air flow increases, the total capacity also increases. At higher air flow rates the latent capacity of the cooling coil is reduced. Indoor temperature and humidity also affect the total capacity of the AC system. As indoor temperatures increase, the sensible capacity also increases. Similarly, as indoor relative humidity increases the latent capacity

of the AC system increases. Manufacturers of AC equipment typically provide a performance map of specific equipment to show how total, s ensible, and latent capacity change with changing indoor and outdoor temperatures and humidity. Power consumption and energy efficiency are also provided in these charts. Types of AC systems available in HVAC are:

1) Cooling Only Split-System:

A split system is a combination of an indoor air handling unit and an outdoor condensing unit. The indoor air handling unit contains a supply air fan and an air-to-refrigerant heat exchanger (or cooling coil), and the expansion device. The outdoor condensing unit consists of a compressor and a condenser coil. Split-systems are typically found in residential or small commercial buildings. These systems have the highest energy efficiency rating (EER) of all the available AC systems. Manufacturers are required to take the EER rating a step further and provide a seasonal energy efficiency rating (SEER) for use by consumers. SEER ratings vary widely and range from 10 to 20. The higher the SEER rating, the more efficient the AC system operates. If heating is required, an alternate method of heating the interior of the building must be used, usually in the form of electric or gas heating.

2) Cooling Only Packaged-System A packaged system is a single unit combining all the components described in the split system. Since the unit is a package, it must be placed outside the building and indoor air is ducted from the building to the packaged system and back through an air distribution system. These units typically have SEER rating from 10 to 18. If heating is required, an alternate method of heating the interior of the building must be used, usually in the form of electric or gas heating.

3) Heat Pump Heat pumps are similar to cooling only systems with one exception. A special valve in the refrigeration piping allows the refrigeration cycle to be operated in reverse. A cooling only system cools the indoor air and rejects heat to the outdoors. A heat pump can also cool the indoor air, but when the valve is reversed, the indoor air is heated. A supplementary electric resistance heater may also be used to assist the heat pump at lower outdoor temperatures. In colder climates, heat pumps require a defrost period. During defrost times the electric heater is the only means of heating the interior of the building. These units are manufactured as either split or packaged systems. 4) Chilled Water System In a chilled water system, liquid water is pumped throughout the building to chilled water coils. Since the liquid water needs to be at a cold temperature, a cooling plant is required. The plant is typically referred to as a chillier plant. Vapour compression equipment in the plant, similar to that described in How does my AC work, cool water to a cold temperature and pump the cold water to air-to-water heat exchangers where needed. 5) Window Air Conditioners As the name implies, a window air conditioner is typically installed in a window or custom opening in a wall. The Window AC can only cool small areas and are not intended to provide cooling to multiple rooms or zones. These air conditioners are manufactured as cool only or can provide both cooling and heating. An optional damper in the unit can provide fresh outdoor air if necessary. 6) Packaged Terminal Heat Pump Packaged terminal heat pumps (PTHP) are are similar to a windowmounted air conditioner. These units are typically installed in a sleeve

passing through the outdoor wall of an apartment, hotel, school classroom, etc. PTHPs are completely self contained and require only an electrical connection in addition to the opening in the building shell. They use the outdoor air as the heat source in winter and as a heat sink in summer. They also can provide ventilation air. Flexibility and lower installed cost are the primary advantages of the PTHP. Disadvantages include in-room maintenance, higher operating cost, relatively short life, imprecise "on-off" temperature control, and they can be rather noisy. How is humidity controlled with an AC system? Humidity is becoming more of a concern to building operators and owners. High indoor humidity leads to mold and mildew growth inside the building. There are several methods of controlling indoor humidity. The simplest (and most expensive) method is to connect a humidistat to an electric heater. When the humidity inside the building rises above the humidistat set point, the heater is turned on. The additional heat causes the air conditioning system to run longer and remove more moisture. A more efficient method of controlling humidity is to use the waste heat from the refrigeration cycle itself. Instead of rejecting the waste heat outdoors, the heat is directed inside when humidity control is required. One form of heat reclaim is called hot-gas reheat or refrigerant de superheating where refrigerant is passed through a heat exchanger located downstream of the cooling coil. The hot high pressure vapour leaving the compressor passes through this heat exchanger prior to entering the condenser coil. This in turn heats the indoor air and again causes the AC system to run longer to meet the thermostat set point. Although more energy is used, this is much more efficient than turning on an electric heater. Another form of heat reclaim is called sub-cool reheat. This strategy takes the warm liquid refrigerant from the condenser and passes it through a heat exchanger located downstream of the cooling coil. Less heat is available using this method because the majority of the heat has already been rejected at the condenser. Since more energy is used to pump liquid (as opposed to a gas) through the heat exchanger it would appear that this method is less efficient than the hot-gas method, however, the liquid in the heat exchanger is sub-cooled in the cold supply air stream which increases the capacity

of the air conditioner. Since more capacity is available, the AC unit is able to meet the thermostat more quickly. Heat pipe heat exchangers or run-around coils perform a similar function when humidity control is required. Two heat exchangers are placed in the air stream, one upstream of the cooling coil and the other downstream of the cooling coil. These heat exchangers are connected together with piping. A heat transfer fluid, whether it be water or refrigerant, is either pumped or gravity fed from one heat exchanger to the other. The heat exchanger downstream of the cooling coil (re-heat coil) cools the liquid medium inside the heat exchanger and heats the air passing over the heat exchanger. The cold liquid inside the heat exchanger is moved to the heat exchanger upstream of the cooling coil (pre-cool coil) where it pre-cools the air passing over the heat exchanger and warms the liquid passing through the heat exchanger. The affect of a heat pipe or run-around coil is to reduce the sensible heat capacity of the AC system. The latent capacity of the AC system increases if directexpansion equipment is used or remains relatively constant if chilled water equipment is used. Since the sensible capacity of the AC system has been reduced, the system must run longer to meet the thermostat set point thereby removing more moisture. How do refrigerants deplete the Ozone layer? Refrigerant 22 (R-22 or MonoChloroDiFlouroMethane, CHClF2) is one of the most common refrigerants and is used in a wide variety of applications such as refrigeration, aerosol propellants, cleaning solvents, and foaming agents for plastics. This refrigerant is believed to be partially responsible for damaging the earths ozone layer and its use is being phased out over the next two decades. The ozone layer is a result of sunlight reacting with oxygen to produce a layer in the stratosphere more than 10 km above the earths surface. As R-22 refrigerant escapes from an AC system through leaks or is released into the atmosphere by other means, the R-22 molecule containing the chlorine atom (monochloro) rises in the atmosphere. Sunlight breaks down the R-22 molecule to yield a free chlorine radical (Cl-). The free chlorine radical combines with ozone (O3), decomposing it into normal oxygen (O2).

AC refrigerants come in many varieties. R-22 is the most common, however, due to interactions with the ozone layer R-22 is being phased out. Refrigerants manufactured as replacements for R-22 are HFC-134a, R-410a, R-410b to name a few. The new refrigerants do not contain the chlorine atom and are not harmful to the earths ozone layer. 2. INDUSTRIAL AIR CONDITIONING SYSTEM In a commercial facility, personal comfort was often an adjunct to equipment maintenance; those who worked with or near equipment that needed to be kept cool were the incidental benefactors of industrial air conditioning. Much is made today, however, of what is known as sick building syndrome.

They can relieve the discomfort of allergies by removing pollen from the air, make long commutes less taxing on drivers and passengers alike, and even help to preserve the health of patients in hospitals. In business and industry, air conditioning systems can improve the efficiency of workers, ensure uniformity in metal work, prevent too much or too little moisture from damaging fragile paper products during manufacture, and keep food fresh during longs periods of shipment and storage.

A deadly enemy of most electronic equipment and personal productivity is heat. Air conditioning is the mechanical replacement of heat with cooled air. In years past, most large commercial buildings and manufacturing facilities are equipped with industrial air conditioning units in part to alleviate the problems associated with overheating of electronic equipment such as computers, electronic testing instruments, and precision electronic manufacturing

equipment. Machinery used to produce critical equipment, usually including precise measurements and tolerances, requires constant cooling to function properly. In a commercial facility, personal comfort was often an adjunct to equipment maintenance; those who worked with or near equipment that needed to be kept cool were the incidental benefactors of industrial air conditioning. Much is made today, however, of what is known as sick building syndrome. This term refers to office buildings, schools, manufacturing, production, and testing facilities where air quality is such that workers, students, customers, clients, and visitors to these facilities were becoming ill simply from remaining in such buildings for any length of time. These various illnesses were the result of breathing and absorbing unhealthful vapors and contaminants emitted by materials used in the construction of the building, as well as inadequate heating, ventilation or air conditioning (HVAC) equipment. Thus, industrial air conditioning is now critical to individual comfort and personal health, not to mention optimum productivity of workers as well as equipment. Nearly all modern industrial air conditioning units are now either ductless or split air conditioning systems, or a combination of both. The cooling machinery, fans, compressors, condensers, cooling towers, air handling, condensate recovery and discharge components are located at a remote location outside the building or facilities, either on the roof or grounds of the facility. The actual discharge of cooled air is accomplished by small, compact units located in various rooms, offices and spaces throughout the interior of the building. Often these room units are separately controlled via individual thermostats. Such is the beauty of ductless air conditioning. Ducted equipment, on the other hand, usually involves an inefficient dampening of louvers to maintain individual room temperature.

The size and capacity of industrial air conditioning equipment is, obviously dependant on the size and design of the facility to be cooled. Industrial air conditioning units commonly range from some two tons, or 24,000 British Thermal Units (BTU) to 150 tons to 150 tons (1,800,000 BTU). A BTU is the amount of heat necessary to raise the temperature of a pound of water one degree, Fahrenheit.

3. Direct Expansion Air Conditioning A direct expansion air conditioning (DX) system uses a refrigerant vapour expansion/compression (RVEC) cycle to directly cool the supply air to an occupied space.

DX systems (both packaged and split) directly cools the air supplied to the building because the evaporator is in direct contact with the supply air,

Expansion refers to the treatment of the refrigerant (a valve reduces its pressure and temperature) prior to it entering the evaporator. DX systems can come equipped with all the components in the unit (packaged system) intended for installation on the rooftop or by the side of a building; or it may have some components installed inside the building and some outside (split system). DX systems require a ventilation fan to distribute the cool air and resupply/re-circulate it.

A RVEC cycle has four basic components; an evaporator, compressor, condenser, and thermal expansion control device. The evaporator (located inside the supply air ductwork) absorbs heat through the process of expanding the refrigerant flowing within it. The refrigerant then flows to a compressor which compresses it causing it to condense in the condenser and release the heat it removed from the supply air. The condensed liquid refrigerant then flows through the thermal expansion control device which controls the flow and pressure of the refrigerant back into the evaporator.

Packaged Systems Packaged DX units contain all 4 parts of the RVEC system, as well as fans and internal ducting. These units are designed to be installed easily to serve local zones cooling needs; multiple units can be installed to service multiple zones in a building.

Split Systems These systems generally have the evaporator and fans inside the building, while the rest of the refrigerant vapour expansion/compression (RVEC) system components are a separate unit placed outside the building. This allows system designs that are more flexible, allowing performance that can satisfy greater variations on system demands. Split units are made to an incremental performance scale, meaning only certain working load sizes are available.

Benefits:

DX systems are less expensive to install, and uses less space in mechanical and electrical rooms than centralized cooling systems

DX systems can be expanded in an incremental fashion to match changing building requirements

Packaged Systems have standardized operating performances per unit, allowing more precise system sizing

Packaged Systems generally require less ventilation, and do not require dedicated condensate lines

Packaged Systems occupy less space than comparable split systems Split Systems tend to be larger allowing for fewer units, and therefore less maintenance costs than a comparable Packaged system

Split Systems have lower noise levels because the compressor unit is located further away from the cooling load area

Split Systems may allow vertical duct shafts to be smaller in size.

REFERENCES 1. http://www.hesperian.org/wpcontent/uploads/pdf/factory/Work_Dangers_5_other_dangers.pdf 2. http://www.estesair.com/Products/Air_Conditioning_Products/Air_Conditioning _Basics/ 3. http://www.ignou.ac.in/upload/Unit%201-32.pdf 4. http://www.fsec.ucf.edu/en/consumer/buildings/commercial/hvac.htm 5. http://www.wisegeek.com/what-is-industrial-air-conditioning.htm 6. http://www.nrgmanagement.ca/direct-expansion-air-conditioning-

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