Case Study Project

(Air conditioning System)

MECHANICAL & ELECTRICAL SYSTEM (SKAA 2032)

EN. KAMAL ARIFFIN

PREPARED BY:

NOOR AINOON BINTI SYAHNAN (SX161674KAWF04)

NAJLA BINTI NASHRUDDIN (SX161940KAWF04)

MUHAMMAD HAIKAL BIN MOHD KAMAL (SX161665KAWF04)

 TABLE ON CONTENT

Item Content Pages

1.0 Introduction 1

2.0 Background of Study 2

3.0 Objective 2–3

4.0 Scope of Study 3

5.0 Building / Room Survey 3

6.0 Cooling Load Calculation 3 – 14

7.0 Design 14 – 22

8.0 Cost Estimation 23 - 30

9.0 Discussion 31

10.0 Conclusion 31
1.0 Introduction

Conducting an air conditioning study is a complicated and difficult procedure

including many different stages. This derives from the nature and the differentiation of
the numerous calculations needed for the completion of this study. Unlike a heating
installation study, in which the basic stage is the calculation of thermal losses, an air
conditioning study primarily requires the calculation of cooling loads.

By completing the cooling loads calculation, the engineer conducting the study can
instantly understand the needs for cooling and air conditioning of each building space.

Structural Survey

WCT Machinery Sdn Bhd

No.3, Jalan Kenanga 4,

Sek BB11, Bukit Beruntung,

48300, Rawang Selangor.

The next stage is choosing the most appropriate air conditioning system for each
space. Different kinds of spaces require different kind of air conditioning and ventilation.
Subsequently, the right choice of the system must be done under certain criteria. In order
to install each air conditioning system, certain calculations and measurements need to be
done.

The installation study for each system must be as accurate as possible; otherwise, the
final installation will have certain miscalculation problems and functional or economic
drawbacks. The aim of this paper is to explain certain calculation methods for a complete
air conditioning study. This is accomplished in two stages: first through the theoretical
part, where certain air conditioning systems calculations methods are categorized, and
second through applied examples, which are taken from a diploma thesis.

More specifically, the systems referred are: floor fan coil units (FCUs), ceiling FCUs,
air duct network with central air conditioning units (CAUs) and variable refrigerant
volume (VRV) system. Finally, this qualitative research aims to highlight the differences

1
 of each calculation method conducted for the above systems and to give certain examples
using a case study of an industrial installation.

2.0 Background of Study

As mentioned before, this paper is based on an air conditioning study for an industrial
facility (Vrellas, 2009). This study is the planning process in theoretical level as far as
concerning the practical application and calculations required for a study from beginning
to completion. Some information was taken from two other similar diploma dissertations,
with the title “air conditioning and ventilation study of an industrial facility” (Seretoudi,
2005) and “heating study of an industrial facility” (Kiriakou, 2008). From the last,
valuable information was taken about air conditioning and heating systems.

Furthermore, certain software was used when conducting the air conditioning study to
give the measurements and the vital data for drawing the conclusions of this paper. The
software used was Adapt Manager and Auto Fine. The technical data about the orifices
were taken by the Aerogrammi (2008). Finally, while compiling the study, the following
regulations were taken into account: . ASHRAE, 1977 Fundamentals Handbook: For the
Calculation of Cooling Loads

 ASHRAE, Handbook of Systems

 ASHRAE, Handbook of Applications

 ASHRAE, Handbook of Equipment

 ASHRAE, Standards for Natural and Mechanical Ventilation

 Carrier Handbook of Air Conditioning System Design

3.0 Objective

The main core of this paper is the qualitative approach of selecting the right air
conditioning system and the best calculation method for the cases examined.

In this case study, we will find out the most accurate method for calculating the
cooling loads, the best calculation tool for installing a CAU in this factory is the

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 psychometric chart and the most suitable for calculating the air duct network of this
building.

4.0 Scope of Study

The focus is on air conditioning systems in human occupied buildings to ensure

comfort air conditioning. The energy related products in this preparatory study are
themselves a complete air conditioning system that ensures a cooling function for comfort
purposes or a part of air conditioning system that supply this function. Whether the heat
extraction is made by an intermediary water-to-air exchanger, the heat is then rejected
outside by a chiller. As for the air conditioning, a chiller can be air cooled, water-cooled
or evaporatively-cooled.

5.0 Building / Room Survey

6.0 Cooling Load Calculation

Space thermal or heat loss is the rate at which heat leaves the building during a time
interval. On the contrary, space heat gain is the rate at which heat enters a space, or heat
is generated within a space during a time interval. Thus, space cooling load is defined as
the rate that heat is removed from the conditioned space in order to maintain a constant
space air temperature. The difference between space heat gain and space cooling load is

3
due to the storage of a portion of radiant heat in the structure. The convective component
is converted to space cooling load instantaneously.

6.1 Cooling loads calculation methods

The methods of calculating cooling loads are based on equations of thermal

equilibrium between the space components and heat sources. The two basic methods for
calculating the cooling loads are: the CARRIER method and the ASHRAE method.
Generally, these two methods follow the same basic principles.

The ASHRAE methods are:

 Cooling load temperature difference (CLCD): this is a hand calculation method

based on representative results from the transfer function method;

 Transfer function method (TFM): this method uses heat accumulation factors to
convert the heat gain into cooling load; and

 Radiant time series (RTS): this is the most accurate method, because it calculates
the delayed heat gain result during a 24-hour cycle in the current cooling load.

6.2 Cooling load categorization

According to ASHRAE, the space cooling load is classified into three categories:

1) The external cooling loads, comprising of:

 Solar heat gain through fenestration areas (Qfes);

 Conduction heat gain through fenestration areas (Qfe);

 Conduction heat gain through roofs (Qrs) and external walls (Qws); and

 Conduction heat gain through interior partitions, ceilings and floors (Qic).

2) The internal cooling loads, comprising of:

 Electric lighting (sensible load only);

 People (sensible heat and latent heat); and

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  Power equipment and appliances (either sensible or latent loads, or sometimes
both).

3) Loads from infiltration and ventilation (both sensible and latent cooling loads).

Respectively, CARRIER classifies the cooling loads in the same minor categories,
without using the major categories.

6.3 Phychrometry

In the general case of air conditioning the challenge is maintaining stable conditions
within a space or even a pre-definite comfort condition. The conductor for transferring
appropriate amounts of sensible and latent heat is the air. Thus, central air conditioning in
its general form consists of the following air components:

 Fresh air: it is the air coming from the outer environment. Its input in the space is
necessary to control air quality, i.e. the content of polluting agents.

 Recirculation air: it is the amount of air that has been recollected from the space,
is being mixed with fresh air and used from the beginning by the central unit. Its
temperature and humidity are those of the conditioned space. The optimal location
from which it can be collected is the lower space, inside the living zone. 462 SS
30,5.

 Air input: it is the mixture of fresh and recirculation air, which after treatment
from the provisions of the air conditioner unit, is brought into the room within the
appropriate conditions in order to achieve the convenience conditions.

 Air discharged: it is the amount of air, which after has been recollected from the
space, is discharged to the outer environment as being inferior. The optimal
location from which it can be collected is the higher space, above the living zone,
where most pollutants gather.

The general case of air conditioning (Figure 1) represents the all air system, i.e. the
system in which the air input fully confronts both sensible and latent space cooling load,
ensuring the desired air quality. Some of the concepts below are:

 RSHF: room sensible heat factor;

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  GSHF: great sensible heat factor; and

 ESHF: effective sensible heat factor.

The slope of the RSHF straight equals the rate of sensible heat and is calculated by
Equation (1):

RSHF = RSH (1)

RLH
where RSH is the room sensible load and RLH is room latent load

Figure 1 : Psychometric chart for the general case of air conditioning

The slope of the GSHF straight equals the rate of active device heat is calculated by
Equation (2):

GSHF = TSH (2)

GTH
where TSH is the total sensible heat and GTH is total heat load of the device.

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 The slope of the straight ESHF equals the effective rate of sensible heat and is
calculated by Equation (3):
ESHF = RSH + BF x OASH (3)
RLH + BF x OATH
where OASH is the sensible load of fresh air, RTH ( = RSH + OALH) the room total
load, OATH ( = OASH + OALH) the total load of fresh air, BF the bypass factor (related
with cooling element of the unit & air speed).

6.4 FCUs connection

The FCUs can be connected with one of the following ways:

1) Two-pipe system;

2) Four-pipe system;

3) Three-pipe or Tichelman or reverse – return system; and

4) One-pipe system.

6.4.1 Two-pipe system

The two-pipe system network consists of two parallel major branches, of equal (or
almost equal, for the corresponding branches) cross sections, flow and return. Each FCU
connects its inlet to the flow branch and its outlet to the return branch. The return branch
begins from the last fan coil and the cross section increases as it is connected with the rest
of the network. Once the first fan coil is connected, the return is driven to the collector. In
this system the units have one coil.

6.4.2 Four-pipe system

The four-pipe system is actually two independent two-pipe systems. In this system the
units can have two coils. Thus, it can be realized that this option is far more expensive
and it is used in cases where simultaneous heating and cooling are required in different
zones or humidity control is desired using the hot water coil as terminal reheat.

6.4.3 Three-pipe system

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 The three-pipe system also consists of two major branches for flow and one for return.
The return, however, starts from the first FCU and the cross section increases as it is
connected with the rest of the network. Once the latter is connected, the return of the final
section goes back to the return collector.

For this very reason, this system is chosen in networks where a fast turnaround
between heating and cooling could be made. So that the system can be depressurized, and
issues like changing over from cooling to heating too fast that cause thermal shock to the
boiler can be avoided. It is most typically used with hot water heating systems (radiators).

6.4.4 One-pipe system

The single pipe system is the simplest system of all. In this system there is no return,
so all FCUs are connected with a single flow pipe. Due to circulation the cooling
performance is decreasing from unit to unit, so this system is rarely used for large
installations. Thus, it is particularly used for small and low-pressure networks with a
small number of fan coils.

6.5 Air duct calculation methods

The calculation of air duct network is often performed according to three basic
methods:

1) Constant pressure loss method (or equal friction method);

2) Static pressure recovery method; and

3) Velocity method.

6.6 Constant pressure loss method

In this method, air vents are dimensioned for constant pressure loss per length meter.
A proper speed is selected in the main duct close to the fan. The pressure loss in the main
duct is then used as a template for the rest of the system. The pressure (or friction) loss is
kept at a constant level throughout the system. The method gives an automatic velocity
reduction through the system.

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 The method may add more cross sectional changes in the main duct and can increase
the number of system components compared to other methods. Specifically, this method
involves the following steps:

1) The desired air flow is calculated according to the cooling load system or the air
rotations;

2) The speed at the beginning of the air duct network is set according to the desired
noise level; (3) Given the desired flow rate and speed, the cross section of the
main duct outcomes with a simple division;

3) The cross sections of all branches are calculated depending on the flow rate
percentage of each branch related to the main duct;

4) The total pressure loss is calculated according to the longest network part; and

5) In the rest of the parts, air duct sizes are calculated, so that all the branches will
have the same total pressure loss.

Moreover, in most air duct networks the last step does not take place during the
designing, but certain regulatory diaphragms are placed at the branches. These are set
after the stoking of the network with air in order to accomplish the best network
balancing. The last step is planning the network design that can be self-balanced.

The concept of self-balancing does not mean that all network branches will have
equal pressure loss; something that happens to all networks regardless the way they have
been dimensioned. Self-balancing means that the network will work according to the
designed conditions (speed calculated at all branches), and will not require regulatory
intervention.

6.7 Static pressure recovery method

With the static pressure recovery method the secondary ducts are selected to achieve
more or less the same static pressure in front of all outlets or inlets. The major 465
Calculation for air conditioning advantage of this method is the common conditions
created for outlets and inlets. This method is the most complicated and therefore is
seldom used. Specifically, this method comprises the following steps:

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 1) The desired air flow is calculated according to the system cooling load or the air
rotations.

2) The speed at the beginning of the air duct network is set according to the desired
noise level. Given the desired flow rate and speed, the cross section of the main
duct derives from a simple division.

3) Except for the terminal branches of the network, the rest of the branches are
calculated on a repetitive basis. The criterion used is that of dividing each duct
into several ducts, the point of bifurcation has the same static pressure.

4) The terminal branches are calculated again so as to produce the required static
pressure on them. The term required static pressure of terminal branch is
understood as the pressure that reaches the flow rate and the design range for the
orifice given for the chosen branch. The static pressure just outside an input or
output orifice is taken equal to zero for normal applications.

5) The total pressure loss in the longest part of the network is calculated. From the
above it is concluded that the method takes into account the actual behaviour of
the network making it more accurate and resulting in more well-balanced
networks. Compared with the method of constant pressure loss method, it creates
larger air duct networks and leads to rapid speed fluctuations along the different
branches.

6.8 Velocity method

This method is used in air duct installations dealing with air deducting systems and
transport of particles through the air in general. Maintaining air speed on these networks
is essential for preventing sedimentation of the particles within the networks.

Specifically, this method uses the following steps:

1) The value of air speed for the entire network is chosen;

2) The cross section of each part of the network is calculated, so that the speed
will remain constant.

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 3) The pressure loss of the network is calculated for a specific geometry and
speed.

6.9 Case study of an industrial installation

The air conditioning systems referred in this paper (Section 7.3) are meant to be
installed in an industrial facility in the region of Bukit Beruntung, in Rawang.
Consequently, all results and conclusions were taken from the study which was conducted
for that building (Vrellas, 2009).

As mentioned before the aim of this paper is to give the basic fundamentals of
compiling an air conditioning study. This is fulfilled through some examples that are
taken from the study referred earlier (Vrellas, 2009). Formulas and math types that are
widely known are avoided for practical reasons. This paper is mainly interested in the
methods in which the certain calculations were done. 466 SS 30,5

Before choosing a calculation method, different methods were compared according to

their difficulty of applying, effectiveness, accuracy, complexity and other factors that
concern an engineer performing that kind of study.

6.10 Cooling loads calculation

The cooling loads in the study were calculated according to the ASHRAE RTS
method, because it is the most accurate. The thermal conductivity factors k were
calculated from the structural elements of the building, based on the data generated by the
architectural design. The cooling loads were calculated for the months July-August (the
most demanding season). While performing the calculation the below conditions were
taken into account:

 The desired internal summer temperature of 271C (80.61F);

 The desired humidity of 60 percent; and

 The required air exchange.

The ventilation is correlated with space air renewals. The recommended air renewals
for each space have been calculated according to the type of space and the number of
people working inside the space. Thus, for the production and assembly spaces eight air
11
renewals per hour are required, for the finished goods spaces six air renewals are
required, and for the offices and boardroom four air renewals per hour are required. While
calculating the cooling loads the below requirements were also taken into account:

 Lighting;

 Number of people;

 Equipment and machinery; and

 Ventilation losses.

The calculation of the installation was made in accordance with the following external
conditions which represent the city of Bukit Beruntung (Table I):

The facility is operational from 8 a.m. to 6 p.m., thus the cooling loads were
estimated for this time zone. The basic example is about the basement of the facility and
more specifically the production space. This space was chosen because it combines all
factors (such as many people, machinery) which affect a space that must be ventilated and
conditioned, thus it is the most demanding space of the building (from the cooling load
perspective). The figure below shows the production space after the completion of the
study. We can notice the necessary air duct network along with one CAUs supporting the
network (see Case B2). The drawing (Figure 2) is the outcome of Auto Line, a
mechanical design software that works with the same principals as Auto Cad.

The drawing below (Figure 2) shows two CAUs. Both CAUs are part of Case B2,
where all facility areas are conditioned by air duct networks along with CAUs.
Furthermore, central unit 1 (yellow color) is for the production space (basement), while
central unit 2 is for the assembly and finished goods space (ground floor) which cannot be
seen in the drawing.

External cooling loads for production area. The first task for calculating the external
cooling loads is finding the surfaces of the examined space. This is done by the
architectural design of the building. The procedure is simple (Table II):

 The type of wall and its orientation is set;

 The factor k of thermal conductivity of the wall is set;

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  The dimensions of the wall (length, height or width), so that its surface is
estimated; and

 The openings are abstracted from the final surface.

Figure 2 : The production space with the air duct network and the central air conditioning
unit (Case B2)

Calculation for air conditioning

Surface Orientation K Length Height Surface Total Abstracted Calculation

type (kcal/ or (m²) surface surface surface (m²)
m² surface (m²) (m²)
hc)

T2 W 0.6 1.50 3.20 4.80 4.80 0.45 4.35

13
T7 W 0.56 1.50 0.30 0.45 0.45 - 0.45

E1 E 1.5 1.70 3.20 5.44 5.44 - 5.44

E1 E 1.5 6.65 3.20 21.28 21.28 - 21.28

E1 E 1.5 0.80 3.20 2.56 2.56 - 2.56

E1 E 1.5 5.00 3.20 16.00 16.00 - 16.00

E1 E 1.5 2.50 3.20 8.00 8.00 - 8.00

T2 W 0.6 6.80 3.20 21.76 21.76 3.60 18.16

Table II : Calculation surfaces for the production space

7.0 Design

7.1 Building description

The following application study is regarding an industrial facility located in Bukit

Beruntung, Rawang, Selangor. The building examined consists of three levels.

The basement, where there are: the production space 249.4 m2 (816.93 ft2), the
warehouse of raw materials and the boiler room along with the cooling room.

The ground floor, where there are: the assembly space 285.6 m2 (935 ft2) and the
area of 135.9 m2 (442.91 ft2 ) for finished products.

The first floor which houses the offices: the sales room 20.4 m2 (65.62 ft2), the
accounting room 19.7 m2 (62.34 ft2), the secretary office 24.2 m2 (78.74 ft2), the
manager’s office 30.4 m2 (98.43 ft2), the conference room 52.5 m2 (170.6 ft2) and the
exhibition room 69.3 m2 (226.38 ft2) with a hall of 25.1 m2 (82.02 ft2) and the essential
WCs. WCs also exist in the other two levels.

The concept of the study conducted was the air conditioning and the ventilation of the
building and the proposal of alternative air conditioning solutions.

 The factor k of thermal conductivity of the wall is set;

14
  The dimensions of the wall (length, height or width), so that its surface is
estimated; and

 The openings are abstracted from the final surface.

Temperature Humidity (%)

Table 1

External conditions Summer 33°C (91.40°F) 47

For Bukit Berungtung,

Rawang Winter 25°C (77°F) 68

For example, T2 wall is shown in the drawing above is first oriented west. Its k factor
is 0.6 kcal/m2 hc, its length is 1.50 m and its height 3.20 m. So, the total surface of T2
western wall is 4.80 m2 . If the openings are abstracted (0.45 m2), the calculation surface
is 4.35 m2 . With this procedure all the upper factors such as solar heat gain through
fenestration areas (Qfes) and conduction heat gain through fenestration areas (Qfe) are
estimated by the program.

By completing this task the engineer is able to calculate the cooling loads per surfaces
and hours for the space. The power unit which will be used for the calculation of the loads
is watt (W), because it gives rounded numbers. Other power units that could be used for
cooling loads are: kcal h1, Btu h1.

7.2.2 Internal cooling loads for production area.

The next task is calculating the internal cooling loads of the examined area (Table
III). As mentioned above the internal cooling loads consist of:

 Lighting: 2 36 fluorescent lamps of 1,300, power 4,988 W, total 5,736 W, Rad. F

59 percent;

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  People: 12 workers, mild machine labour, 110 sensible, 185 latent, Rad. F 49
percent; and

 Machinery: 1 machine of total power 25 kW sensible, 8 kW latent, Rad. F 49

percent.

Thus, the total cooling loads for the production spaces can be seen in Table IV.

Load type 8 am 9a.m 10a.m 11a.m 12a.m 1 p.m 2 p.m 3 p.m 4 p.m 5 p.m 6 p.m

Lighting 5,296 5,43 5,499 5,533 5,550 5,584 5,601 5,618 5,635 5,652 5,659
2

People 1,029 1,13 1,184 1,217 1,236 1,249 1,262 1,268 1,275 1,281 1,288
(sensible) 2

People 2,220 2,22 2,220 2,220 2,220 2,220 2,220 2,220 2,220 2,220 2,220
(patent) 0

People 3,249 3,35 3,404 3,437 3,456 3,469 3,482 3,488 3,495 3,601 3,508
(total) 2

Machines 25 25 25 25 25 25 25 25 25 25 25
(sensible, k)

Machines 8 8 8 8 8 8 8 8 8 8 8
(latent, k)

Machines 33 33 33 33 33 33 33 33 33 33 33
(total, k)

Table III. Additional loads/hour the production space (W)

7.2.3 Cooling loads for all facility areas.

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 By following the same methodology, the cooling loads for the other building areas
were calculated (Vrellas, 2009) and are shown at Table V:

1) Basement level:

 Production space (already estimated)

 Warehouse (not air conditioned, only products inside).

2) Ground floor level:

 Assembly space

 Finished products space

3) First floor level:

 Sales room

 Accounting room

 Secretary office

 Manager office

 Conference room and

 Exhibition room

Cooling 8 a.m 9 a.m 10a.m 11a.m 12a.m 1 p.m 2 p.m 3 p.m 4 p.m 5 p.m 6 p.m
load
type

Sensible 30.49 31.05 31.45 31.76 32.05 32.37 32.62 32.77 32.78 32.70 32.50

Latent 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22

Total 40.71 41.27 41.67 41.98 42.27 42.59 42.84 42.99 43.00 42.92 42.72

Table IV. Total loads/hour for production space (kW)

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 8 a.m 9 a.m 10a.m 11a.m 12a.m 1 p.m 2 p.m 3 p.m 4 p.m 5 p.m 6 p.m

Basement level

p 40.7 41.3 41.7 41.9 42.2 42.6 42.8 42.9 43 42.9 42.7

w - - - - - - - - - - -

Ground floor level

as 10 10.5 10.9 11.1 11.3 11.7 11.9 12 12 11.9 11.6

fp 5.7 7.2 9 10.7 11.9 12.4 11.9 10.7 9.3 8.3 7.3

First floor level

sa 2.1 3.1 3.3 3.3 3.3 3.3 3.2 3.1 2.9 2.9 2.8

ac 1.9 2.9 2.9 2.7 2.6 2.6 2.5 2.5 2.4 2.5 2.5

se 1.3 1.7 1.7 1.7 1.6 1.7 1.7 1.7 1.6 1.6 1.5

ma 1.9 2.9 3 3 3 3.1 3.1 3.1 2.9 3 3

co 1.6 2.5 2.8 3 3.1 3.2 3.2 3.1 2.9 3 3.1

ex 1.7 1.8 1.9 1.9 2 2 2.1 2.2 2 2.3 2.4

Total 67 74 78 80 82 84 84 83 80 79 78

Table V. Total loads/hour for each building space and for the entire facility without the
ventilation, estimated for the 23 of July (kW)

From Table V we can realize that we have basically two space types. Those that require
great cooling loads with many air renewals like production space, assembly and those that
require less cooling loads with few or no air renewals.

7.3 Proposed air conditioning system solutions

So, two solutions of air conditioning are proposed for each of the two kinds of spaces
having completely different needs in ventilation and air conditioning. First, the air
conditioning of the offices (the first floor) can be accomplished either with floor FCUs (for
18
cooling and heating) or with multi-zone air conditioning VRV system, respectively. While,
the air conditioning of the production space (the basement) and the assembly and finished
products areas (ground floor) can be accomplished either with two air duct systems with two
CAUs or with ceiling FCUs (cooling only) with an independent ventilation system,
respectively. Summing up, the above the cases examined are:

a) Office area

1) Cooling-heating with floor FCUs

2) Cooling-heating with VRV system

b) Production assembly finished products spaces

1) Ceiling FCUs and independent air duct network (ventilation)

2) Air duct networks with CAUs.

7.4 Psychrometry

The psychrometric chart derives from the cooling loads calculated and shows the
individual systems that we have subjectively divided the facility. The psychrometry of
two systems was calculated. The first system involves the production area and the second
system involves the assembly finished products area. This chart is used for calculating the
CAU 1 in B2 case, which can also be seen in Figure 2:

1) Indoor conditions

Desired temperature = Trdb - Trwb : 26.00 - 18.67°C

Desired humidity = Fr - Wr : 50.00 - 10.62% (g/kg)

2) Outdoor conditions

Outdoor temperature = Tadb - Tawb : 33.20 - 23.99°C

Outdoor humidity = Fa - Wa : 47.00 - 15.22% (g/kg)

3) Mixing point conditions

Point temperature mixing = Tmdb - Tmwb : 29.60 - 21.47°C

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 Humidity mixing point = Fm - Wm : 49.13 - 12.92% (g/kg)

4) Entering unit conditions

Temperature input = Tedb - Tewb : 29.60 - 21.47°C

Humidity input = Fe - We : 49.13 - 12.92% (g/kg)

5) Exiting unit conditions

Temperature output = Tldb - Tlwb : 13.84 - 12.89°C

Humidity output = Fl - Wl : 90.18 - 8.98% (g/kg)

6) Entering room conditions

Flow temperature = Tsadb - Tsawb : 13.84 - 12.89°C

Water supply = Fsa - Wsa : 90.18 - 8.98% (g/kg)

More specifically in Figure 3, point 1 shows the conditions inside the room
before the air treatment; point 2 shows the conditions outside the building, from
where the central unit will take air and must change it according to our demands;
point 3 shows the conditions inside the central unit; point 4 shows the conditions
when the outdoor air enters the central unit (in this case it coincides with point 3);
point 5 shows the conditions when the treated air exits the unit; and point 6 shows the
conditions when the treated air from the central unit enters the room (in this case it
coincides with point 5).

7.5 FCUs

The two-pipe system was chosen for the FCUs of both cases (A1 and B1). The
advantage of the two-pipe system is that the water in the primary flow in pipe is only used
in one FCU before being returned to the primary return pipe for reheating or re-cooling.
This means that it is possible to achieve equal temperature in all cooling elements unlike
the single pipe system. The advantage of a fully pumped two-pipe system is a fast
heating-cooling response and a better heat/cool balanced for all FCUs.

7.6 Air ducts

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 The air ducts were calculated by the constant pressure loss method. This method is
straightforward and easy to use, while it gives an automatic reduction of the air flow
velocities throughout the system. The reduced velocities are in general within the noise
limits of the application environment. However, this method increases the number of
components compared to other methods, and gives a poorer pressure balance to the
system. This leads to the need for more adjusting dampers that may increase the system
cost compared to other methods.

By using this method we prefer quality and calculation convenience against

installation cost. The application of the method can be noticed in Table VI. The first
column shows the air duct network. The certain network branches are numbered. The
main duct is numbered with 1 and as the network proceeds inside the building, numbers
are increasing. The total flow rate coming from the unit is 7,992 m3 /h and is decreasing
while it is being divided into the smaller ducts. Two types of ducts have been used:
rectangular and circular. The air speed is decreasing, but we cannot tell the same about
the friction inside the network.

Figure 3 : Psychometric chart for production spaces

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Air duct Duct Flow Duct Duct Duct Air Friction/ Part Duct Total friction
network length rate type width height speed m (mm friction friction (mmY∑)
part (m) (m3 (mm) (mm) (m/s) Y/m) (mmY∑) (mmY∑)
/s)

1.2 4.75 7,992 REC 2,000 250 6.00 0.05 3.05 0.25 3.34

2.3 4.24 4,303 REC 950 250 6.00 0.08 4.41 0.33 4.74

3.4 3.65 3,689 REC 800 250 5.95 0.08 3.03 0.30 3.34

4.5 3.65 3,074 REC 700 250 5.67 0.08 2.76 0.30 3.06

5.6 3.65 2,459 REC 550 250 5.36 0.08 2.46 0.30 2.76

6.7 3.65 1,844 CIR 450 5.02 0.08 2.16 0.30 2.46

7.8 3.00 1,229 CIR 300 4.53 0.08 1.76 0.25 2.01

Table VI. Air duct network

22
 8.0 Estimation cost

NO DESCRIPTION * PRICE GOODS

UNIT TOTAL TOTAL
PER SERVIC
/ PRICE AMOUNT
UNIT E TAX
UoM (RM) (RM)
(RM) (GST)
6%

1 Preliminaries, Insurance, Workman, L/S 1,000.00 1,000.00 60.00 1,060.00

Compensation Professional service and
etc:

I. Contractor All Risk Policy with L/S

the sum insured of not less or
equal to the contract value.

II. Safety Regulation / safety of L/S

Workmen

III. Prepare Safety plan to be L/S

approved by SHO

IV. Prepare safety signage L/S

V. Cleaning/Disposal of rubbish and L/S

handling over.

VI. Other Preliminaries item(not state L/S

in BQ deem necessary)

2 To supply labour, tool and material for L/S 200.00 200.00 12.00 212.00
related work to ensure the installation
work are satisfied for a complete of
installation and system operation.

I. Carefully remove and make good L/S

existing walls and ceiling and
clear all debris from site

23
NO DESCRIPTION * PRICE GOODS
UNIT TOTAL TOTAL
PER SERVIC
/ PRICE AMOUNT
UNIT E TAX
UoM (RM) (RM)
(RM) (GST)
6%

3 Supply, delivery, install, testing and L/S 4,481.13 2,481.13 268.87 4,749.99
commissioning Air Cooled Ceiling
Exposed Split unit Non inverter complete
with anti-vibration mounting and all
other associated requirements and
specification below:

Location :

I. Cooling Capacity 40,000 Btu/hr

at building WCT Machinery
Sdn Bhd (FH40CBV1M) (R40DV1)

Room size : 1420 sqft

Note:
 Brand : Daikin
 Refrigerant R410 A
 Remote Wired
 Individual Drain Pipe
 0.61 mm Thickness of Cooper
Pipe
 All material inside metal trunking
cable tray or conduit Unit below
20,000 Btu/h
 2.5 mm sq PVC inside conduit
 Two (2) pole Switch for On/Off
Unit above 30,000 Btu/h to
50,000 Btu /h
 4.0 mm sq PVC inside conduit
 Direct On line Starter in Metal
Box

TOTAL CARRIED TO SUMMARY 6,021.99

24
8.1 Product Information

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9.0 Discussion

The product functionality of the different products has been respected and should not be
affected by the proposed measures. The main risk was the size limitation, which mainly
regards split and VRF air conditioners indoors. It was already included when drawing the
analysis and the scenarios. Options to decrease the energy consumption of the products are
available in the different scenarios with reasonable heat exchange surface increase and
consequent limited size increase. It also means that this is completely possible to reach the
present efficiency requirements, without complicated options to increase the dehumidification
capability of the products.

The main monetary impact for the buyer is because of higher prices. In practice, this is an
important market barrier for the penetration of higher efficient products in the commercial
area. At the time of design, first cost is still the main parameter looked at. The adversion to
risk is also relatively high as the designer bears the consequence of not satisfying systems and
not the benefit of low energy bills. These split incentives can only be reduced by regulatory
measures.
10.0 Conclusion
The purpose of this paper is the qualitative approach of selecting the right air
conditioning system and the best calculation method for the cases examined. Thus, the most
accurate method for calculating the cooling loads of this industrial facility is the ASHRAE
RTS. The best calculation tool for installing a CAU in this factory is the psychometric chart,
which analyzes every phase of the conditioned air inside and outside the CAU. While,
considering the most efficient FCUs connection pipe system for this industrial building, the
two-pipe system proves to be the one. Regarding the air duct calculation method, constant
pressure loss method seems to be the most suitable for calculating the air duct network of this
building.

Finally, expanding the scope of this paper can lead to a future selection guide for the best
system and calculation method, when conducting an air conditioning study for an industrial
building. In addition to this, it would be interesting to examine if different results derive from
different calculation method application; and furthermore if this leads to major or minor
changes on the final decisions for installing an air conditioning system in an industrial facility
depending on the applied method.
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