Alexandria University

Faculty of Engineering
Mechanical Engineering Department

Design of central air conditioning system for

"Safa" pharmaceutically

Scientific report

Submitted to Mechanical Engineering Department

Faculty of Engineering- Alexandria University
In partial fulfillment of the requirements of the degree
For
Master of Engineering
In
Mechanical Engineering

By

Eng:Sameh Tawfik Abdel-Fattah Mahmud

Bsc Mechanical Engineering-Military Technical collage

2009
 Alexandria University
Faculty of Engineering
Mechanical Engineering Department

Design of central air conditioning system for

"Safa "pharmaceutically

By

Eng:Sameh Tawfik Abdel-Fattah Mahmud

Bsc Mechanical Engineering-Military Technical collage

Examiner's committee Approved

Prof Dr/Abdel Hamid Attia El_said

Professor Doctor in Mechanical Engineering Department
Faculty of Engineering- Alexandria University

Prof Dr/Mahamed Abdel-Fattah Tiaema

Professor Doctor in Mechanical Engineering Department
Faculty of Engineering- Alexandria University

Prof Dr/Ibtihal Y. EL-Bastawissi

Vice- Deen for high studies and research
Faculty of Engineering- Alexandria University
Advisor's committee Approved

Prof Dr/Abdel Hamid Attia El-said

Professor Doctor in Mechanical Engineering Department
Faculty of Engineering- Alexandria University
 Δ˰˰ϳέΪϨϜ˰˰˰γϹ΍ Δό˰ϣΎ˰Ο
Δ˰˰˰˰γΪ˰ϨϬϟ΍ Δ˰˰˰˰˰˰˰˰˰˰ϴϠϛ
ΔϴϜϴϧΎϜϴϤϟ΍ ϯϮϘϟ΍ Ϣδϗ

By:

Eng. : SAMEH TAWFEEK ABDEL

LFATTAH

Master of Engineer ing

( 2009 )

Supervised By:
 ACKNOWLEDGEMENT

First of all we would to show our gratitude to all the

heat division staff who helped in developing our
Knowledge in heat transfer applications, especially in
the field of air conditioning.

We are deeply grateful to our friend and teacher

Prof. Dr. ABD EL-HAMID ATTIA

As he encouraged and lead us to accomplishing this
project and easing every depressing situation, with
friendship and sincerely, till this project has come to
reality.

Finally, to everyone participated in this project. Thank

you all for making this project a lovely memory and a
valuable experience.
 ABSTRACT

This project aims to design a central air

conditioning system for Pharmaceutical Factory.

The design focuses on the air conditioning system

for Pharmaceutical facility, by making complete
cooling & heating load calculations, selection of
equipments suitable for the central air
conditioning system (such as chillers, handling
units, pumps ………… etc), airduct network
for the central air conditioning system and water
pipe network for the air handling units.
 CONTENTS

1. INTRODUCTION

1.1 Terminology
1.2 Start-Up and Qualification of Pharmaceutical Clean Room
1.3 Air-Handling Plant
1.4 Desiccant Dehumidification
1.5 Duct Space
1.6 Pump Types
1.7 Energy Consumption
1.8 Control Fundamentals

2. ZONING & BUILDING SURVAY

2.1 Zoning
2.2 Building Survay

3. LOAD CALCULATIONS

3.1 The aim of load assessment

3.2 Program Procedure
3.3 Load Calculation
3.4 Results
4. SELECTION OF EQUIPEMENT

4.1 Air Handling Uint Selection

4.1.1 General
4.1.2 Unit Selection

4.2 Chiller Selection

4.2.1 General
4.2.2 Chiller Selection Statement
4.2.3 Chiller Selection

4.3 Pump Selection

4.3.1 General
4.3.2 Flow Rate
4.3.3 Pump Selection

4.4 Desiccant Dehumidification System Selection

4.4.1 General
4.4.2 Liquid Desiccant Dehumidifiers
4.4.3 Desiccant Dehumidification Systems selection

4.5 Filter Selection

4.5.1 General
4.5.2 Filter Classification
4.5.3 Filter selection

4.6 Damper Selection

4.6.1 General
4.6.2 Damper Selection
 4.7 Diffuser Selection
4.7.1 General
4.7.2 Diffuser Selection

5. DUCT DESIGN

5.1 General
5.2 Calculation
5.3 Result

6. PIPING NETWORK

6.1 General
6.2 Water Pipe Section Design
6.3 Result

REFERENCES
٦ Chapter 1- Introduction –

1. INTRODUCTION

T
he earliest drugstores date back to the Middle Ages. The first known drugstore
was opened by Arabian pharmacists in Baghdad in 754, and many more soon
began operating throughout the medieval Islamic world and eventually
medieval Europe. By the 19th century, many of the drug stores in Europe and North
America had eventually developed into larger pharmaceutical companies.

Most of today's major pharmaceutical companies were founded in the late 19th and
early 20th centuries. Key discoveries of the 1920s and 1930s, such as insulin and
penicillin, became mass-manufactured and distributed. Switzerland, Germany and
Italy had particularly strong industries, with the UK, US, Belgium and the
Netherlands following suit.

The pharmaceutical industry utilizes many types of Heating, Ventilating, and air
Conditioning (HVAC) systems for applications ranging from research and
development to bulk and finished product manufacturing. In every facility, the
HVAC system plays an important role in assuring the environment is suitable for
personnel comfort and safety and product integrity. This course begins with a review
of basic HVAC system fundamentals and follows with a discussion of primary
components such as fans, coils, dehumidifiers and filters. The course provides an
overview of critical parameters for HVAC that can affect products and processes and
explores the basic concepts of controlling these parameters using properly designed
HVAC systems. In addition, this course addresses specific concerns of what HVAC
can and cannot do to maintain GMP as addressed in facilities designed to
manufacture bulk pharmaceutical chemicals (BPC or API), oral solid dosage (OSD)
products, sterile products, and bulk biopharmaceuticals. HVAC systems for
warehouse facilities used for storage of product, raw materials, and components are
addressed.

After discussion of facility-specific systems, the requirements for commissioning and

qualification are explored with emphasis on distinguishing between and non-critical
components. Other course topics include HVAC controls, monitoring of critical
parameters, and system construction. Dust collection systems and laboratory fume
hoods will not be covered, as these systems are addressed by other sources. The
course concludes with suggestions for maintenance.
٧ Chapter 1- Introduction –

1.1 TERMINOLOGY
Acceptance criteria:

The upper and lower limits of the room environment (critical parameters); if these
limits are exceeded, the product may be considered adulterated.

As-built clean room:

A clean room that is complete and ready for operation, with all services connected
and functional, but without production equipment or personnel in the room.

Aseptic space:

A space controlled such that bacterial growth is contained within acceptable

limits; not a “sterile” space

At-rest clean room;

A clean room that is complete with the production equipment installed and
operating, but without personnel in the room.

CFR:

Code of Federal Regulations

CFU (colony forming unit):

A visible growth of micro organisms arising from a single cell or multiple cells.

Challenge:

A dispersion of known particle size and concentration used to test filter integrity
and efficiency.
٨ Chapter 1- Introduction –

Class 1:

Particle count not to exceed 1 particle per cubic foot (35 particles/ m³) of a size 0.5
µm and larger. This criterion should be based on a large sampling of counts.

Class 10:

Particle count not to exceed 10 particles per cubic foot (350 particles/ m³) of a
size 0.5 µm and larger, with no particle exceeding 5.0 µm.

Class 100:

Particle count not to exceed 100 particles per cubic foot (3500 particles/ m³) of a
size 0.5 µm and larger.

Class10,000:

Particle count not to exceed 10,000 particles per cubic foot (353,000 particles/ m³ )
of a size 0.5 µm and larger or 65 particles per cubic foot (2300 particles/ m³ ) of a
size 5.0 µm and larger.

Class 100,000:

Particle count not to exceed 100,000 particles per cubic foot (3,530,000 particles/
m³) of a size 0.5 µm and larger or 700 particles per cubic foot (24,700 particles/
m³) of a size 5.0 µm and larger.

Clean room:

A specially constructed enclosed area environmentally controlled with respect to

airborne particulates, temperature, humidity, air pressure, air pressure flow
patterns, air motion, vibration, noise, viable organisms, and lighting

Clean space:

A defined area in which the concentration of airborne particles is controlled

at for below specified limits
.
٩ Chapter 1- Introduction –

Conventional flow clean room:

A clean room with nonunidirectional or mixed air flow patterns and velocities.

Critical parameter:

A room variable (such as temperature, humidity, air changes, room pressure,

particulates, viable, etc.) that, by law or by determination from product
development data, affects product strength, identity, safety, purity, or quality
(SISPQ).

Critical surface

The surface of the work part to be protected from particulate contamination.

Design conditions:

The environmental conditions for which the clean space is designed.

Exfiltration:

Leakage of air out of a room through cracks in doors and pass-through, through
material transfer openings, etc., due to a difference in space pressures

First air:

The air that issues directly from the HEPA filter before it passes over any work
location.

GMP:

Good manufacturing practice, as defined by CFR 21 (also, cGMP = current GMP)

High efficiency particulate air (HEPA) filter:

A filter with efficiency in excess of 99.97% of 0.3 µm particles.

١٠ Chapter 1- Introduction –

Makeup air:

Air introduced to the air system for ventilation, pressurization, and replacement
of exhaust air.
Monodispersed particles:

A replacement for DOP in determining the cleanliness level of a room using a

concentration of particles approximately 0.2 µm in size.

Nonunidirectional flow work station:

A work station without uniform airflow patterns and velocities.

Operational clean room:

A clean room in normal operation with all services functioning and with
production equipment
and personnel present and performing their normal work functions.

Parenteral product:

A pharmaceutical product normally meant to be injected into the patient.

Parenterals are manufactured under aseptic conditions or are terminally sterilized
to destroy bacteria and meet aseptic requirements.

Particle concentration:

The number of individual particles per unit volume of air. Particle size. The
apparent maximum linear dimension of a particle in the plane of observation.

Polydispersed particles:

A filter challenge utilizing particles of different sizes to determine the cleanliness

of a space.

Primary air:

Air that recirculates through the work space.

١١ Chapter 1- Introduction –

Secondary air:

That portion of the primary air circulated through the air-conditioning equipment.

Ultra low penetration air (ULPA) filter:

A filter with a minimum of 99.999% efficiency on 0.12 µm particles.

Unidirectional flow:

Formerly called laminar flow. Flow of air in generally parallel streamlines with
uniform velocity and in the same direction.

Work station:

An open or enclosed work surface with direct air supply.

1.1.1 What is GMP?

GMP refers to the Good Manufacturing Practice Regulations promulgated by the US

Food and Drug Administration. These regulations, which have the force of law,
require that manufacturers, processors, and packagers of drugs, medical devices,
some food, and blood take proactive steps to ensure that their products are safe, pure,
and effective. GMP regulations require a quality approach to manufacturing, enabling
companies to minimize or eliminate instances of contamination, mixups, and errors.
This in turn, protects the consumer from purchasing a product which is not effective
or even dangerous. Failure of firms to comply with GMP regulations can result in
very serious consequences including recall, seizure, fines, and jail time.

GMP regulations address issues including recordkeeping, personnel qualifications,

sanitation, cleanliness, equipment verification, process validation, and complaint
handling. Most GMP requirements are very general and open-ended, allowing each
manufacturer to decide individually how to best implement the necessary controls.
This provides much flexibility, but also requires that the manufacturer interpret the
requirements in a manner which makes sense for each individual business.

In the design of air conditioning or ventilating systems it is essential to restrict the

dissemination of infection between different areas and to discourage the spread of
smells. Four aspects of design help to achieve these aims:
1) Different departments should be treated by independent system.
١٢ Chapter 1- Introduction –

2) A balance must be secured between the supply and extract air quantities to
maintain a slightly negative or positive pressure in certain areas, according to the
desire to limit the emission of microbial infection and/or smells.
3) A relatively bacteria-free air quality should be achieved by adopting a proper
standard of filtration efficiency.
4) Enough fresh air must be handled to dilute odours to an acceptably low level.

HEPA filters Shane in the figure are effective in achieving a low bacteria count
by removing virtually all particles from the air stream down to one micron (1µm) in
size. Smith and Rowe (1977) claimed that the
standards of fresh air supply recommended for
hospitals were based on outdated and insufficient
studies and offer evidence that as mush as 80% of the
air supplied can be recalculated from the treated space
provided, of course, that it is properly filtered. The
rates of fresh air supply recommended by ASHRAE
are, nevertheless, quite satisfactory. CIBSE, on the
other hand, does not make recommendations directly
but refers to the figures quoted in the various hospital
building notes, published by the Department of Health.
There is every reason to suppose that both these sources give satisfactory recom-
mendations.

1.1.2 Clean Room

1.1.2.a) A clean Room

The Federal Standard 209 E of USA defines it as:

“A room in which the concentration of airborne particles is controlled to specified
limits”. Therefore, while designing the airconditioning system for sterile areas in
pharmaceutical plants it is very necessary to study the application, identify various
factors affecting the particulate count and decide the level of contamination that can
be permitted. A cleanroom is an environment, typically used in manufacturing or
scientific research, that has a low level of environmental pollutants such as dust,
airborne microbes, aerosol particles and chemical vapors. More accurately, a
cleanroom has a controlled level of contamination that is specified by the number of
particles per cubic meter at a specified particle size. To give perspective, the ambient
air outside in a typical urban environment might contain as many as 35,000,000
particles per cubic meter, 0.5 μm and larger in diameter, corresponding to an ISO 9
cleanroom
١٣ Chapter 1- Introduction –

Air flow pattern for "Turbulent Cleanroom" Air flow pattern for "Laminar Flow Cleanroom"

1.1.2.b) Room Classification

Cleanrooms used for pharmaceutical manufacturing have their own standards. The
two most widely used are those published by the European Union and the USA.
European Union Guide to Good Manufacturing Practice
The most recent pharmaceutical standard used in Europe came into operation on
January 1997. It is called ‘The rules governing medicinal products in the European
Union. Volume 4.

Maximum permitted number of particles /m3 equal to

or above

Grade At rest (b) In operation

0.5μ m 5μm 0,5 μ m 5,0 μ m

A 3 500 0 3 500 0

B 3 500 0 350 000 2 000

C 350 000 2 000 3 500 000 20000

D 3 500 000 20 000 not defined not defined

١٤ Chapter 1- Introduction –

Notes:

(a) In order to reach the B, C and D air grades, the number of air changes should be
related to the size of the room and the equipment and personnel present in the room.
The air system should be provided with appropriate filters such as HEPA for grades
A, B and C.

(b) The guidance given for the maximum permitted number of particles in the "at
rest" condition corresponds approximately to the US Federal Standard 209E and the
ISO classifications as follows: grades A and B correspond with class 100, M 3.5, ISO
5; grade C with class 10 000, M 5.5, ISO 7 and grade D with class 100 000, M 6.5,
ISO 8.
(c) The requirement and limit for this area will depend on the nature of the operations
carried out. The particulate conditions given in the table for the "at rest" state should
be achieved in the unmanned state after a short "clean up" period of 15-20 minutes
(guidance value), after completion of operations. The particulate conditions for grade
A in operation given in the table should be maintained in the zone immediately
surrounding the product whenever the product or open container is exposed to the
environment. It is accepted that it may not always be possible to demonstrate
conformity with particulate standards at the point of fill when filling is in progress,
due to the generation of particles or droplets from the product itself.

1.1.2.c) Clean room operating parameters

1- Room cleanliness

Expressed as a classification per Feed's. 209E (e.g., Class 10, Class 100, Class
1,000, Class 10,000, Class 100,000), room cleanliness levels are the basis of
any clean room design. It is important to know what classification you require,
since an over-designed room can be costly to build and costly to operate.

2- Room temperature & humidity:

If the process is not affected by temperature/humidity conditions which fall

outside of human comfort ranges, do not specify tight tolerances. A typical
specification is 70º F±2 and 30-70% RH. Tighter tolerance will result in
unnecessarily escalated costs.

3- Lighting level:

A level of 100 foot-candles at the work surface is more than adequate for close
assembly work. Higher lighting levels are costly in terms of energy consumption
and initial cost. Lower levels can be maintained by control switching.
١٥ Chapter 1- Introduction –

4- Process flow:
This deals with the process being carried out within the room. The process will
dictate the materials of construction as well as the layout of the facility. If the
process is general in nature, a more flexible layout is recommended. The
process should be defined as completely as possible before any clean room is
laid out. This sounds elementary, but a poorly defined process will result in an

Unsatisfactory clean room, or one in which modifications are being made before
the paint is dry. A knowledgeable clean room consultant will have experience in
process flow and will be able to offer valuable assistance.

1.1.2.d) Room construction and operation

Controlling particulate contamination from other than supply air will depend upon the
classification of the space and the type of system and operation involved. Typical
items, which may vary with the room class, include the following Construction
Finishes:
 General. Smooth, monolithic, cleanable, and chip resistant, with minimum
seams, joints, and no crevices or moldings.
 Floors. Sheet vinyl, epoxy, or polyester coating with carried up wall base, or
raised floor with and without perforations using the above materials.
 Walls. Plastic epoxy-coated drywall, baked enamel, polyester, or porcelain
with minimum projections.
 Ceilings. Plaster covered with plastic, epoxy, or polyester coating or with
plastic-finished acoustical tiles when entire ceiling is not fully HEPA filtered.
 Lights. Teardrop shaped single lamp fixtures mounted between filters or flush
mounted and sealed.
 Service penetrations. All penetrations for pipes, ducts, conduit runs, etc.,
should be fully sealed or gasket.
 Appurtenances. All doors, vision panels, switches, clocks, etc., should have
either flush mounted or sloped tops. Personnel and Garments
 Hands and face are cleaned before entering area.
 Lotions and soap containing lanolin are used to lessen the emission of skin
particles.
 Wearing cosmetics and skin medications is not permitted.
 Smoking and eating are not permitted.
 Lint-free smocks, coveralls, gloves, and head and shoe covers are worn
١٦ Chapter 1- Introduction –

1.1.3 Materials and Equipment

 Equipment and materials are cleaned before entry.

 Nonshedding paper and ballpoint pens are used. Pencils and erasers are not
permitted.
 Work parts are handled with gloved hands, finger cots, tweezers, and other
methods to avoid transfer of skin oils and particles.

1.1.4 Particulate Producing Operations

 Grinding, welding, and soldering operations are shielded and exhausted.

 Containers are used for transfer and storage of materials entries
 Air locks and pass-through are used to maintain pressure differentials and
reduce contamination.

1.1.5 Pharmaceutical environmental facilities

Implementation of Good Manufacturing Practices (GMP) in the pharmaceutical

industry made it necessary for bio-clean rooms. Bio-clean rooms can be classified
into two types: those requiring higher levels of clean-room conditions; and those
that prevent cross contamination. YAMATO SCIENTIFIC constructs bio-clean
rooms to effectively meet the various conditions of GMP by considering well the
characteristics of specific pharmaceuticals.

1.2 START-UP AND QUALIFICATION OF PHARMACEUTICAL

CLEAN ROOMS

1.2.1 Qualification of HVAC for Aseptic Pharmaceutical

Manufacturing

Qualification of pharmaceutical clean room HVAC systems is part of the overall

commissioning of the building and its systems, except that documentation is more
rigorous. The qualification covers the equipment affecting critical parameters and
their control. Other groups within the manufacturing company, such as the safety or
environmental groups may also require similar commissioning documentation for
systems in their areas of concern. The most important objective in meeting the
requirements of the approving agency is to:
1- State what you are going to do and then verify that it was done and
2- Show that you are protecting the product and meeting your acceptance criteria.
١٧ Chapter 1- Introduction –

1.2.2 Qualification Plan and Acceptance Criteria

Early in the design, the owner and designer should discuss who will be responsible
for as-built drawings, setting up maintenance files, and training. They should create a
qualification plan for the HVAC systems, which includes:
1- A functional description of what the systems will do,
2- Maps of room pressures and cleanliness zones served by each air handler,
3- A list of critical components to be qualified,
4- A list of owner’s procedures that must be followed for the qualification of
equipment and systems that affect critical parameters,
5- A list of qualification procedures (IQ/OQ/PQ protocols) that must be written
especially for the project, and
6- A list of needed commissioning equipment.

1.2.3 Nonaseptic Pharmaceutical Manufacturing

Although the previous discussion centers on aseptic manufacturing clean spaces, the
design and qualification of pharmaceutical manufacturing for nonaseptic products
(like topical and oral products) generally follows the same approach, but with fewer
critical parameters and fewer components to be qualified. However, in many facilities
that manufactures powdered materials, humidity may become a more important, and
more tightly controlled, critical parameter. In that case, HEPA filters perform more of
a dust capture role than bacteria control and may be efficiency tested rather than
pinhole scanned. To avoid over design and over qualification costs, the Owner must
determine the function of the facility and the qualification documentation needed.

1.2.4 Noise and vibration

Noise is one of the most difficult variables to control. Particular attention must be
given to the noise generated by contamination control equipment. Prior to the start of
the Design, the noise and vibration criteria should be established. In normal
applications of contamination control equipment, vibration displacement levels need
not be dampened below
0.5 µm (20 micro inches) in the l to 50 Hz range. However, electron microscopes and
other ultra sensitive instrumentation may require smaller deflections in different
frequency ranges. Photolithography areas may prohibit floor deflections greater than
0.076 µm. As a general rule, the displacement should not exceed one-tenth of the line
width.

For highly critical areas, vane axial fans should be considered. These fans generate
less noise in the lower frequencies, and they may be dynamically balanced to
١٨ Chapter 1- Introduction –

displacements of less than 4 µm, which will decrease the likelihood of vibration
transmittal to sensitive areas.

1.3 AIR-HANDLING PLANT

Commercial, packaged, air-handling units occupy between 0.4 and 0.1 m² per m³ s¯¹
of air delivered and their heights are from 0.5 to 2.0 m over the range of duties from
0.5 to 20 m³s¯¹, the better quality, quieter units requiring more space and being
higher that those that are cheaper and noisier. Individual, forward-curved, centrifugal
fans need from 0.06 to 0.03 m² per m³ s¯¹ of air, over a similar span of airflow rates.

Air-handling plant rooms may accommodate a packaged air-handling unit for supply
air; an extract fan and motor set; ducts for supply, recalculated, discharge and fresh
air; silencers; duct-mounted heated batteries; controls; switch-gear; pumps and lagged
pipes. The ducts are large and of a complicated shape, usually having to cross over
one another, and plant is best erected on concrete plinths. Taking account of these
factors and of the need for enough space to give access for maintenance suggests that,
for preliminary planning purposes, it is wise to allow 12 m² plan area plus 13 m² per
m³ s¯¹ of air handled, with a clear internal height of 2.7 m plus 0.1 m per m³ s¯¹ of
airflow, up to a maximum of 4.2 m.

1.3.1 The supply of fresh air

As means of air conditioning, particularly in tropical countries, fan coil systems have
much in their favor, not least being the relatively small amount of time required for
design. In the simplest and cheapest form of system the cooler coil in the unit
receives chilled water at the lowest practical temperature and does both the sensible
and latent cooling. Fresh air enters fortuitously through ill-fitting windows and
condensate off the coil is drained to waste. A small improvement accrues if outside
air, plus traffic noise and dirt, comes in through an purpose-made hole in the wall
behind the unit, induced through the casing and mixed with recalculated air by the
fan, prior to being blown over the cooler coil and delivered to the room.

A third possibility is to add a mechanical ventilation system that handles filtered and
heated (as necessary) fresh air, ducted at low velocity to supply grilles located at high
level on the corridor side of the room and blowing towards the windows. While this
assists proper air distribution and removes noise and dirt from the air, the fan coil
units still run wet. In this connation, if a changeover mode is used, wet and dirty unit
coils may generate unpleasant smells, absorbed during the previous form of
operation, as they dry out when hot water circulates.

The fourth and best option is to provide a cooler coil for dehumidification in the
central air-handling plant and arrange for the fan coil units to run dry, doing only
sensible cooling. The units will then cost more money because they will remove less
١٩ Chapter 1- Introduction –

sensible heat with the higher secondary chilled water temperature necessary to
prevent latent cooling. This extra cost is partly offset by the sensible cooling
contribution of the ducted air. As with the induction system, there is no need to install
piping for condensate drainage. Any condensate formed during start-up, drains into
an emergency collection tray beneath the cooler coil and is subsequently re-
evaporated.

When fan coil units are installed at high level, above suspended ceilings, it is
essential to ensure that the air distribution in the room is satisfactory and that any
ducted fresh air is also properly admitted to the room.

The air supplied from the fan coil unit must be smoothly fed into a ceiling diffuser
that will give draught-free, quiet air distribution. The used air must be extracted from
the room in a proper fashion that does not result in any short-circuiting or noise. If
there is any doubt about the air distribution, tests should be carried out to establish air
temperatures, air velocities, and noise levels, either in the manufacturer’s works or in
a full-scale mock-up. The fan in the unit must be able to develop enough additional
pressure to offset the resistance to airflow of any air distribution ducting and diffusers
attached to the unit.

When a fresh-air ducted supply is used in conjunction with fan coil units located
above a suspended ceiling, the fresh-air duct branch for each module should be
extended to be close to the back of the fan coil unit. The fresh air will then be handled
as part of the fan coil unit duty and be properly distributed in the room. When this is
done, the effect the fresh air has on the state of the air entering the fan coil unit must
be considered and its influence on the capacity of the fan coil unit assessed.
1.3.2 Fan noise:
When air passes over a fan blade a pressure gradient is developed across it that is
uniform if laminar flow occurs, generating little noise. This case seldom prevails in
practice and the airstreams is not laminar but separates in a random way from the
curvature of the blade, forming eddies in a fluctuating pattern with vortices that are
shed from the trailing edge. With centrifugal fans, vortices may also be formed at the
leading edges of the bladed. Noise over a wide spectrum is produced, its power
depending on fan selection, efficiency, size and speed. Further noise is created by
turbulence within the casing and matters may be aggravated by obstructions at the fan
outlet or inlet and also by ill-conceived or badly installed duct con-nations. Although
it does not seem possible to relate fan efficiency directly with noise, some
approximate generalizations can be made. A given fan will be noisier if it works at a
higher fan total pressure or if it handles more air. Further, fans with higher discharge
velocities tend to be noisier than those with lower. With axial flow fans, tip clearance
should be minimal since much of the noise generated is at the blade tips. Reducing
fan capacity by throttling at a damper produces noise. It is best to use an inverter to
regulate the speed of the driving motor or variable pitch blades in the case of axial
flow fans. It is possible to overdo the attempt to specify a quiet fan. If the
٢٠ Chapter 1- Introduction –

manufacturers are restricted in terms of impeller diameter, tip speed, outlet velocity
and efficiency, they may find it impossible to offer a fan that will operate on the
stable part of a centrifugal fan is designed like an in volute, its radius of curvature
increasing with the angle turned through from the cut-off. Consequently, the static
pressure in the casing increases from the cut-off to the fan discharge but there is a
sharp fall in static pressure as the cut-off is passed again. The result is that noise is
produced here at the blade-passage frequency.

Non-aerodynamic noises are generated by out-of-balance impellers; bearings,

particularly ball or roller; driving motors, giving noises largely of magnetic origin
that are notably bad with single phase motors of more than the smallest size.
Coupling and vee-belt drives seldom cause complaint, properly selected.

compares the noise spectra of two fans, each selected to deliver 2830 ls¯¹ at a fan
total pressure of 0.623 kPa. It can be seen that the axial flow fan is the noisier and
this emphasizes that its selection and installation requires care. It is not merely a
matter of fitting silencers but also of ensuring that noise does not break out through
the flexible couplings and is not radiated objectionably from the casing. Silencers
should be bolted directly onto the flanges of axial flow fans at both ends, the flexible
coupling being fitted at the extremes of the silencer-fan-silencer combination.
Radiation from the casing may be dealt with by installing the fan in a plant room with
walls having adequate sound reduction indices. All holes in the walls, etc. must be
made good with grout and the annular holes where ducts and pipes pass through the
walls tightly plugged with fiberglass, or similar material. It is often acoustically fatal
to locate a fan above a suspended ceiling, even if silencers are fitted. A partial
remedy for such a difficult situation is to cover the fan casing completely with a layer
of sound-absorbing material and, most important, to put a layer of heavy, barrier
matting on top. The covering must be done very carefully, with 75 mm lap joints for
the outer barrier mat. Leaving small gaps in the coverage will nullify the effort and
expense. A further, if expensive remedy is to install a massive sub ceiling, suspended
from resilient hangers. Again it is important that there is no gap around the edges and
that ceiling is free from holes or cracks.

1.4 DESICCANT DEHUMIDIFICATION

Desiccant systems in HVAC applications, an alternative or supplement to

mechanical refrigeration, are used primarily where simultaneous maintenance of
temperature and humidity control is an important benefit to the user .
Desiccants are defined as materials which attract and hold water vapor.
With desiccant systems the sensible and latent functions are separated. A
desiccant material is used to remove the moisture by absorption or adsorption.
Refrigeration is then used to lower the temperature only to the desired level for
distribution. This refrigeration is done at a higher temperature than in a typical
٢١ Chapter 1- Introduction –

conventional HVAC thereby achieving a higher operating COP (lower kW/ton).A

reduction in energy costs for air conditioning is possible.

They can be used to create very low humidity environments (5-10% relative
humidity) which would otherwise be difficult and expensive to maintain using
compression-refrigeration equipment. Desiccant-based energy recovery systems
basically decouple the latent load from the equipment (typically mechanical
cooling) handling the sensible load. It is often used on projects where the latent
load is in excess of that which can be done by conventional unitary cooling
equipment. They are often considered when controlling relative humidity is
essential to avoiding the growth of microbials.

1.4.1 Advantages

If they are properly applied and are correctly designed, desiccant systems can also
produce these benefits:
1- Independent control of latent loads in the ventilation air.
2- Eliminate condensation on cooling coils and in drip pans, and reduce
humidity levels in ducts. This will virtually eliminate the growth of mold,
mildew, and bacteria. The combination can reduce maintenance and help
avoid indoor air quality problems.
3- Lower humidity levels in occupied spaces provides equivalent comfort
levels at higher ambient temperatures. This could allow chilled water set-
points to be raised and there-by save energy and reduce system operating
costs.
4- Reduce the mechanical cooling load, permitting the use of smaller chillers
and possibly even smaller ducting in new construction. These construction
cost offsets should be factored into any economic evaluation.

1-4-2: Disadvantages

While there are special design situations where desiccant/evaporative chilling

systems are potentially economic, the complication of such systems limits their
acceptance, especially in situations where there are limited or no on-site qualified
operating personnel. Other disadvantages include:
1- Increased first cost,
2- Increased maintenance of the added desiccant equipment,
3- Cost of energy (usually natural gas) to regenerate the desiccant at a high
temperature to drive off the entrained moisture.

In some cases, the need for piping of cooling (typically tower) water to remove the
heat of adsorption and pre cool the heated air off the desiccant units
٢٢ Chapter 1- Introduction –

1.4.3 Applications

Desiccant systems can be used to create very low humidity environments (5-10%
relative humidity) which would otherwise be difficult and expensive to maintain
using compression-refrigeration equipment. Pharmaceuticals and others
manufacturing hygroscopic products require low humidity operating
environments. Candy, seed, and photo-film manufacture often require dry air to
speed drying of the product. They can be used to retrofit a project where the
installed conventional equipment can not maintain the desired humidity levels or
where conditions have changed to create a humidity problem (example: original
design had too low an outdoor air intake). Heat pipes are often coupled with
desiccant systems to improve performance.

Desiccant systems are potentially best applicable where:

1- Extremely low humidity (less than 30% relative humidity) is required,
2- The latent load is large in comparison with the sensible load,
3- The cost of energy to regenerate the desiccant is low when compared with
the cost of chilling the air below its dew point.
4- The air would have to be chilled to a subfreezing dew point with
mechanical refrigeration.
5- The process requires continuous delivery of air at subfreezing
temperatures. With desiccant removal of water in the air the defrost
problem on the chilling coils is minimized.

1.4.4 Technology Types (Resource)

There are two broad categories -- liquid and solid desiccant systems.
1- Liquid desiccant systems use spray air washer type equipment with remote
regeneration. They are typically used for large applied industrial
applications.
2- Solid, inorganic, crystalline desiccants are impregnated in inert materials
and used in a unit with a honeycomb type heat-wheel. They are typically
used for commercial HVAC applications.
Solid desiccant systems are available in single-wheel and dual-wheel factory
packaged units. The single wheel units include a desiccant wheel, cooling coil and
reheat coil (hot gas, electric, steam, hot water, etc.). Outdoor air is dehumidified
by the desiccant wheel, a cooling coil reduces the air temperature to the desired
dew point, and the reheat coil raises the air to the desired dry bulb temperature.
٢٣ Chapter 1- Introduction –

The dual-wheel units use a desiccant-based wheel and a sensible-only heat wheel
along with the conventional chilled water or direct expansion coil. During the
cooling mode the sensible-only wheel is used as a post-cooler (partially cool hot
dry air off the desiccant wheel while preheating regeneration air) or to reheat the
over-cooled dehumidified air.

Heat is required to regenerate or reactivate the desiccant material (drive off the
absorbed water vapor and discharge it outdoors using a scavenger air stream). Part
of the wheel is exposed to the conditioned or process air and the balance to the
reactivation air stream. Natural gas is usually used to provide the heat for
regeneration in single wheel units; a combination of exhaust air and gas heat may
be used on dual-wheel systems.

In addition to the supply air fan, desiccant units require:

1- A process air fan to pull air through the wheel and over the cooling coil,
2- A reactivation air fan
3- A fractional hp motor to rotate the wheel
4- In some cases, a fractional hp motor driving an inducer fan to push flue
gases outdoors.

1.4.5 Efficiency

The combination of desiccant dehumidification and mechanical cooling can allow

the chilled water or direct expansion system to operate at a higher evaporator
temperature and thus a higher efficiency and reduce operating costs. The amount
will depend on site requirements.

Desiccant units typically remove about 4 to 8 pounds or more of moisture per hour
for each 1,000 cfm of circulated air. The lower the air flow face velocity through
the desiccant and the higher the inlet air humidity the more the moisture that is
removed. The addition of a dual wheel reduces the amount of mechanical cooling
and reactivation heat required.

While desiccant equipment is durable and efficient where properly applied, it does
require special maintenance. Good filtering of both air streams (incoming and
outgoing) is vital. The filtering system must be clearly visible to maintenance
personnel, it must be easily inspected, removed and replaced, and a maintenance
schedule must be established and followed. If a solid desiccant is clogged with
particulate or a liquid desiccant's properties are changed by entrained particulates,
its efficiency drops rapidly and it may have to be prematurely replaced.

The wheel(s) and their rotating mechanisms must be clearly visible to

maintenance personnel, they must be easily inspected, maintained and repaired.
Care must be taken to not allow holes to be drilled in the casings, access doors to
٢٤ Chapter 1- Introduction –

become warped, etc., as if humid air leaks into either the dry air ductwork or into
the unit itself, the system efficiency is markedly reduced. The life expectancy of
the wheel is also dependent on the proper operation of the regeneration system.

1.5 DUCT SPACE

At a very early stage in the design process an estimate must often be made of
probable space to be occupied by the ductwork. It is never wise to underestimate
space requirements at the conceptual phase and Table 6.4, therefore, lists
conservative suggestions for the supply air quantities needed for office blocks.
Generalization for other applications is best made by

Table 6.4 supply air quantities required for office blocks with different air-
conditioning system

Specific supply air

quantity
System
(l s¯¹m¯²)

Perimeter induction 3.25

Variable air volume 8.5

Double duct 12.5

Ducted, uncoiled, fresh air for a fan coil system 1.8-2.7*

Ducted, cooled and dehumidified air for a fan coil 3.0-5.0+

system

* depends on the amount of smoking.

+ depends on the moisture contests of the supply air and room air.

Means of a rough estimate of the sensible heat gain and the use bearing in mind that
the choice of conventional air distribution terminals is limited to about 25 air changes
per hour or 12.5 ls¯¹ m¯². The figures in Table 6.4 refer to the total treated floor area,
i.e. the modular area plus the area of the central corridor.
٢٥ Chapter 1- Introduction –

1.6 PUMP TYPES

The centrifugal pump with a volute casing is the type most commonly used for
building services and, among the many system available, one method of
classification is according to the drive arrangement:
1- Integral canned rotor – the impeller is fixed to the shaft of the rotor, which
revolves in a rotor can filled with water. The stator and the electrical
connexions are outside the rotor can and, since the pump shaft does not emerge
from the casing, there is no need for a shaft seal to limit water leakage. Such
pumps are common in domestic heating installations and, if they are light
enough in weight, may be fixed directly in the pipeline without additional
support. Otherwise, they are floor-mounted. Such pumps must never be used in
chilled water lines because condensation then occurs on the electrical
connexions and causes continual difficulties.
2- Direct-coupled – the motor shaft is coaxial with and attached to the impeller
shaft through a flexible coupling, both motor and pump being mounted on a
common base plate. Difficulties In shaft alignment are sometimes experienced
and a shaft seal is necessary to limit leakage from the pump casing.
3- Close-coupled – the motor and pump are separate but the impeller is
mounted on an extension of the motor shaft. There is consequently no
possibility of misalignment but motor noise can be transmitted directly into the
piping system. Although the pump has no bearings, as those of the motor serve
for both, a shaft seal is needed.
4- Belt-driven – vee-belts and pulleys provide the drive connexion between the
pump and its motor, the whole assembly being fixed on a common base-plate.
A shaft seal is necessary.

Modifying the pump performance is done by changing the impeller in cases (2)
and (3), by altering the pulleys in case (4) and by electrical methods for case (1).
That part of the pump where the impeller shaft passes through the casing is
formed into what is called a stuffing box, containing either a packed gland or a
mechanical seal. The former contains replaceable, asbestos string or the like,
lubricated with graphite grease or former contains replaceable, asbestos string or
the like, lubricated with haplite grease or something similar. A screwed top the
gland may be tightened to control seepage but some leakage is desirable to give
shaft lubrication and cooling at the gland. The packing is replaced when worn. If
there is a negative pressure at the pump suction air can be drawn into the system
and to prevent this occurring a lantern ring may be fitted to divert a small amount
of water from the pump discharge to the gland. A mechanical seal comprises a
spring-loaded labyrinth of carbon-ceramic or carbon-stainless steel faces, through
which there is virtually no leakage but which may offer some difficulty in
replacement should this be necessary. Both types of seal can be used for water
temperatures up to 100°C but beyond this special arrangements for materials and
٢٦ Chapter 1- Introduction –

cooling are needed. For mechanical seals in particular, the working pressure and
temperature are critical to performance and cooling water from an external source
must be supplied when they operate above 100°C it is essential that the piping
system is properly flushing out before a pump with a mechanical seal is run and
all seals must be provided with flushing connexions to keep the seal interfaces free
from contamination. Mechanical seals should only be fitted to pumps that are of
suitable design, namely, those with short, stiff shafts having adequate bearings.

Mechanical seals must not be regarded as bearings. Seal faces will be damaged if
the pump runs without water, even as a momentary dry run, when the electrician
tests the direction of rotation, is sufficient to cause serious damage and render the
seal useless.

Other aspects of classification are according to construction: horizontal or vertical

impeller shafts split casings which facilitate impeller changes, cleaning and
maintenance, single or double suction impellers, single or multi-stage, self-
priming, etc.

Although ventilated ceilings can be used for air change rates from about 7 h¯¹
upwards, they are unsuitable for small duties and only come into practical
application for rates exceeding about 25 h¯¹, where conventional air distribution
terminals become difficult to select for draught less condition. Proprietary ceilings
are available that will satisfactorily distribute from 30 to 520 l s¯¹ m¯² of live tile
area with static pressures in the ceiling from 3 to 37 Pa, depending on the type of
the tile selected. When unavoidable, it is sometimes possible to locate extract
grilles in the ceiling itself but this is the least favored position and it is much
preferred to position them at low level in the walls, or in the floor. Rydberg (1962)
has shown that if the whole of the ceiling is made live air distribution can be poor,
particularly with a low air change rate, and it is even possible to get the downward
flow of air moving obliquely across the room to a low-level extract point, giving
draughts in part of the room and stagnant conditions elsewhere. The secret of good
distribution is to achieve turbulent mixing, above the occupied zone, between the
down-moving cold air and the rising, warm, convection currents. This is often
done by making only part of the ceiling live, the live tiles being positioned over
the major sources of sensible heat gain, e.g. computer cabinets. There is then
ample opportunity for entrainment and good mixing.

In computer room applications many of the cabinets have in-built fans that
forcibly eject air upwards, ensuring turbulent mixing with the down-coming air
and it is then possible, and often essential, for a very much larger proportion of the
ceiling to be live. It is generally not feasible to use 100% of the gross ceiling area
because of the presence of light fittings and perhaps down stand beams above the
ceiling the these dead areas must be subtracted from the gross area to establish the
maximum usable net ceiling area. Air change rates as high as 250 h¯¹ have been
٢٧ Chapter 1- Introduction –

successfully used with extract grilles at low level in the walls, but with rates up to
720 h¯¹, as in clean rooms, it may be necessary to use the whole of the floor area
as an extract grille when laminar down flow is wanted.

To get good distribution beneath the ceiling it is first essential to arrange for good
air distribution above it by introducing the air to the ceiling plenum chamber
through a rudimentary duct system with a number of dampened outlet spigots
blowing air horizontally across the top of the suspended ceiling. Large ceiling
plenum chambers must be divided into zones by down stand barriers from the
soffit of the slab. Such zones should not exceed 500 m³ and should be of fire-
resistant material. The exit velocities from the supply spigots should not be greater
than 5 ms¯¹ and the spigots ought to be as far above the suspended ceiling as
possible, otherwise there is the risk that air may be entrained upward through the
live tiles in the vicinity of the spigot. Access tiles are required near the spigots for
damper adjustment during commissioning.

The exact design of the ceiling must be left to the manufacturer but a guide to safe
blowing distances, based on manufacturers’ literature.
There is a risk that small holes in the thicker (10-15 mm) non-metallic ceiling tiles
may block with dirt, after a period of use. To minimize this risk it is recommended
that the air handling plant includes a bag filter with a minimum atmospheric dust
spot efficiency of 60% and a pre-filter having an arrestance of 80%.
It cannot be too strongly emphasized that the chamber above the ventilated ceiling
must be properly sealed, insulated and vapor-sealed. If there are cracks or
openings in the structure of the plenum chamber the system will be an abject
failure because the conditioned air will leak away. If the soffit of the slab and the
four side-walls, together with any down stand beams, are not properly insulated,
and vapor-sealed, heat gains, or losses, will nullify the effectiveness of the
installation. It should be remembered that the temperature difference.

1.7 ENERGY CONSUMPTION:

Energy consumption falls into two parts: the thermal energy used in burning fossil
fuel for heating and the electrical energy used to the mechanical plant or,
occasionally, used for heating. Making an accurate estimate is virtually impossible at
the design stage because.
٢٨ Chapter 1- Introduction –

Table 8.3 Relative costs of various systems

Approximate relative costs of various systems

Fan coil VAV plus Low

Plus ducted Perimeter Dual Velocity

Air Heating Duct Ducted

High 1.3 1.4 1.5 1.3

Average 1.0 1.0 1.2 1.2

Low 0.7 0.6 0.9 1.1

Table 8.4 Relative costs of systems for different applications

Approximate relative costs of systems for various applications

Public

Rooms in Theatres,

hotels Etc. hospitals restaurants Factories

High 1.4 1.3 3.9 1.4 1.2

Average 1.0 1.0 2.6 1.0 0.8

low 0.6 0.6 1.4 0.6 0.5

Note:

The costs are related to a unit cost for the fan coil system in table 8.3.
٢٩ Chapter 1- Introduction –

Table 8.2 percentage contribution of the components of a system to its total cost

Approximate percentage of the total

Capital cost for a VAV system plus

Perimeter heating over a treated floor

Area of

Component 6000 m² 15000 m²

Refrigeration plant, cooling towers

8 6
and pumps

Air-handling plant and silencers 15 14

Chilled water pipe and insulation 3 3

Cooling water pipe 2 1

LTHW pipe, insulation and pumps 5 4

Ductwork, insulation, grilles and

39 45
diffusers

Terminal units 11 11

Automatic controls 5 5

Boilers, flues and gas installation 4 3

Space heating 3 3

Electrical supplies to control panels

2 2
and plant

Water treatment 1 1

Fire detection 2 2

Totals 100% 100%

٣٠ Chapter 1- Introduction –

1.8 CONTROL FUNDAMENTALS

1.8.1 Control

A closed loop or feedback control system measures changes in the controlled

variable and actuates the control device to take corrective action, which continues
until the variable is brought to Feedback Control System a desired value within
the design limitations of the controller. This system of transmitting the value of
the controlled variable back to the controller is known as feedback. In an open
loop or feed forward control system there is no direct link between the value of the
controlled variable and the controller. Feed forward control anticipates the effect
an external variable will have on the system. An example is an outdoor thermostat
that controls heat flow to a building in proportion to the calculated load of changes
in outdoor temperature. In essence, the designer of this system presumes a fixed
relationship between outdoor air temperature and the heat requirement of the
building and takes control action based on the outdoor air temperature. The actual
space temperature has no effect on this controller. Because there is no feedback of
the controlled variable (space temperature), the control is known as open loop.

Feed forward control can also be used effectively on a feedback controller to

modify the control based on an external variable affecting the control loop. The
controller is then a feedback controller with feed forward compensation.

1.8.2 Terminology

Illustrates the components of a typical control loop. The sensor measures the
controlled variable and conveys values to the controller. The controller compares
those values with the set point and sends a signal for corrective action to the
controlled device. Thermostats, humidistat, flow controllers, and pressure
controllers are examples of controllers.

The controller seeks to maintain the set point, which is the desired value of the
controlled variable.
The controlled device reacts to signals received from the controller to vary the
flow of the control agent. It may be a valve, a damper, an electric relay, or a motor
driving a pump or a fan.
The control agent is the medium manipulated by the controlled device. It may be
air flowing through a damper or gas, steam, or water flowing through a valve.
The process plant is the apparatus being controlled. It reacts to the control agent
and effects the change in the controlled variable.
The controlled variable is the temperature, humidity, pressure, or flow being
controlled.
٣١ Chapter 1- Introduction –

A control loop can be represented in the form of a block diagram, in which each
component is modeled and represented in its own block. The flow of information
from one component to the next is shown by lines between the blocks. The figure
shows the set point being compared to the feedback of the controlled variable. The
difference, or error, is fed into the controller, which sends a control signal to the
controlled device. In this case, the controlled device is a valve that can change the
amount of steam flow through the coil. The amount of steam flow is the input to
the next block, which represents the output. The process plant block affects the
controlled variable, which is temperature. The output is sensed by the sensing
element and fed to the controller as feedback, completing the loop.

Each component of Figure 2 can be represented by a transfer function, which is an

idealized mathematical representation of the relationship between the input and
output variables of the component. The transfer function must be sufficiently
detailed to cover both the dynamic and static characteristics of the device. The
dynamics of the component are represented in the time domain by a differential
equation.

1.8.3 Computer for utomatic control

Computers can perform the control schemes described in this chapter. The covers
computer components and some of the ways computers are being used in the
HVAC industry. Other technical publications are available that describe the
application of computers in the HVAC control industry.

1.8.4: control components

Although control components may be classified in several ways, this section

groups them by their function within a complete control system. The first
subsection, Controlled Devices, considers controlled devices, or final control
elements, including (1) relays; (2) valves; (3) dampers; and (4) variable air volume
(VAV) boxes, which contain a damper or damper-like mechanism. Operators,
which are used to drive the valve or damper assembly, are also covered.

The second subsection, Sensors, considers the sensing element that measures
changes in the controlled variable. Examples of sensor types included are
temperature, humidity, water and air pressure, water and air differential pressure,
and water and airflow rate. While many other kinds of special sensors are
available, these represent the majority of those found in the HVAC control
systems and subsystems described in the section on Control System Design
Application.
٣٢ Chapter 1- Introduction –

In the third subsection, Controllers, various types of controllers are reviewed.

Controllers are classified according to the control action they initiate to maintain
the desired condition (set point).
They may use two-position, floating, proportional, PI, or PID control. This section
also describes the various devices, such as pneumatic, electronic, and digital
controllers, available for making the control decision in a modulating control
system. Thermostats (devices that combine a temperature sensor and controller
into a single unit) are also covered.

1.8.5 controlled devices

The controlled device most often regulates or varies the flow of steam, water, or
air within an HVAC system. Water and steam flow regulators are known as
valves, and airflow control devices are called dampers; they perform essentially
the same function and must be properly sized and selected for the particular
application. The control system’s link to the valve or damper is a component
called an operator, or actuator. This device uses electricity, compressed air, or
hydraulic fluid to power the motion of the valve stem or damper linkage through
its operating range.

1.8.6 Valves

An automatic valve is designed to control the flow of steam, water, gas, and other
fluids and may be thought of as a variable orifice positioned by an electric or
pneumatic operator in response to impulses or signals from the controller. It may
be equipped with a throttling plug or V-port specially designed to provide the
desired flow characteristics.

Renewable composition disks are common. They are made of the materials best
suited to the media handled by the valve, the operating temperature, and the
pressure. For high pressures or for superheated steam, metal disks are often used.
Internal parts of valves, such as the seat ring, throttling plug or V-port skirt, disk
holder, and stem, are sometimes made of stainless steel or other hard and
corrosion-resistant metals.

1.8.7 Types of automatic valves include the following:

 A single-seated valve is designed for tight shutoff. Appropriate disk

materials for various pressures and media are used.
 A double-seated or balanced valve is designed so that the pressure acting
against the valve disk is essentially balanced, reducing the operator force
required. It is widely used where fluid pressure is too high to permit a
٣٣ Chapter 1- Introduction –

single-seated valve to close. It cannot be used where tight shutoff is

required.
 A three-way mixing valve has two inlet connections, one outlet connection,
and a double-faced disk operating between two seats. It is used to mix two
fluids entering through the inlet connections and leaving through the
common outlet, according to the position of the valve stem and disk.
 A three-way diverting valve has one inlet connection, two outlet
connections, and two separate disks and seats. It is used either to divert the
flow to one of the outlets or to proportion the flow to both outlets.
 A butterfly consists of a heavy ring enclosing a disk that rotates on an axis
at or near its center; it is similar in principle to a round single-blade damper.
The disk seats against a ring machine.

1.8.8 Operators

1.8.8.a) Valve operators are of five general types:

1. A solenoid consists of a magnetic coil operating a movable plunger. Most are

for two-position operation, but modulating solenoid valves are available with a
pressure equalization bellows or piston to achieve modulation. Solenoid valves are
generally limited to relatively small sizes (4 in. or less).

2. An electric motor operates the valve stem through a gear train and linkage.
Electric motor opera tars are of the following three types:
a) Unidirectional—for two-position operation. The valve opens during one half
revolution of the output shaft and closes during the other half revolution. Once
started, it continues until the half revolution is completed, regardless of
subsequent action by the controller. Limit switches built into the operator stop the
motor at the end of each stroke. If the controller has been satisfied during this
interval, the operator continues to the other position.
b) Spring-return—for two-position operation. Electric energy drives the valve to
one position, and a spring returns it to its normal position.
c) Reversible—for floating and proportional operation. The motor can run in
either direction and can stop in any position. It is sometimes equipped with a
return spring. In proportional control applicant tons, the motor also drives a
feedback potentiometer for rebalancing the control circuit.

3. A pneumatic operator consists of a spring-opposed, flexible diaphragm or

bellows attached to the valve stem. An increase in air pressure above the
minimum point of the spring range compresses the spring and simultaneously
moves the valve stem. Springs of various constants can sequence the opera ton of
two or more devices, if properly selected or adjusted. For example, a chilled water
٣٤ Chapter 1- Introduction –

valve operator may modulate the valve from fully closed to fully open over a
range of 3 to 8 psig, while a sequenced steam valve may operate from 8 to 13 psig.
Pneumatic operators are used primarily for proportional control. Two-position
control is carom plashed using a two-position controller or a two-position
pneumatic relay to apply either full air pressure or no pressure to the valve
operator. Pneumatic valves and valves with spring-return electric operators can be
classified as normally open or normally closed.
d) A normally open valve will assume an open position, providing full flow, when
all operating force is removed.
e) A normally closed valve will assume a closed position, stopping flow, when all
operating force is removed.

4. Spring less pneumatic operators, which use two opposed diaphragms or two
sides of a single diaphragm, are generally limited to special applications involving
large valves or high pressures.

5. An electric-hydraulic actuator is similar to a pneumatic one, except that it uses

an uncompress bile fluid, which is circulated by an internal electric pump.

1.8.9 Sensors

The sensor is the component in the control system that measures the value of the
controlled variable. A change in the controlled variable (such as the temperature
of water flowing in a pipe) produces a change in some physical or electrical
property of the primary sensing element that is then translated or amplified by
mechanical or electrical signal. A device that converts one form of energy
(mechanical or thermal) to another (electrical) is known as a transducer. In some
cases, the sensing element is a transducer, such as a thermostat, in which a change
in temperature causes a change in electrical resistance.

With the trend toward electronic miniaturization and solid-state sensing elements,
sensor selection has become a specialty. New measurement technologies and
manufacturers are emerging regularly, expanding the options available to the
control system designer and outdating older texts on sensor application. This
section does not describe all the technologies for measurement and transmission of
even the common variables of temperature, humidity, pressure, and flow rate.

1.8.9.a) Temperature Sensors

Temperature-sensing elements depend on one of three physical phenomena: (1) a

change in relative dimension due to differences in thermal expansion, (2) a change
in state in a vapor- or liquid-filled bellows, or (3) a change in some electrical
٣٥ Chapter 1- Introduction –

property. Within each category, there are a variety of sensing element

configurations to measure room, duct, water, and surface temperatures.

The specific types of temperature-sensing technologies commonly used in HVAC

applications are as follows:
 A bimetal element is composed of two thin strips of dissimilar metals fused
together. Because the two metals have different thermal expansion coefficients,
the element bends as the temperature vary it's and produces a change in
position. Depending on the space available and the movement required, the
strip may be straight, U-shaped, or wound into a spiral. This element is
commonly used in room, insertion, and immersion thermostats.
 A rod-and-tube element consists of a high-expansion metal tube containing a
low-expansion rod with one end attached to the rear of the tube. The tube
changes length with changes in temperature, causing the free end of the rod to
move. This element is commonly used in certain types of insertion and
immersion thermostats.
 A sealed bellows element is filled with vapor, gas, or liquid after being
evacuated of air. Tempera true changes cause changes in the pressure or
volume of the gas or liquid, resulting in a change in force or movement. This
element is often used in room thermostats.
 A remote bulb element is a sealed bellows or diaphragm to which a bulb or
capsule is attached by means of a capillary tube; the entire system is filled with
vapor, gas, or liquid. Temperature changes at the bulb result in volume or
pressure changes, which are communicated to the bellows or die phragm
through the capillary tube. The remote bulb element is useful where the
temperature mea siring point is remote from the desired thermostat location. It
usually is provided with fittings suitable for insertion into a duct, pipe, or tank.
Averaging bulbs are used in large ducts where a single sensing point may not
be representative.
 A heritor makes use of the change in electrical resistance of a semiconductor
material due to a representative change in temperature. The characteristic curve
of a thermostat is nonlinear over a wide range. It has a negative temperature
coefficient; that is, the resistance decreases as the tem perturb increases. For
electronic control systems, a variety of techniques is available to ensure a
linear change over a particular temperature range. In a digital control system,
one technique for con vetting the nonlinear response is to store a computer
“look-up table” that maps the temperatures corresponding to measured
resistances. Thermostats are used because of their relatively low cost and the
large change in resistance possible for a small change in temperature.
 A resistance temperature detector (RTD) is another sensor that makes use of
the temperature dependence of electrical resistance. Most metallic materials
increase in resistance with increasing temperature. Over limited ranges, this
variation is linear for such metals as platinum, copper, ting stem, and some
٣٦ Chapter 1- Introduction –

nickel/iron alloys. Platinum, for example, is linear within 0.3% from 0 to

300°F. The RTD sensing element is available in several different forms for
surface or immersion mounting. Flat grid windings are used for measurements
of surface temperatures. For direct measurement of fluid temperatures, the
winding of resistance wire is encased in a stainless-steel bulb to protect it from
corrosion. The RTD measurement circuit typically consists of three wires, to
correct for line resin trance. In many cases, the three-wire RTD is mated to an
electronic circuit (transmitter) to produce a 4 to 20 mA current signal over a
finite temperature range.
 A thermocouple is formed by the junction of two wires of dissimilar metals.
An electromotive force dependent on the wire materials and the junction
temperature exists between the wires. When the wires are joined at two points,
a thermocouple circuit is formed. As long as one junction is kept at a constant
temperature different from that of the other junction, electric current flows
through the circuit as a result of the difference in voltage potential developed
between the two junctions. The constant temperature junction is called the cold
junction. Various systems are used to provide cold junction compensation.
Advances in solid-state circuitry have produced thermocouple transmitters with
built-in cold junction and linearization circuits. When attached to the proper
thermocouple, this circuit can provide a linear zed signal (such as 4 to 20 mA
dc) to a controller or an indicating digital meter.

1.8.9.b) Humidity Sensors

Humidity sensors, or hygrometers, can be used to measure the relative humidity or

dew point of ambient or moving air. Hygroscopic (water-absorbent) materials
respond directly to atmospheric moisture. Two types of hygrometers are available
for use in central systems—mechanical and electronic.

A mechanical hygrometer makes use of the fact that a hygroscopic material, when
exposed to water vapor, retains moisture and expands. The change in size or form
is detected by a mechanical linkage and converted to a pneumatic or electronic
signal. The most direct indicator of relative humidity is the change in length of an
unhampered human hair. Human hair exhibits a total change of about 2.5% of its
original length as the relative humidity changes from 0 to 100%. A human hair
hygrometer can measure relative humidity from 5 to 100% to within 5% at
temperatures above 32°F.

Other materials used in mechanical humidity sensors include organic materials

(e.g., wood fibers, paper, and cotton) and manufactured materials (e.g., nylon).
Electronic hygrometers can be of the resistance or capacitance type. The
resistance type uses a conductive grid coated with a hygroscopic substance. The
conductivity of the grid varies with the water retained; thus, the resistance varies
according to the relative humidity. The conductive element is arranged in an
٣٧ Chapter 1- Introduction –

alternating current-excited Wheatstone bridge and responds quickly to humidity

changes. The capacitance type is a stretched membrane of nonconductive film
with metal electrodes on both sides that is mounted within a perforated plastic
capsule. The change in the sensor’s capacitance is nonlinear with respect to rising
relative humidity. The signal is linear zed and compensated for temperature in the
amplifier circuit to provide an output signal as the relative humidity changes from
0 to 100%.

1.8.9.c) Pressure Transmitters, Controllers, and Transducers

A pneumatic pressure transmitter converts a change in absolute, gage, or

differential pressure to a mechanical motion using a bellows, diaphragm, or
Bourdon tube mechanism. When corrected through appropriate linkage, this
mechanical motion produces a change in the air pressure to a controller. In some
instances, the sensing and control functions are combined in a single component, a
pressure controller.

An electronic pressure transducer moves a potentiometer or differential

transformer by mechanical linkage of a diaphragm or Bourdon tube. Another type
of transducer uses a strain gage bonded to a diaphragm. The strain gage detects the
displacement resulting from the force applied to the diaphragm. Electronic
circuitry for temperature compensation and amplification produces a standard
output signal.

1.8.9.d) Flow Rate Sensors

The following basic sensing principles and devices are used to sense water or fluid
flow: orifice plate, Pitot tube, venture, turbine meter, magnetic flow meter, vortex
shedding meter, and Doppler Effect meter. These vary in range, accuracy, cost,
and suitability for use with clean or dirty fluids, making them appropriate for
different applications. In general, the pressure differential devices (orifice plates,
venture tubes, and pitot tubes) are less expensive and simpler to use but have
limited range; thus, their accuracy depends on how they are applied and where in a
system they are located.

More sophisticated flow devices, such as turbine, magnetic flow, and vortex
shedding meters, usually have a better range and are more accurate over a wide
range. When retrofitting, however, the expense of shutting down a system and
cutting into a pipe must be considered. In this case, a noninvasive meter, such as a
Doppler Effect meter, can be more cost-effective than a flow meter.
٣٨ Chapter 1- Introduction –

1.8.10 Controllers

Controllers take the sensor input, compare it with the desired control condition
(set point), and regulate an output signal to cause a control action at the controlled
device. The controller and sensor can be combined in a single instrument, such as
a room thermostat, or they may be two separate devices. When separate pneumatic
units are used, the pneumatic controller is usually referred to as a receiver-
controller.

1.8.10.a) Electric/Electronic Controllers

For two-position control, the controller output may be a simple electrical contact
that starts a burner or pump or actuates a spring-return valve or damper operator.
Single-pole, double-throw
(SPDT) switching circuits are used to control a three-wire unidirectional motor
operator; they are also used for heating-cooling applications. Either single-pole,
single-throw (SPST), or SPDT circuits can be modified for timed two-position
action.

For floating control, the controller output is an SPDT switching circuit with a
neutral zone where neither contact is made. This control is used with reversible
motor operators.

1.8.10.b) No indicating, Indicating, and Recording Controllers

The no indicating controller is most common in HVAC work and includes all
varieties in which the sensing element provides no visual indication of the value of
the controlled variable. A separate thermometer, relative humidity indicator, or
pressure gage is required for an indication. For example,
a separate thermometer is often attached to the cover of room thermostats.
An indicating controller has a pointer added to the sensing element or attached to
it by a linkage, so that the value of the controlled variable is indicated on a
suitable scale.

A recording controller is similar to an indicating controller, except that the

indicating pointer is replaced by a recording pen that provides a permanent record
on special chart paper.

Proportional control provides a continuously or incrementally changing output

signal to position an electrical actuator or controlled device.
٣٩ Chapter 1- Introduction –

1.8.10.c) Pneumatic Receiver-Controllers

Pneumatic receiver-controllers are normally combined with sensing elements

having a force or position output in order to obtain a variable air pressure output.
The control mode is usually proportional, but other modes, such as proportional-
plus-integral, can be used. These controllers are generally classified as no relay,
relay direct, or relay indirect.

A no relay pneumatic controller uses a restrictor in its air supply and a bleed
nozzle. The sensing element positions an air exhaust flapper, which varies the
nozzle opening, causing a variable air pressure output to be applied to the
controlled device, usually a pneumatic operator. The response time is relatively
long, since all air must flow through the small orifice to position the actuator.

A relay-type pneumatic controller, either directly or indirectly through a restrictor,

nozzle, and flapper, actuates a relay device that amplifies the air volume available
for control. This arrangement provides quicker response to a measured variable
change.

Controllers are further classified by construction as direct- or reverse-acting.

Direct-acting controllers increase the output signal as the controlled variable
increases. For example, a direct-acting pneumatic thermostat increases output
pressure when the sensing element detects a temperature rise.
Reverse-acting controllers increase the output signal as the controlled variable
decreases. A reverse-acting pneumatic thermostat increases output pressure when
the temperature drops.

1.8.10.d) Direct Digital Controllers

A direct digital controller uses a digital computer to implement control algorithms

on one or multiple control loops. It differs fundamentally from pneumatic or
electronic controllers in that the control algorithm is stored as a set of program
instructions in memory (software or firmware). The controller itself calculates the
proper control signals digitally rather than using an analog circuit or mechanical
change.

A digital controller can be either single- or multicolor. Interface hardware allows

the digital computer to process signals from various input devices, such as the
electronic temperature, humidity, and pressure sensors described in the section on
Sensors. Based on the digitized equivalents of the voltage or current signals
produced by the inputs, the control software calculates the required state of the
output devices, such as valve and damper actuators and fan starters. The output
devices are then moved to the calculated position via interface hardware, which
٤٠ Chapter 1- Introduction –

converts the digital signal from the computer to the analog voltage or current
required to position the actuator or energize a relay.

The user enters parameters such as set points, proportional or integral gains,
minimum on- and off-times, or high and low limits. The control algorithms stored
in the computer’s memory, in conjunction with actual input values, make the
control decisions. The computer scans the input devices, executes the control
algorithms, and then positions the output device(s) in a time-multiplex scheme.
Digital controllers can be classified with regard to the way they store control
algorithms in memory.

Preprogrammed control routines are typically stored in permanent memory, such

as programmable read-only memory (PROM). The user can modify parameters
such as set points, limits, and minimum off-times within the control routines, but
the program logic cannot be changed without replacing the memory chips. This
prevents unauthorized alteration.

User-programmable controllers allow the algorithms to be changed by the user.

The programming language provided with the controller can vary from a
derivation of a standard language to a custom language developed by the
controller’s manufacturer. Preprogrammed routines for proportional control, PI
control, Boolean logic, timers, and so forth, are typically included
In the language. Standard energy management routines may also be
preprogrammed and may interact with other control loops where appropriate.

A terminal allows the user to communicate with and, where applicable, modify the
program in the controller. These terminals can range from hand-held units with an
LCD and several buttons to a full-size console with a cathode-ray tube (CRT) and
typewriter-style keyboard. The terminal can be limited in function to allow only
the display of sensor and parameter values or powerful enough to allow changing
or reprogramming the control strategies. In some instances, the terminal can
communicate remotely with one or more controllers, allowing centralized system
displays, alarms, and commands.

1.8.10.e) Thermostats

Thermostats combine the control and sensing functions into a single device.
Because thermostats are so prevalent, this section describes the various types and
their operating characteristics.
 The occupied-unoccupied or dual-temperature room thermostat reduces
temperature at night.
 It may be indexed (changed from occupied to unoccupied operation or vice
versa) individually from a remote point or in a group by a manual or time
switch. Some electric types have an individual clock and switch built in.
٤١ Chapter 1- Introduction –

 The pneumatic day-night thermostat uses a two-pressure air supply system, the
two pressures often being 13 and 17 psig or 15 and 20 psig. Changing the
pressure at a central point from one value to the other actuates switching
devices in the thermostat and indexes it. Supply air mains are often divided
into two or more circuits, so that switching can be done in separate areas of the
building at different times. For example, a school building may have separate
circuits for classrooms, offices and administrate dive areas, the auditorium, the
gymnasium, and locker rooms.
 The heating-cooling or summer-winter thermostat can have its action reversed
and its set point changed by indexing. It is used to actuate controlled devices,
such as valves or dampers that rage late a heating source at one time and a
cooling source at another. The indexing is often done Manu ally by switch or
automatically by another thermostat that senses the temperature of the control
agent (outdoor temperature or another suitable variable).
 The pneumatic heating-cooling thermostat uses a two-pressure air supply
similar to that described for occupied-unoccupied thermostats.
 Multistage thermostats are arranged to operate two or more successive steps in
sequence.
 A sub master thermostat has its set point raised or lowered over a
predetermined range, in accord dance with variations in output from a master
controller. The master controller can be a thermostat, manual switch, pressure
controller, or similar device. For example, a master thermostat measuring
outdoor air temperature can be used to readjust the set point of a sub master
thermostat that con trolls the water temperature in a heating system. Master-
sub master combinations are sometimes said to have single-cascade action.
When reset is accomplished by a single thermostat having more than one
measuring element, it is known as compensated control.
 A wet-bulb thermostat is often used (in combination with a dry-bulb
thermostat) for hum troll.

 Both a wick and other means of keeping the bulb wet with pure (distilled)
water and rapid air motion, to ensure a true wet-bulb measurement, are
essential. Because of maintenance problems, wet-bulb thermostats are seldom
used.
 A dew-point thermostat is designed to control dew-point temperatures. Dew
point is measured in several ways; the most accurate is to measure the
temperature of an electrically heated chemical layer.
 A dead-band thermostat has a wide differential over which the thermostat
remains neutral, require in neither heating nor cooling. This differential may be
adjustable up to 10°F. The thermostat con trolls to maximum or minimum
output over a small differential at each end of the dead band.
٤٢ Chapter 2-zoning & Building survey-

2. ZONING & BUILDING SURVEY

2.1 Zoning

Location:

Borg Elarab Alexandria,

Building Construction:

Consists of: one floors

The CODE given for each zone.

Coding system:

Example:

Zone # 01

K 0 1

AHU

● The first figure indicates the AHU, such that:

AHU #1 AHU-K
AHU #2 AHU-L
٤٣ Chapter 2-zoning & Building survey-

AHU #3 AHU-M
AHU #4 AHU-N
AHU #5 AHU-O
AHU #6 AHU-P

● The second and third figures indicate the zone number.

2.2 BUILDING SURVAY

1- The AREA of each zone.

2- The VOLUME of each zone.

3- The AIR CHANGE of each zone.

4- The CASSIFICATION of each zone.

Are shown in the following tables:

AHU-K

AIR
NO TITLE AREA HIGHT VOLUME CLASS
CHANGE
K01 mixture room 13 3 39 30 D
medicine
K02 preparation 115 3 345 30 D
corridor
medicine
K03 preparation room 30 4.5 135 30 D
#1
medicine
K04 preparation room 31 4.5 139.5 30 D
#2
medicine
K05 weighing room # 35.5 3 106.5 30 D
1
K06 pre - weigh room 35.5 3 106.5 30 D
٤٤ Chapter 2-zoning & Building survey-

AHU-L

AIR
NO TITLE AREA HIGHT VOLUME CLASS
CHANGE
L01 storage room 25 3 75 30 D
gel preparation
L02 68 4.5 306 30 D
department
gelatin and dye
L03 54 3 162 30 D
weighing room

AHU-M

AIR
NO TITLE AREA HIGHT VOLUME CLASS
CHANGE
M01 corridor # 1 36 3 108 30 D

M02 tank wash 41 2.95 120.95 30 D

M04 corridor # 3 55 3 165 30 D

M05 corridor 85 2.5 212.5 30 D

AHU-N

AIR
NO TITLE AREA HIGHT VOLUME CLASS
CHANGE
DRAYING
N01 260 1.95 507 60 C
TANNEL (1&2)
٤٥ Chapter 2-zoning & Building survey-

AHU-O

AIR
NO TITLE AREA HIGHT VOLUME CLASS
CHANGE
O01 ENCAPSULATION 282 2.25 634.5 60 C

AHU-P

AIR
NO TITLE AREA HIGHT VOLUME CLASS
CHANGE
blister & carton
P01 96 3 288 60 C
packing

P02 clean storage 18 3 54 60 C

P03 Q &A room 9 3 27 60 C

P04 capsule polishing 18 3 54 60 C

P05 finishing 125 3 375 60 C

P06 material lock 38 3 114 60 C

46 Chapter 3- Load calculations –

3. LOAD CALCULATIONS

3.1 The aim of load assessment

M ost air conditioning systems operate at their design loads for only a small
part of their life and it follows, therefore, that the designer should be
concerned not only with the maximum heat gains and cooling loads but
Also with the way these change thought the day and over the year. Establishing the
pattern of such variations will be of help in choosing the correct system and in
selecting the best form of automatic control. Applications lie in the commercial,
industrial, institutional and domestic sectors for the climates of the world.

-Outside Design Condition (ODC)"O"

The outside design condition is the dry bulb temperature and wet bulb temperature
which Simultaneously Occurring during the summer.
In Alexandria Tdb=39°C&Twb=26°C.

-Inside Design Condition (IDC)"R"

The inside design condition depend on the zone activity as shown:

1- AHU-K Tdb=22 oC & r.h=40%
2- AHU-L Tdb=22 oC & r.h=45%
3- AHU-M Tdb=22 oC & r.h=45%
4- AHU-N Tdb=22 oC & r.h=20%
5- AHU-O Tdb=22 oC & r.h=45%
6- AHU-P Tdb=22 oC & r.h=45%

By using Fridgetech AHU Performance Analyser program to calculate cooling

loads:
47 Chapter 3- Load calculations –

Fridgetech AHU Performance Analyser program

An overview of the program

The first page of the program

48 Chapter 3- Load calculations –

An overview of the program

The second page of the program

49 Chapter 3- Load calculations –

An overview of the program

The third page of the program

50 Chapter 3- Load calculations –

3.2 Program Procedure

First Page (Mixing)

1- Click the Mixing bottom

2- Enter the air total volume
3- Enter the mixing ratio %
4- Enter the return air parameters
5- Enter the outdoor air parameters
51 Chapter 3- Load calculations –

Second Page (Cooling)

1- Switch to second page by click on Cooling bottom

2- Using the Import Mixing Results bottom to recall the previous data entered in
the first page
3- Get the final result of the cooling capacity.
4- Check the resulting cooling capacity
52 Chapter 3- Load calculations –

Third Page (Heating)

1- Click on the Heating bottom

2- Using the Import Cooling Results bottom to recall the previous data entered
in the second page
3- Check the amount of heat added
53 Chapter 3- Load calculations –

3.3 Load Calculation

1- For AHU-K

Outside Design Condition (ODC):

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=٥0%

Inside Design Condition

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=40%

Mixing ratio = 20% Fresh air

AIR
NO TITLE VOLUME CLASS CMH
CHANGE
K01 mixture room 39 D 30 1170
medicine
K02 345 D 30 10350
preparation corridor
medicine
K03 preparation room 135 D 30 4050
#1
medicine
K04 preparation room 139.5 D 30 4185
#2
medicine weighing
K05 106.5 D 30 3195
room # 1
K06 pre - weigh room 106.5 D 30 3195

TOTAL 26145

Cooling Capacity= 132.183 kW

54 Chapter 3- Load calculations –

2- For AHU-L

Outside Design Condition (ODC):

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=٥0%

Inside Design Condition

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=45%

Mixing ratio = 20% Fresh air

AIR
NO TITLE VOLUME CLASS CMH
CHANGE
L01 storage room 75 D 30 2250
gel preparation
L02 306 D 30 9180
department
gelatin and dye
L03 162 D 30 4860
weighing room

TOTAL 16290

Cooling Capacity= 77.995 kW

55 Chapter 3- Load calculations –

3- For AHU-M

Outside Design Condition (ODC):

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=٥0%

Inside Design Condition

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=45%

Mixing ratio = 20% Fresh air

AIR
NO TITLE VOLUME CLASS CMH
CHANGE
M01 corridor # 1 108 D 30 3240

M02 tank wash 120.95 D 30 3628.5

M0٣ corridor # 3 165 D 30 4950

M0٤ corridor 212.5 D 30 6375

TOTAL 18193.5

Cooling Capacity= 87.755 kW

56 Chapter 3- Load calculations –

4- For AHU-N

Outside Design Condition (ODC):

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=٥0%

Inside Design Condition

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=20%

Mixing ratio = 20% Fresh air

NO TITLE VOLUME CLASS AIR CHANGE CMH

DRAYING
N01 507 C 60 30420
TANNEL (1&2)
TOTAL 30420

Cooling Capacity= 178.159 kW

57 Chapter 3- Load calculations –

5- For AHU-O

Outside Design Condition (ODC):

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=٥0%

Inside Design Condition

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=45%

Mixing ratio = 20% Fresh air

AIR
NO TITLE VOLUME CLASS CMH
CHANGE
O01 ENCAPSULATION 634.5 C 60 38070

TOTAL 38070

Cooling Capacity= 185.243 kW

58 Chapter 3- Load calculations –

6- For AHU-P

Outside Design Condition (ODC):

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=٥0%

Inside Design Condition

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=45%

Mixing ratio = 20% Fresh air

AIR
NO TITLE VOLUME CLASS CMH
CHANGE
blister & carton
P01 288 C 60 17280
packing

P02 clean storage 54 C 60 3240

P03 Q &A room 27 C 60 1620

P04 capsule polishing 54 C 60 3240

P05 finishing 375 C 60 22500

P06 material lock 114 C 60 6840

TOTAL 54720

Cooling Capacity= 268.106 kW

59 Chapter 3- Load calculations –

7- For AHU-Q

Outside Design Condition (ODC):

Dry bulb Temperature Tdb=39 oC
Wet bulb Temperature Twb=26 oC

Inside Design Condition

Dry bulb Temperature Tdb=22 oC
Relative Humidity rh=٥0%

Mixing ratio = ALL Fresh air

AIR
NO TITLE VOLUME CLASS CMH
CHANGE
O01 fresh air 36767.7

TOTAL ٣٦٧٦٧.٧

Cooling Capacity= 534.529 kW

60 Chapter 3- Load calculations –

3.4 RESULTS

1- The Code of zone

2- Cooling Parameter
3- The Cooling Capacity
61 Chapter 3- Load calculations –

AHU-K (MEDICINE)
Altitude: 0m

Mixed Air (RA + OA)

Mixed Air Total Volume: 7.2224 m3/s
26000.64 m3/hr

Percent Return Air: 80% RA

Return Air Volume: 5.77792 m3/s Percent Outdoor Air: 20% OA
Return Air Dry Bulb: 22 °C Outdoor Air Volume: 1.44448 m3/s
Return Air RH: 40.6% Outdoor Air Dry Bulb: 22 °C
Outdoor Air RH: 49.9%
Mixing Results
Leaving Volume: 26000.64 m3/hr
Mixed Air Dry Bulb: 22.0 °C
Mixed Air RH: 42.4 %
Mixed Air Dew Point: 8.7 °C

Cooling
Return Air Volume: 7.2224 m3/s
26000.64 m3/hr
Return Air Dry Bulb: 22 °C Supply Air Dry Bulb: 11 °C
Return Air RH: 42.5% Supply Air RH: 65.1 %

Cooling Results

Leaving Volume: 24964.50 m3/hr

Total kW: 132.183 kW
Sensible: 94.631 kW
Latent: 37.552 kW
SHF: 0.72
Condensate: 51.90 litres/hr

Heating
Return Air Volume: 6.9346 m3/s
24964.56 m3/hr
Return Air Dry Bulb: 11 °C Supply Air Dry Bulb: 15 °C
Return Air RH: 65.2% Supply Air RH: 50.2 %

If Heat Is Reheat After Cooling Heating Results

Effective Duty: 97.440 kW Leaving Volume: 25316.0 m3/hr
Sensible: 59.887 kW Total kW: 34.74 kW
Latent: 37.552 kW
SHF: 0.61
62 Chapter 3- Load calculations –

AHU-L (GELATINE)
Altitude: 0m
Mixed Air (RA + OA)
Mixed Air Total Volume: 4.4445 m3/s
16000.20 m3/hr

Percent Return Air: 80% RA Percent Outdoor Air: 20% OA

Return Air Volume: 3.5556 m3/s Outdoor Air Volume: 0.8889 m3/s
Return Air Dry Bulb: 22 °C Outdoor Air Dry Bulb: 22 °C
Return Air RH: 45.2% Outdoor Air RH: 49.9%
Mixing Results
Leaving Volume: 16000.20 m3/hr
Mixed Air Dry Bulb: 220°C
Mixed Air RH: 46.0%
Mixed Air Dew Point: 9.9 °C

Cooling
Return Air Volume: 4.4445 m3/s
16000.2 m3/hr
Return Air Dry Bulb: 22 °C Supply Air Dry Bulb: 11 °C
Return Air RH: 45.8% Supply Air RH: 74.9%
Cooling Results

Leaving Volume: 15368.78 m3/hr

Total kW: 77.995 kW
Sensible: 58.183 kW
Latent: 19.812 kW
SHF: 0.75
Condensate: 27.15 litres/hr

Heating
Return Air Volume: 4.2691 m3/s
15368.76 m3/hr
Return Air Dry Bulb: 11 °C Supply Air Dry Bulb: 15 °C
Return Air RH: 75.0% Supply Air RH: 57.7%

If Heat Is Reheat After Cooling Heating Results

Effective Duty: 56.602 kW Leaving Volume: 15585.1 m'/hr
Sensible: 36.790 kW Total kW: 21.39kW
Latent: 19.812 kW
SHF: 0.65
63 Chapter 3- Load calculations –

AHU-M (CORR&WASHING)
Altitude: 0m
Mixed Air (RA + OA)
Mixed Air Total Volume: 5.0007 m3/s
18002.52 m3/hr

Percent Return Air: 80% RA Percent Outdoor Air: 20% OA

Return Air Volume: 4.00056 m3/s
Return Air Dry Bulb: 22 °C Outdoor Air Volume: 1.00014 m3/s
Return Air RH: 45.2% Outdoor Air Dry Bulb: 22 °C
Outdoor Air RH: 49.9%
Mixing Results
Leaving Volume: 18002.52 m3/hr
Mixed Air Dry Bulb: 22.0 °C
Mixed Air RH: 46.1 %
Mixed Air Dew Point: 9.9 °C

Cooling
Return Air Volume: 5.0007 m3/s
18002.52 m3/hr
11 °C
Return Air Dry Bulb: 22 °C Supply Air Dry Bulb: 74.9%
Return Air RH: 45.8% Supply Air RH:
Cooling Results

Leaving Volume: 17292.08 m3/hr

Total kW: 87.755 kW
Sensible: 65.464 kW
Latent: 22.291 kW
SHF: 0.75
Condensate: 30.54 litres/hr

Heating
Return Air Volume: 4.8034 m3/s
17292.24 m3/hr
Return Air Dry Bulb: 11 °C Supply Air Dry Bulb: 15 °C
Return Air RH: 75.0 % Supply Air RH: 57.7 %
If Heat Is Reheat After Cooling Heating Results
Effective Duty: 63.685 kW Leaving Volume: 17535.7 m3/hr
Sensible: 41.394 kW Total kW: 24.07 kW
Latent: 22.291 kW
SHF: 0.65
64 Chapter 3- Load calculations –

AHUF-N (DRYING ROOMS)

Altitude: 0m
Mixed Air (RA + OA)
Mixed Air Total Volume: 8.334 m3/s
30002.40 m3/hr
Percent Return Air: 80% RA
Percent Outdoor Air: 20% OA
Return Air Volume: 6.6672 m3/s
Outdoor Air Volume: 1.6668 m3/s
Return Air Dry Bulb: 27.5 °C
Outdoor Air Dry Bulb: 27.5 °C
Return Air RH: 8.7%
Outdoor Air RH: 8.7%
Mixing Results
Leaving Volume: 30002.40 m3/hr
Mixed Air Dry Bulb: 27.5 °C
Mixed Air RH: 8.7%
Mixed Air Dew Point: -8.5 °C

Cooling
Return Air Volume: 8.334 m3/s
30002.4 m3/hr
Supply Air Dry Bulb: 10 °C
Return Air Dry Bulb: 27.5 °C Supply Air RH: 23.1 %
Return Air RH: 8.7%
Cooling Results

Leaving Volume: , 28245.73 m3/hr

Total kW: 178.159 kW
Sensible: 171.911 kW
Latent: 6.248 kW
SHF: 0.96
Condensate: 8.04 litres/hr

Heating
Return Air Volume: 7.846 m3/s
28245.60 m3/hr
Return Air Dry Bulb: 10 °C Supply Air Dry Bulb: 10 °C
Return Air RH: 23.5% Supply Air RH: 23.5 %
If Heat Is Reheat After Cooling Heating Results
Effective Duty: 178.159 kW Leaving Volume: 28245.C
Sensible: 171.911 kW Total kW: 0.00 kw
Latent: 6.248 kW
SHF: 0.96
65 Chapter 3- Load calculations –

AHU-O (ENCAPSULATION)
Altitude: 0m
Mixed Air (RA + OA)
Mixed Air Total Volume: 10.556 m3/s
38001.60 m3/hr

Percent Return Air: Return 80% RA Percent Outdoor Air: 20% OA

Air Volume: 8.4448 m3/s
Return Air Dry Bulb: 22 °C Outdoor Air Volume: 2.1112m3/s
Return Air RH: 45.2% Outdoor Air Dry Bulb: 22 °C
Outdoor Air RH: 49.9%
Mixing Results
Leaving Volume: 38001.60 m3/hr
Mixed Air Dry Bulb: 22.0 °C
Mixed Air RH: 46.1 %
Mixed Air Dew Point: 9.9 °C

Cooling
Return Air Volume: 10.556 m3/s
38001.6 m3/hr
Return Air Dry Bulb: 22 °C Supply Air Dry Bulb: 11 °C
Return Air RH: 45.8% Supply Air RH: 74.9 %

Cooling Results

Leaving Volume: 36501.93 m3/hr

Total kW: 185.243 kW
Sensible: 138.188 kW
Latent: SHF: 47.055 kW 0.75
Condensate: 64.47 litres/hr

Heating
Return Air Volume: 10.1394 m3/s
36501.84 m3/hr
Return Air Dry Bulb: 11 °C Supply Air Dry Bulb: 15 °C
Return Air RH: 75.0% Supply Air RH: 57.7 %
If Heat Is Reheat After Cooling Heating Results
Effective Duty: 134.434 kW Leaving Volume: 37015.7 m3/hr
Sensible: 87.379 kW Total kW: 50.81 kW
Latent: 47.055 kW
SHF: 0.65
66 Chapter 3- Load calculations –

AHU-P (FINISHING)
Altitude: 0m
Mixed Air (RA + OA)
Mixed Air Total Volume: 15.2779 m3/s
55000.44 m3/hr

Percent Return Air: 80% RA Percent Outdoor Air: 20% OA

Return Air Volume: 12.22232 m3/s Outdoor Air Volume: 3.05558 m3/s
Return Air Dry Bulb: 22 °C Outdoor Air Dry Bulb: 22 °C
Return Air RH: 45.2% Outdoor Air RH: 49.9 %

Mixing Results

Leaving Volume: 55000.44 m3/hr

Mixed Air Dry Bulb:
22.0°C
Mixed Air RH: Mixed 46.0%
Air Dew Point: 9.9 °C
Cooling
Return Air Volume: 15.2779 m3/s
55000.44 m3/hr

Return Air Dry Bulb: 22 °C Supply Air Dry Bulb: 11 °C

Return Air RH: Supply Air RH: 74.9%
45.8%
Cooling Results

Leaving Volume: 52829.94 m3/hr

Total kW: 268.106 kW
Sensible: 200.003 kW
Latent: 68.104 kW
SHF: 0.75
Condensate: 93.31 litres/hr
Heating
Return Air Volume:
14.675 m3/s
52830.00 m3/hr
Return Air Dry Bulb: Supply Air Dry Bulb: 15 °C
Return Air RH: 11 °C Supply Air RH: 57.7 %
75.0%

If Heat Is Reheat After Cooling Heating Results

Effective Duty: 194.569 kW

Leaving Volume:
Sensible: 126.466 kW 53573.7 m3/hr
Latent: 68.104 kW Total kW: 73.54 kW
SHF: 0.65
67 Chapter 3- Load calculations –

AHU-Q (FRESH AIR)

Altitude: 0m

Mixed Air (RA + OA)

Mixed Air Total Volume: 10.2783 m3/s
37001.88 m3/hr

Percent Return Air: 0%RA Percent Outdoor Air: 100% OA

Return Air Volume: 0m3/s Outdoor Air Volume: 10.2783
Return Air Dry Bulb: 39 °C Outdoor Air Dry Bulb: 39 °C
Return Air RH: 35.3% Outdoor Air RH: 35.3%
Mixing Results
Leaving Volume: 37001.88 m3/hr
Mixed Air Dry Bulb: 39.0 °C
Mixed Air RH: 35.3 %
Mixed Air Dew Point: 20.9 °C

Cooling
Return Air Volume: 10.2783 m3/s
37001.88 m3/hr
Return Air Dry Bulb: 39 °C Supply Air Dry Bulb: 12 °C
Return Air RH: 35.3% Supply Air RH: 90.9%

Cooling Results

Leaving Volume: 33398.60 m3/hr

Total kW: 534.529 kW
Sensible: 308.363 kW
Latent: 226.166 kW
SHF: 0.58
Condensate: 310.22 litres/hr

Heating
Return Air Volume: 9.2774 m3/s
33398.64 m3/hr
Return Air Dry Bulb: 12 °C Supply Air Dry Bulb: 17 °C
Return Air RH: 91.0% Supply Air RH: 65.9%

If Heat Is Reheat After Cooling Heating Results

Effective Duty: 476.599 kW Leaving Volume: 33984.3 m3/hr
Sensible: 250.433 kW Total kW: 57.93 kW
Latent: 226.166 kW
SHF: 0.53
٦٨ Chapter 4- Selection of equipment–

4. SELECTION OF EQUIPMENT

4.1 AIR HANDLING UNIT SELECTION

4.1.1 GENARAL

A
n air handling system cools by moving air across a coil containing a cooling
medium (e.g. chilled water or a refrigerant). The next two figure show air
handling systems that use a chilled water coil and a refrigeration evaporator
(direct expansion) coil, respectively. Chilled water control is usually proportional,
whereas control of an evaporator coil is two positions. In direct expansion systems
having more than one coil, a thermostat controls a solenoid valve for each coil and
the compressor is cycled by a refrigerant pressure control. This type of system is
called a ″pump down ″ system. Pump down may be used for systems having only one
coil, but more often the compressor is controlled directly by the thermostat.
٦٩ Chapter 4- Selection of equipment–

Two basic types of cooling systems are available:

1-Chillers typically used in larger systems.

2-Direct expansion (DX) coils, typically used in smaller systems.

In a chiller , the refrigeration system cools water which is then pumped to coils in the
central air handling system or to the coils of fan coil units, a zone system, or other
type of cooling system. In a DX system, the DX coil of the refrigeration system is
located in the duct of the air handling system. Condenser cooling for chillers may be
air or water (using a cooling tower), while DX systems are typically air cooled.
Because water cooling is more efficient than air cooling, large chillers are always
water cooled.

Commercial packaged, air-handling units occupy between 0.4 m² per (m³/s) of air
delivered and their heights are from 0.5to 2.0 m over the range of duties from 0.5 to
20(m³/s) , the better quality, quieter units requiring more space and being higher than
those that are cheaper and noisier. Individual, forward-curved, centrifugal fans need
from 0.06to 0.03 m² per ( m³/s) of air, over a similar span of airflow rates.

Air-handling plant rooms may accommodate a packaged air-handling for supply air,
an extract fan and motor set; ducts for supply, reticulated, discharge and fresh air,
silencers; duct-mounted heated batteries; controls; switch-gear; pumps and lagged
pipes. The ducts are large and of a complicated shape, usually having to cross over
one another and plant is best erected on concrete plinths. Taking account of these
factors and of the need for enough space to give access for maintenance suggests that,
for preliminary planning purposes, it is wise to allow 12 m² plan area plus 13 m² per
(m³/s) of air handled, with a clear internal height of 2.7 m plus 0.1 m per (m³/s) of air
flow, up to a maximum of 4.5 m.
٧٠ Chapter 4- Selection of equipment–

SELECTION DIAGRAM

AIR VELOCITY (m/s)

The unit size selection is made on the basis of two parameters:

1. the Air volume
2. the Coil Face air velocity
Each model is identified by a very simple nomenclature: for example CS-200
corresponds to the air volume of 20000 m3/h at 2,5 m/s coil face velocity.The
Selection Diagram shows the possibility of achieving smaller or greater air volumes
for the same unit by varying the coil face velocity.This enables selection to be
optimized in terms of cost, dimensions, noise criteria, power, etc.
٧١ Chapter 4- Selection of equipment–

Filter section
The heating and cooling coils for the treatment of the air are housed in section and
are of finned block type, having the following standard characteristics:
1- Copper tube and aluminum fins .
2- Tube pitches 60 and 30 mm.
3- Rows pitch 30 mm.
4- Fins pitch 2.0, 2.5, and 3.0 mm.
5- (4 and 6 mm for special application).
6- Tube diameter 5/8".
7- Coil framework galvanized sheet steel.
8- Connections - threaded.
9- Electric heaters with multi-stage sheathed.
elements with plain surface or extended fin
surface dependent on duty.

Fan section

1- Forward blade and backward blade fans .

The fans are always of belt drive, double
inlet type, manufactured in galvanized steel
sheet, with steel shaft and ball bearings.
2- The fan drive is affected through belts of
trapezoidal shape.
3- The motor pulley is made from aluminum or
cast iron.
4- Fixed and variable pulleys are available.
5- The complete fan motor assembly will be
mounted on a base constructed of extruded
aluminum profiles and mounted on vibration
isolators.
6- Standard vibration isolators are of rubber, with spring type available on
request.
7- The anti-vibration connection mounted between the fan outlet and the casing is
made of an aluminum profile frame with self-extinguishing cloth.
8- The foregoing characteristics apply also to the return air and exhaust air fan
sections.
9- The units with twin fans operating in parallel are equipped with non-return
dampers to prevent air re-circulation in the case of one fan not running.
٧٢ Chapter 4- Selection of equipment–

Air mixing box section

Complete with up to 3 dampers to provide mixing control of fresh, recirculated and

exhaust air streams.

The dampers are available in:

1- Extruded aluminum profile blade
2- Extruded aluminum with tight shut off
edge seal

Complete with:
1- Opposed blades
2- Shaft
3- Hand operation levers
4- Extension for connection of actuator motor
or piston

The damper blades are gear wheel driven.

4.1.2 UNIT SECTION

٧٣ Chapter 4- Selection of equipment–

AIR HANDLING UNIT TABLE

٧٤ Chapter 4- Selection of equipment–
٧٥ Chapter 4- Selection of equipment–
٧٦ Chapter 4- Selection of equipment–

A.H.U- K (MEDICINE) Class D

Air volume (Vs) m³/hr 26000

Velocity (v) m/s 2.5
MODEL CS 370
Width mm 2600
Height mm 2020
Prefilter(G4) 250
RETURN

FILTER (F7) 650

UNIT

(mm)
RETURN FAN 2150
(mm)
MIXING BOX 2000
(mm)
LENGTH OF

TOTAL LENGTH OF THE UNIT(mm) 5050

MIXING BOX 2000
(mm)
COOLING COIL 450
WITH ELEMINATOR
SUPPLY

(mm)
UNIT

NO OF ROWS 5/6
HEATING COIL 450
(mm)
SUPPLY FAN 2150
(mm)
FILTER (F9) 650
(mm)
TOTAL LENGTH OF THE UNIT (mm) 5700
٧٧ Chapter 4- Selection of equipment–

A.H.U-K (MEDICINE) CLASS D arrangement

٧٨ Chapter 4- Selection of equipment–

A.H.U - L (GELATINE) Class D

Air volume (Vs) m³/hr 16000

Velocity (v) m/s 2.5
MODEL CS200
Width mm 1960
Height mm 1600
Prefilter(G4) 250
RETURN

FILTER (F7) 650

UNIT

(mm)
RETURN FAN 1750
(mm)
MIXING BOX 1650
(mm)
LENGTH OF

TOTAL LENGTH OF THE UNIT(mm) 4300

MIXING BOX 1650
(mm)
COOLING COIL 450
WITH ELEMINATOR
(mm)
SUPPLY
UNIT

NO OF ROWS 5/6
HEATING COIL 450
(mm)
SUPPLY FAN 1750
(mm)
FILTER (F9) 650
(mm)
TOTAL LENGTH OF THE UNIT (mm) 4950
٧٩ Chapter 4- Selection of equipment–

A.H.U-L (GELATINE) CLASS D arrangement

٨٠ Chapter 4- Selection of equipment–

A.H.U - M (CORR & WASHING) Class D

Air volume (Vs) m³/hr 18000

Velocity (v) m/s 2.5
MODEL CS250
Width mm 2240
Height mm 1660
Prefilter(G4) 250
RETURN

FILTER (F7) 650

UNIT

(mm)
RETURN FAN 1900
(mm)
MIXING BOX 1650
(mm)
LENGTH OF

TOTAL LENGTH OF THE UNIT(mm) 4450

MIXING BOX 1650
(mm)
COOLING COIL 450
WITH ELEMINATOR
SUPPLY

(mm)
UNIT

NO OF ROWS 5/6
HEATING COIL 450
(mm)
SUPPLY FAN 1900
(mm)
FILTER (F9) 650
(mm)
TOTAL LENGTH OF THE UNIT (mm) 5100
٨١ Chapter 4- Selection of equipment–

A.H.U-M (CORR & WASHING) CLASS D arrangement

٨٢ Chapter 4- Selection of equipment–

A.H.U - N (DRAYING ROOMS) Class C

Air volume (Vs) m³/hr 30420

Velocity (v) m/s 2.5
MODEL CS300
Width mm 2400
Height mm 1840
Prefilter(G4) 250
RETURN

FILTER (F7) 650

UNIT

(mm)
RETURN FAN 2050
(mm)
MIXING BOX 1850
(mm)
4800
LENGTH OF

TOTAL LENGTH OF THE UNIT(mm)

MIXING BOX 1850
(mm)
COOLING COIL 450
WITH ELEMINATOR
(mm)
SUPPLY
UNIT

NO OF ROWS 5/6
HEATING COIL 450
(mm)
SUPPLY FAN 2050
(mm)
FILTER (H10) 1500
(mm)
TOTAL LENGTH OF THE UNIT (mm) 6300
٨٣ Chapter 4- Selection of equipment–

A.H.U-N (DRAYING ROOMS) CLASS C arrangement

٨٤ Chapter 4- Selection of equipment–

A.H.U - O (ENCAPSULATION) Class C

Air volume (Vs) m³/hr 38000

Velocity (v) m/s 2.5
MODEL CS450
Width mm 3340
Height mm 1940
Prefilter(G4) 270
RETURN

FILTER (F7) 650

UNIT

(mm)
RETURN FAN 2200
(mm)
MIXING BOX 2300
(mm)
TOTAL LENGTH OF THE UNIT(mm) 5420
LENGTH OF

MIXING BOX 2300

(mm)
COOLING COIL 450
WITH ELEMINATOR
(mm)
SUPPLY
UNIT

NO OF ROWS 5/6
HEATING COIL 450
(mm)
SUPPLY FAN 2300
(mm)
FILTER (H10) 1600
(mm)
TOTAL LENGTH OF THE UNIT (mm) 7100
٨٥ Chapter 4- Selection of equipment–

A.H.U-O (ENCAPSULATION) CLASS C arrangement

٨٦ Chapter 4- Selection of equipment–

A.H.U - P (FINISHING) Class C

Air volume (Vs) m³/hr 55000

Velocity (v) m/s 2.5
MODEL CS680
Width mm 4020
Height mm 2300
Prefilter(G4) 270
RETURN

FILTER (F7) 650

UNIT

(mm)
RETURN FAN 2050
(mm)
MIXING BOX 2300
(mm)
LENGTH OF

TOTAL LENGTH OF THE UNIT(mm) 5270

MIXING BOX 2300
(mm)
COOLING COIL 450
WITH ELEMINATOR
SUPPLY

(mm)
UNIT

NO OF ROWS 5/6
HEATING COIL 450
(mm)
SUPPLY FAN 2050
(mm)
FILTER (H10) 1600
(mm)
TOTAL LENGTH OF THE UNIT (mm) 6850
٨٧ Chapter 4- Selection of equipment–

A.H.U-P (FINISHING) CLASS C arrangement

٨٨ Chapter 4- Selection of equipment–

A.H.U – Q (FRESH AIR)

Air volume (Vs) m³/hr 37000

Velocity (v) m/s 2.5
MODEL CS450
Width mm 3340
Height mm 1940
SAND TRAP LOVER 700

Prefilter(G4) 270
FILTER (F7) 650
(mm)
LENGTH OF

COOLING COIL 450

WITH ELEMINATOR
(mm)
NO OF ROWS 5/6

HEATING COIL 450

(mm)

SUPPLY FAN 2200

(mm)

TOTAL LENGTH OF THE UNIT (mm) 4720

٨٩ Chapter 4- Selection of equipment–

A.H.U – Q (FRESH AIR)arrangement

٩٠ Chapter 4- Selection of equipment–

4. SELECTION OF EQUIPMENT

4.2 CHILLER SELECTION

4.2.1 GENERAL

A
air cooled chiller is often our only option if we don't have an existing cooling
tower. If we don't have 85° F plant water to use for our condenser, so we
have to use a kinds of high efficiency air cooled chillers

Since air cooled chillers transfer the heat from the process to the surroundings in the
form of air, the environment in which these chillers will be used must be suitable. Air
cooled chillers, for instance, must be located in an open, well-ventilated space to
avoid overheating. The rejected heat from units with centrifugal blowers can be
reclaimed to supplement a building's heating system in the winter and transferred out
during the summer using exhaust ducts.

Chiller types are classified by type of refrigeration cycle: vapor compression or

absorption. In addition, those using the vapor compression cycle are referred to by the
type of compressor: centrifugal or positive displacement. A positive displacement
compressor can be either reciprocating or screw
٩١ Chapter 4- Selection of equipment–

4.2.2 CHILLER SELECTION STATEMENT

● Total central load capacity = A .H .U capacity

● Total central load capacity = 520 T. R

● We will choose two chillers each chiller capacity =260 T. R

● By using the chiller catalogue with frequency = 50 HZ

● Leaving chilled water temperature (LCWT) = 5° C

● Condenser entering air temperature (CEAT) = 39° C

WE WILL GET FROM TABLE:

● Type: YCAS 1093 SB

● Capacity=912 KW

● Compressor motor input (I/P) =260 KW

● Cooler flow rate (I/P) =141 m3 /hr

٩٢ Chapter 4- Selection of equipment–

4.2.3 CHILLER SELECTION

Using YORK tables for Chiller selection

٩٣ Chapter 4- Selection of equipment–

Low pressure liquid refrigerant enters the cooler and is evaporated and superheated
by the heat energy absorbed from the chilled water passing through the cooler shell.
Low pressure vapour enters the compressor where pressure and superheat are
increased. High pressure vapour is passed through the oil separator where compressor
oil is removed and recirculated to the compressor via the oil cooler. The high pressure
٩٤ Chapter 4- Selection of equipment–

oil-free vapour is fed to the air cooled condenser coil and fans where the heat is
removed. The fully condensed liquid enters the economiser. A small percentage of
the of the liquid passes through an expansion valve, into the other side of the
economiser where it is evaporated. This low pressure liquid subcools the major part
of the refrigerant. Medium pressure vapour then returns to the compressor. The
subcooled refrigerant then passes through the expansion valve where pressure is
reduced and further cooling takes place before returning to the cooler.
٩٥ Chapter 4- Selection of equipment–

Chiller Type YCAS 1093 overview

Type of Chiller YCAS 1093

٩٦ Chapter 4- Selection of equipment–

Chiller YCAS 1093 Characteristics

٩٧ Chapter 4- Selection of equipment-

4. SELECTION OF EQUIPMENT

4.3 PUMP SELECTION

4.3.1 GENERAL

A
Centrifugal pumps turning in the normal way, the backward-curved vanes on
the impeller rotate the water and impart kinetic energy to it, directing the
liquid outwards from the suction eye, over the vanes to the casing, where it
flows away at high pressure. The kinetic energy of the water leaving the impeller,
corresponding to its velocity head, is converted into potential energy, corresponding
to its static head, either by a volute casing or by a diffuser casing, The former is the
more usual design for pumps used in building services and with it most of the energy
conversion takes place as the volute finally expands to the pump outlet.
The total pump head, H, or pressure, pt is analogous to fan total pressure and is
defined by:

H= (Hd + V²d /2g) – (Hs +V²s/2g) ………….. (1)

Where:
Hd and Hs are the static heads at pump discharge and Pump suction.
Vd and Vs are the corresponding velocities of water flow
V²/2g. is the velocity head.

Equation (1) states that the total pump head is the difference between the total heads
at pump discharge and suction, in accordance with Bernoulli's.

The static pressure datum for a system is established by the connexion from the feed
and expansion tank, if the circuit is closed. In the case of an open circuit, the pond of
the cooling tower is the feed and expansion tank and the static water level in it
establishes the system datum pressure. If the feed and expansion tank has a water
level at a higher ho above the centre-line of the impeller it imposes a static head of ho,
or static pressure of po =ρgho , on a closed circuit at the point of connexion, whether
the pump runs or not. If the connexion is made at pump suction po =pss and this is the
lowest static pressure in the system. When the connexion is at the pump discharge, po
=psd and this is the highest static pressure in the system. It is generally desirable to
make the connexion at the pump suction in chilled water circuits so that there is no
٩٨ Chapter 4- Selection of equipment-

risk of capitation if a large pressure drop should occur across an item of plant
elsewhere in the system.

Pump types

The centrifugal pump with a volute casing is the type most commonly used for
building services and, among the many styles available, one method of classification
is according to the drive arrangement:

1- Integral canned rotor-the impeller is fixed to the shaft of the rotor, whish
revolves in a rotor can filled with water. The stator and the electrical connexion
are outside the rotor can and, since the pump shaft does not emerge from the
casing, there is no need for a shaft seal to limit water leakage. Such pumps are
common in domestic heating installation and, if they are light enough in
weight, may be fixed directly in the pipeline without additional support.
Otherwise, they are floor-mounted. Such pumps must never be used in chilled
water lines because condensation then occur on the electrical connexion and
causes continual difficulties

2- Direct- coupled – the motor shaft is coaxial with attached to the impeller shaft
through a flexible, both motor and pump being mounted on a common base
plate. Difficulties in shaft alignment are sometimes experienced and a shaft
seal in necessary to limit leakage from the pump casing.

3- Close-coupled – the motor and pump are separate but the impeller is mounted
on an extension of the motor shaft. There is consequently no possibility of
misalignment but motor noise can be transmitted directly into the piping
system. Although the pump has no bearing, as those of the motor serve for
both, a shaft seal is needed.

4- Belt-driven – vee-belt and pulleys provide the drive connexion between the
pump and its motor, the whole assembly being fixed on a common base-plate.
A shaft seal is necessary.

The available catalogues for pump selection operates at 60 Hz, in Egypt the electrical
frequency is 50 Hz, therefore the flow rate and head should be converted from 50 Hz
to 60 Hz operation, using the following equation:
٩٩ Chapter 4- Selection of equipment-

4.3.2 FLOW RATE

Q60 /Q50 =N60/N50

Where: Q60=Flow rate at 60Hz

Q50=Flow rate at 50Hz
N60=Speed at 60 Hz
N50=Speed at 50 Hz

Q = mo . cp . ΔT
Where : Q = 910 kW
cp = 4.18 kj/kg.K
ΔT= 6 oC

mo = 36.28 kg/ s
Vo = 36.28 X 3.6 = 130.6 m3/hr
Factor of safety = 15%
We select 2 pump Q=151 m3/hr for each
Number of pump = number of chiller +1 stand by = 3

HEAD

Htotal=H chiller +H pump +H pipe +H fittings +H AHU

H pipe =13 m
H pump =0.5 m
H chiller =5 m
H AHU =2 m
H fittings =6 m

H total =5+0.5+13+6+2 = 26.5 m

For 20% F.O.S

H = 32 m

Each pump: Head =32 m Flow rate =151 m3/hr

١٠٠ Chapter 4- Selection of equipment-

4.3.3 PUMP SELLECTION

Using GRUNDFOS – WinCAP ver 7.44 tables
١٠١ Chapter 4- Selection of equipment-

PUMP PERFORMANCE
١٠٢ Chapter 4- Selection of equipment-

Pump profile
١٠٣ Chapter 4- Selection of equipment–

4. SELECTION OF EQUIPMENT

4.4 DESICCANT DEHUMIDIFICATION SYSTEM SELECTION

4.4.1 GENERAL

D
esiccant-based air-conditioning offers significant advantages over
conventional systems. Desiccant systems are already successfully used in
some supermarkets. It is expected that these systems will gradually attain
wider market penetration due to environmental requirements and potential energy
savings.

The advantages of desiccant air-conditioning are summarized below:

1- No CFC refrigerants are used.
2- Indoor air quality is improved.
3- Large latent heat loads and dry air requirements are conveniently handled.
4- Individual control of temperature and humidity is possible.
5- The energy source may be natural gas and/or waste heat.
6- Less circulated air is required.
7- Summer electric peak is reduced.
.

4.4.2 Liquid Desiccant Dehumidifiers

Liquid desiccants can sorb water in both liquid and vapor forms. Absorption (in
liquid desiccants) occur when the water vapor partial pressure of the surrounding air
is larger than that at the desiccant surface. When an air stream is brought in contact
with a desiccant, water vapor from the air is attracted by the desiccant, the air is
dehumidified, and the water content of the desiccant rises. As the water sorbed by the
desiccant increases, the sorption rate decreases and finally stops when sorption
equilibrium is reached.
For dehumidification to be resumed, water must be removed from the desiccant by
heating. This process is referred to as adsorption, reactivation, or regeneration. The
heat of sorption (or desorption) is generally higher than the latent heat of vaporization
of water; it approaches the latter as sorption equilibrium is reached. Some typical
liquid desiccants are water solutions of calcium chloride (CaCl), lithium chloride
(LiCl), lithium bromide (LiBr), and triethylene glycol.
١٠٤ Chapter 4- Selection of equipment–

Figure below is a schematic of a liquid spray tower. A desiccant solution from the
sump is continuously sprayed downward in the absorber, while air, the process
stream, moves upward. The air is dehumidified and the desiccant solution absorbs
moisture and is weakened. In order to maintain the desired solution concentration, a
fraction of the solution from the sump is passed through the regenerator, where it is
heated by the heating coil and gives up moisture to the desorbing air stream. The
strong, concentrated solution is then returned to the sump. The heat liberated in the
absorber during dehumidification is removed by the cooling coil to facilitate
continuous absorption (see Figures 9.16.1 and 9.16.3). The process air stream exits at
a relatively low temperature. If sufficiently low water temperature is available
(an underground well, for example), the process stream could provide both sensible
and latent cooling
١٠٥ Chapter 4- Selection of equipment–

4.4.3 Desiccant Dehumidification Systems selection

Kathabar liquid desiccant dehumidification systems

Operating Principle

 Kathabar liquid desiccant dehumidification systems operate on the principal of

chemical absorption of water vapor from an airstream. The desiccant solution
(Kathene) consists of a specific concentration of salt and water. Kathene will
not vaporize and is not affected by common airborne contaminants.

 The ability of Kathene to remove water vapor from air is determined by the
temperature and concentration of the solution. The concentration of Kathene
can be variable to allow for air to be delivered at any relative humidity between
20% and 80%.

 For any given desiccant concentration, lower solution temperatures enable the
Kathabar dehumidifier to deliver cooler, drier air than other systems. The
diagram below shows the basic elements of a Kathabar system. In operation,
air to be conditioned is cooled and dehumidified by contacting Kathene in the
conditioner. By continuously circulating the desiccant through a heat
exchanger, energy is extracted from the air and transferred to a coolant. The
amount of heat extracted by the Kathabar dehumidifier is modulated by
controlling coolant flow through the heat exchanger.
١٠٦ Chapter 4- Selection of equipment–

Using KATHABAR tables

١٠٧ Chapter 4- Selection of equipment–
١٠٨ Chapter 4- Selection of equipment–
١٠٩ Chapter 4- Selection of equipment–

Desiccant Dehumidification Unit overview

١١٠ Chapter 4- Selection of equipment-

4. SELECTION OF EQUIPMENT

4.5 FILTER SELECTION

4.5.1 GENERAL

A
Advanced Production methods often require very clean air, and in many
cases these requirements are certain to increase. For example, the
PHARMACEUTICAL industry needs a very clean manufacturing
environment for its HVAC systems production (HVAC - heating, ventilating, and air
conditioning). There will be a need to control particle contamination down 1/10 of
third dimension (0.1 micrometer).

The "heart" of the clean room is the filter, but there are various considerations
regarding room classification, choice of filter, and how filters influence the
environment.

TERMINOLOGY
Media: is the filtering material. It is a paper that can be pleated back and forth to
form a compact filter element. Close-pleating is necessary to fit all the required
media into the desired space because the paper has a high resistance to air flow and
the media velocity is usually in the range of 6 fpm (.03 m/s).

Separators: are devices which support the media and provide channels through
which the air can flow to reach the media and then, after passing through the media,
flow out of the filter.

Filter: Pack is the combination of media and separators.

Filter Frame (Cell Side): is the rigid box into which the pack fits.

Sealant: is the adhesive or other material intended to create a leak-proof seal between
the filter pack and the filter frame.

Edge sealant: is intended to prevent any bypass of unfiltered air around the filter. In
many instances, it is a gasket attached to the filter frame.
١١١ Chapter 4- Selection of equipment-

4.5.2 Filter Classification

Coarse filters
EFFICIENCY
MEDIUM

Coarse
G2 > 65%

filters
G3 > 80%
G4 > 90%
Fine Filters
HIGH EFFICIENCY

F5 > 40%
Fine Filters

F6 > 60%
F7 > 80%
F8 > 90%
F9 > 95%
MPPS (Most Penetrating Particle Size)
H10 > 85%
VERY HIGH EFFICIENCY

HEPA

H11 > 95%

H12 > 99,5%
H13 > 99,95%
H14 > 99,995%
U15 > 99,9995%
ULPA

U16 > 99,99995%

U17 > 99,999995%
١١٢ Chapter 4- Selection of equipment-

Cleanroom Filtration

Cleanrooms commonly use HEPA filters in air recirculation. These filters are the
main causes of filter system energy consumption in this kind of laboratory. However,
filtration of the make-up outside air for a cleanroom also consumes some energy. The
air flow usually requires filtration with a 20-25 percent efficient prefilter and a 90-95
percent efficient final filter. [NAFA Guide..., 1993]

All classes of cleanrooms do not require the same recirculation rate or degree of air
filtration. Down-flow cleanroom classes can be related to the percentage of the
ceiling area that contains HEPA filters. According to the NAFA Guide to Air
Filtration (1993), several sources suggest the following relationships between
cleanroom class and percent of the ceiling that should incorporate HEPA filters.

ClassPercent

(Fed. Std. 209)(Ceiling Area)

100 90
1,00075
10,00060
100,00040

Air cleanliness of less than Class 100 requires the use of ULPA or SULPA filters in
the ceiling. The filters should make up at least 90 percent of the ceiling.
١١٣ Chapter 4- Selection of equipment-

4.5.3 Filter selection

By using CAMFIL Catalogue
١١٤ Chapter 4- Selection of equipment-

For MEDIUM EFFICIENCY (G Type)

١١٥ Chapter 4- Selection of equipment-

For HIGH EFFICIENCY (F Type)

١١٦ Chapter 4- Selection of equipment-

For VERY HIGH EFFICIENCY (H Type)

HEPA FILTER
١١٧ Chapter 4- Selection of equipment-

For VERY HIGH EFFICIENCY (H Type)

HEPA FILTER
١١٨ Chapter 4- Selection of equipment-

FILTER QUICK SELECTION

١١٩ Chapter 4- Selection of equipment-
١٢٠ Chapter 4- Selection of equipment-

4. SELECTION OF EQUIPMENT

4.6 DAMPER SELECTION

4.6.1 GENERAL

A
manual zone damper or heating duct damper or cooling duct damper is
particularly valuable in balancing air flow in buildings whose HVAC system
includes long duct runs to some areas and short duct runs to other areas. If we
take no steps to balance the air flow among building areas, when the blower fan is
running, the rooms closest to the blower will receive the most air flow and more
distant rooms can be difficult to heat or cool.

Dampers are mechanical doors that are manually (by

hand) or automatically (under thermostatic control) open or
closed in order to control the amount of warm or cool
air flowing to a particular room or area in a building.
By totally or partially closing the damper door, the
owner or occupants of the building can balance the flow
of conditioned air into various areas.

In an air conditioning system wherein the outdoor air

and recirculated air mixing dampers are operated to control the volume and condition,
such as temperature, of the mixture of outdoor air and return air to be discharged to at
least one zone, a control apparatus is disclosed having sensors for sensing the
condition and volume of the mixture and a control system responsive to the sensors
for controlling the operation of the outdoor air and recirculated air dampers for
maintaining a predetermined condition and a predetermined volume of the mixture.
In addition, an exhaust air damper may also be provided, controlled by the control
system, for regulating the amount of air returned for the system.

OTHER DESIGN CONSIDERATIONS TO BE NOTED ARE:

Control of duct Pressure

The control of supply air duct static pressure within the design limits of the terminal
units is an essential requirement of variable volume systems and such control is easily
achieved by any or a combination of the following methods, depending on the size
and configuration of the air distribution system:
1. Control of supply air duct fan output by means of a static pressure regulator
operating in conjunction with its capacity modulation device. In smaller
systems this device need be no more than fan motor speed control although
١٢١ Chapter 4- Selection of equipment-

acceptable performance will probably be achieved with a face and by-pass

damper configuration.
2. Dividing the air distribution systems into the most conveniently selected low
pressure supply duct zones, supplied from low/medium pressure main ducts or
risers, by the fitting of branch duct dampers operating in conjunction with
branch supply duct static pressure regulators.

4.6.2 DAMPER SELECTION

Usually dampers are sized simply to match the duct into which they will be fitted.
Generally, this is an adequate selection method but, under certain circumstances, it
can lead to difficulties. Normally the air velocities in airconditioning ducting at full
volume should be between 1200 and 1800 ft/min ( 6-9m/s). If velocities outside these
limits are used, or if there are any substantial restrictions such as silencers, filters or
multiple bends and transformation pieces in the ducting, then a closer examination of
the situation may be warranted.
١٢٢ Chapter 4- Selection of equipment-

By using Damper tables from EGAT

١٢٣ Chapter 4- Selection of equipment-

Number of
Number of

Position Position
Blades

Blades
in mm

in mm

in mm

in mm

of of
H

H
B

drive arm drive arm

X in mm X in mm

100 100 1 50 650 800 5 400

150 150 1 75 700 900 5 450
200 200 1 100 750 1000 6 575
250 250 l 125 800 1100 7 540
300 300 1 150 850 1200 7 600
350 350 2 240 900 1300 8 725
400 400 2 275 950 1400 c 690
450 450 2 300 1000 1500 c 750
500 500 3 240 1050 1600 10 875
550 600 3 300 1100 1700 11 840
600 700 4 425 1200 1800 11 900

Note: B x H are duct dimensions.

Any combination of dimensions B x H listed above can be supplied.
Larger sizes supplied in multiples details on request
١٢٤ Chapter 4- Selection of equipment-

Standard damper dimensions should be selected if possible. When non-

standard sizes are required the technical information for the next smallest
standard height should be used as an appropriate performance guide. For
full details refer to Trox.

Minimum/Maximum Sizes
 A 100 x 100mm minimum size
 A 1200 x 1800mm maximum size
١٢٥ Chapter 4- Selection of equipment–

4. SELECTION OF EQUIPMENT

4.7 DIFFUSER SELECTION

4.7.1 GENERAL

A
diffuser for a ceiling allows a ceiling fan to be mounted directly below the
diffuser so that the fan may distribute the air being delivered out of the
diffuser. The diffuser includes an upper box section mounted on a lower
section that mounts the diffuser on the ceiling. The down rod of the ceiling fan is
connected to the diffuser to support the ceiling fan. The down rod may be supported
above the upper section so that the electrical connections between the ceiling fan and
an electrical source may be positioned outside of the diffuser.

Preliminary Selection

The table below gives a guide for selecting diffuser sizes. To determine the max.
volume flow rate Vmax it has been assumed that the sound power level LWAmax should
always equal 40 dB(A). If higher sound levels are permitted, the maximum volume
flow rate can be increased.
For the recommended minimum volume flow rate Vmjn, the effective discharge
velocity Veff must never fall below 2 m/s. This ensures that the air flow will attach to
the ceiling (Coanda effect). If the air velocity falls below this level, there is a
possibility, particularly with cold air, that the air flow may fall (dump).
١٢٦ Chapter 4- Selection of equipment–

4.7.2 Diffuser Selection

Using EGAT tables for Swirl Diffuser

١٢٧ Chapter 4- Selection of equipment–

Determination of Volume Flow Rate

To determine the volume flow rate in the installed position -for commissioning -
the arithmetic mean of the effective discharge velocity is determined using a pitot
tube.
The equations below can be used for a calculation of the air volume flow, ignoring
the very small effect of air temperature variation.
١٢٨ Chapter 4- Selection of equipment–

Air diffusers of type DLR can be fitted with a wide range of accessories to meet
almost all installation requirements. These diffusers are available in a range of
different formats, face only, face section plus butterfly flap damper or connecting
ring; also complete with plenum box with either top or side entry.
١٢٩ Chapter 4- Selection of equipment–

Description

The newly developed HIW/HICV range of high induction, variable and constant
volume swirl diffusers have been designed to meet the most stringent requirements of
new and refurbished commercial and industrial systems. This versatile range of
diffusers are supplied complete with a very low acoustically designed plenum box
and radial front face plate, which is easily installed in most plastered and inverted "T"
type ceilings. As the plenum box is fitted with a side entry spigot the height required
in the ceiling void can be substantially reduced. The side entry also ensures the direct
fitting of flexible connections, thereby elimi¬nating unrequired noise generating twist
and bends in the

ducting. The high induction and radial distribution achieved by the diffusers, even at
minimum air quantities in variable volume applications, ensures efficient air
movement in the airconditioned zone by eliminating stratification of warm air and
correct draft free distribution of colder air. As all moving parts are contained within
the specially con¬structed plenum box, the noise generated in the process of varying
the air quantity is absorbed within the plenum box. Connections between electronic
master and sub units are accomplished with the use of uni-directional plug in cables,
thus ensuring simple and correct installation of control and electrical connections.
١٣٠ Chapter 4- Selection of equipment–

The side range of accessories - such as circular flap damper and air flow straightener
for installation into high velocity ducts, duct mounting subframe and standard
subframe for vertical duct installation - increase the possibilities.
The attractively shaped diffuser face can be installed or removed via one central
screw. The screw head is covered with a decorative cap. Supply and extract air
plenum boxes have different internal construction to ensure optimum acoustics for
the different flow conditions.
The plenum boxes can, if required, be fitted with a control damper operated through
the front face. The face of the diffuser is electro dip stove enamel finish white (RAL
9002) as standard; the rear mounted accessories are similarly finished but in black
(RAL 9005). The plenum box is galvanised sheet steel.

Installation & Fixing

All types and sizes are intended for installation in continuous flat suspended ceilings.
When plenum boxes are used, the entire unit can be fixed into the ceiling using the
standard suspension brackets.
The diffuser face can be removed by the central screw; to accommodate this, the
centre plate has a countersunk hole.
To cover the screw head, a cap is supplied - which is pressed into the screw slot.
If a vertical, rigid duct is supplied by the client, the diffuser can be mounted by
means of a subframe and central screw or it can be fixed directly to the duct wall, e.g.
using type AR connecting ring and self-tapping screws. Some examples of different
types of installation are shown below:
131 Chapter 5- Duct design –

5- DUCT DESIGN

5.1 GENERAL

A
ir systems use ductwork to distribute heated or cooled air throughout the
home . The duct system is a collection of tubes that distribute conditioned air
to the home’s room. This system can make a big difference in both the cost
and the effectiveness of heating and cooling the home. It also has an important affect
on the comfort and health of the occupants.

1. The Air Handling Unit is a cabinet that includes or houses the central furnace, air
conditioner, or heat pump and the plenum and blower assembly that forces air
through the duct work.

2. The Supply Ductwork carries air from the air handler to the rooms in a house.
Typically each rooms has at least one supply duct and larger rooms may have
several.
3. The Return Ductwork carries air from the conditioned space back to the air
handler.
4. Supply and Return Plenums are boxes made of duct board, metal, and drywall or
wood that distributes air to individual ducts or registers.

The Ductwork is a branching network of round or rectangular tubes generally

constructed of sheet metal, fiberglass board, or a flexible plastic and wire composite
material and located within the walls, floors, and ceiling. The three most common
types of duct material used in home construction are metal, fiberglass duct board, and
flex-duct.

Flex-duct is installed between the register and plenum box, and plenum box and air
handler, usually in a single, continuous piece. While flex duct has fewer seams, the
inner lining and outer insulated covering can tear or be pinched closed. Also longer
flex-duct runs can restrict the flow of air; proper design and installation is very
important.

Both metal and fiberglass duct board are rigid and installed in pieces. Fiberglass duct
board, like flex-duct, is made of an insulation material.Duts are built of the duct
132 Chapter 5- Duct design –

board. The seams in the duct board should be carefully sealed with mastic or high
quality duct tape. Rectangular metal duct, especially the kind used for plenums and
larger trunk runs, is often insulated on the inside with fiberglass duct liner. If it’s not
insulated on the inside, metal ducts should be insulated on the outside using a
fiberglass but with an attached metal foil vapor retarded. The insulation should be at
least two inches thick, and the vapor barrier installed on the outside of the insulation
facing away from the duct.
The seams in the insulation are usually stapled together around the duct and then
taped. All of the seams should be sealed before insulation is installed. All return and
supply ducts located outside the conditioned space, in attics, crawlspaces, or
basement, for example, should be sealed and insulated.
Ductwork joints join pieces of ductwork. Elbows are manufactured pieces of duct
used for turns. Boots connect ductwork to registers. Registers and Grilles are the
coverings for duct openings into the conditioned space.

Generally, to avoid noise and to minimize energy consumption by fan power, it is

best to design VAV systems as medium velocity, in the rang of 10-12 .5 m / s, rather
then as high velocity, in the rang of 15-20 m / s. Exceeding velocity of 15 m / s
should be avoided and 20 m / s should never be exceeded. Run-outs feeding VAV
terminals, of whatever type, should be sized for 10 m / s, or less.
To assist in balance air distribution, main ducts should be sized by static regain where
building space permits. It is wise to keep a distance of at least six duct diameters
between successive fittings and to adopt conical tees. An air-tight supply system is
essential and this means ducting must be pressure-tested after installation. It is
possible that, with the conservative approach to sizing suggested above, the fan total
pressure may not be high enough to bring the system within the range of pressures
those codes of practice regard as necessary for pressure tests. Pressure tests should be
carried out nevertheless. Well designed systems are likely to fan total pressures of the
order of 1.0 – 1.25 kpa, rather then 1.5 kpa upward. Duct layouts should be simple
and a circular, spirally-wound duct is preferable to rectangular ducting, the cost of the
latter, if air-tight, begin some four times that of the former. A spirally-wound flat oval
duct is acceptable, to a limited extent, and is better than rectangular duct, or flat-oval
duct, never exceed an aspect ratio 4 : 1.Extract systems are generally much less
extensive than supply duct schemes, since the location of the supply terminals
dictates the quality of the air distribution. Extract duct systems should never be sized
by high velocity methods. Steel ducts under large suction pressures are structurally
unstable and, in any event, suction pressure reducing valves, where used, will tend to
get fouled with dirt and become increasingly unreliable in performance. Supply air
terminals will not give good air distribution and will perform badly if erected above
egg-crate ceilings and, even when located flush with the lower surface of the egg-
crate, air distribution is likely to be poor
133 Chapter 5- Duct design –

Variable Air Volume Systems (VAV)

In the 1970's, the design community made serious efforts to reduce system energy
costs and, at the same time, add independent zone control: It was during this period
the variable air volume (VAV) systems gained their popularity. VAV systems are
designed to supply only the volume of conditioned air to a space that is needed to
satisfy the load. Fan energy is saved when the volume of air handled by the fan is
reduced. Air volume control is accomplished by installing modulating dampers, or in
some cases, an air valve, in the supply duct to each zone. As the room temperature
demand becomes satisfied, the thermostat signals the damper to move the supply air
zone valve toward the closed position.

When zone valves are throttled, the static pressure in the supply duct changes. A
static pressure sensor located in the supply duct senses the static pressure change, and
either increases or decreases the airflow from the source, using variable speed control
or dampers on the main air supply fan.
134 Chapter 5- Duct design –

5.2 CALCULATION

Using (ductSizer Version 6.4) program:

135 Chapter 5- Duct design –

Program procedure:

1-Enter the Temprature and Humidity

2- Enter the Flow rate in (cfm)

3- Enter the velocity of the air (fpm)

4- We can get the Head Loss

5- Calculate the duct size by make Head Loss Constant.

6- Calculate all the duct size of the whole branch.

136 Chapter 5- Duct design –

5.3 RESULTS

For AHU-K
The velocity is 1400 fpm
The Head loss is 0.05 in.WC/100ft

Q Width Hight Aspect

Item
(cmh) CFM (in) (in) ratio
1 26250 15447 58 30 1.9
2 19780 11642 50 30 1.7
3 9310 5479 40 20 2.0
4 8570 5044 38 20 1.9
5 7090 4173 32 20 1.6
6 5610 3301 26 20 1.3
7 4130 2430 22 20 1.1
8 1170 688 22 8 2.8
9 590 344 20 8 2.5
137 Chapter 5- Duct design –

For AHU-L
The velocity is 1400 fpm
The Head loss is 0.072 in.WC/100ft

Q Width Hight Aspect

Item
(cmh) CFM (in) (in) ratio
1 16290 9587 40 26 1.5
2 9900 5823 40 18 2.2
3 9130 5373 38 18 2.1
4 6880 4049 30 18 1.7
5 4590 2701 22 18 1.2
6 3060 1801 22 14 1.6
7 2300 1350 22 12 1.8
8 1530 900 14 12 1.2
9 770 450 12 10 1.2
138 Chapter 5- Duct design –

For AHU-M
The velocity is 1400 fpm
The Head loss is 0.042 in.WC/100ft

Q Width Hight Aspect

Item
(cmh) CFM (in) (in) ratio
1 18200 10708 50 28 1.8
2 14570 8574 50 24 2.1
3 9610 5657 42 18 2.3
4 8900 5240 38 18 2.1
5 8200 4824 35 18 1.9
6 4250 2501 22 18 1.2
7 3550 2085 22 14 1.6
8 2850 1668 20 12 1.7
9 2130 1252 18 10 1.8
10 1420 836 12 10 1.2
11 700 416 12 6 2.0
139 Chapter 5- Duct design –

For AHU-N
The velocity is 1400 fpm
The Head loss is 0.047 in.WC/100ft

Q Width Hight Aspect

Item
(cmh) CFM (in) (in) ratio
1 30420 17904 80 26 3.1
2 15200 8946 50 24 2.1
3 11400 6709 50 20 2.5
4 7600 4473 50 14 3.6
5 3800 2236 24 14 1.7
6 1520 894 22 10 2.2
7 760 447 22 6 3.7
140 Chapter 5- Duct design –

For AHU-O
The velocity is 1400 fpm
The Head loss is 0.042 in.WC/100ft

Q Width Hight Aspect

Item
(cmh) CFM (in) (in) ratio
1 38070 22407 86 30 2.9
2 35700 21012 80 32 2.5
3 33330 19617 80 30 2.7
4 30960 18222 80 28 2.9
5 28590 16827 80 26 3.1
6 19110 11247 50 30 1.7
7 9480 5579 50 26 1.9
8 7110 4184 30 18 1.7
9 4740 2789 24 18 1.3
10 2370 1394 18 12 1.5
11 790 464 18 8 2.3
141 Chapter 5- Duct design –

For AHU-P
The velocity is 1400 fpm
The Head loss is 0.047 in.WC/100ft

Q Width Hight Aspect

Item
(cmh) CFM (in) (in) ratio
1 54720 32206 86 42 2.0
2 28440 16739 58 36 1.6
3 23640 13913 54 32 1.7
4 18840 11088 50 28 1.8
5 14040 8263 44 24 1.8
6 12440 7321 42 22 1.9
7 11640 6851 42 20 2.1
8 9240 5438 40 18 2.2
9 7640 4496 40 16 2.5
10 3820 2248 22 10 2.2
11 1910 1124 12 10 1.2
12 800 472 12 6 2.0
142 Chapter 5- Duct design –

For AHU-Q
The velocity is 1400 fpm
The Head loss is 0.028 in.WC/100ft

Q Width Hight Aspect

Item
(cmh) CFM (in) (in) ratio
1 37000 21777 80 36 2.2
2 12000 7062 40 28 1.4
3 6800 4002 36 18 2.0
4 3600 2118 30 14 2.1
5 13680 8054 40 30 1.3
6 7600 4473 34 22 1.5
١٤٣ Chapter 6- piping network–

6. PIPING NETWORK

6.1 GENERAL

T he central cooling system generates chilled water for distribution to a building

or group of building. It consists of one or more chillers may all be the same or
different capacities and/or different types. The energy may be provided by
electricity or a fuel –combustion source .control chiller system optimization is an
important control function to minimize energy use especially in multiple chiller
plants.

Strategies for total chiller system optimization include:

1. Supplying chilled water at a temperature that minimizes chiller and pump

energy while satisfying the current demand load.

2. Selecting the chiller or chiller combination in multiple chiller plants to satisfy

the current load at minimum operating cost. The influence of refrigerant head
pressures and chiller efficiency curves must be considered.

3. Using rejected heat when a heating load exists at the same time as cooling
loads.

Chilled water systems for cooling of commercial building usually provide water
between 40 and 50f to finned coils in room units or air handlers .The amount of water
delivered to the cooling coils and/or produced by chiller is related to temperature
difference (TDW) across the coil or chiller and energy (tons of refrigeration )by the
equation
١٤٤ Chapter 6- piping network–

System objectives

1. Provide the minimum flow of chilled water through the chiller as specified by the
manufacturer.
2. Provide a stable pressure difference across supply and return mains.
3. Prevent freeze –up in chiller and/or coils exposed to outdoor air.
4. Control system pumps and bypass valves to prevent short cycling of pumps or
radical pressure changes across control valves at the terminal units.

In addition, for systems with two or more chillers operating at once, the chilled water
control and distribution system should:

1. Prevent return water from mixing with chilled water before leaving the chiller
plant.
2. Shut off flow through idle chillers.

The next figure shows a typical arrangement where the same pipes carry hot water
for heating or chilled water for cooling to the same terminal units. These are
usually fan coil units.

Water return arrangements

The recalculating system is further classified according to water return arrangements.

When two or more units are piped together, one of the following piping arrangements
may be used:
1) Reverse return piping.
2) Reverse return header with direct return risers.
3) Direct return piping.
If the units have the same or nearly the same pressure drop thru them, one of the
reverse return methods of piping is recommended. However, it the units have
different pressure drops or require balancing valves, then it is usually more
economical to use a direct return.

Reverse return piping is recommended for most closed piping applications; it cannot
be used on open systems. It is often the most economical design on new construction.
The length of the water circuit thru the supply and return piping is the same for all
units. Since the water circuits are equal for each unit, the major advantage of a
reverse return system is that it seldom requires balancing.
١٤٥ Chapter 6- piping network–

6.2 WATER PIPE SECTION DESIGN

Using (pipeSizer Version 6.2) program:

١٤٦ Chapter 6- piping network–

Program Procedure:

1- Select pipe type.

2- Select water temperature.
3- Choose pipe diameter.
4- Enter water flow rate.
5- Get fluid velocity, if it is not within allowed range then change pipe diameter.
6- Get head loss.
١٤٧ Chapter 6- piping network–

5.3 RESULTS

The following tables show the cooling capacity of the specified zone or section, and
the corresponding

● water flow rate Q (cmh)

● water velocity V (m/s)

● pipe diameter d (inch)

● Pressure p (m/m)

C.C Velocity Head

Flow rate Diameter
No Loss
(gpm) (Inch)
kw (T.R) (ft/s) m/s (ft/100 ft)

1 1820 520 1250 5.1 1.5 10 0.8

2 1166 330 800 5.1 1.6 8 1.1

3 630 180 430 5.2 1.6 4 2.5

4 360 100 250 6.3 1.9 4 3.5

5 185 50 130 5.5 1.7 3 3.8

6 90 25 60 4.0 1.2 2.5 2.8

 ‫شروط التصنيع الدوائي الجيد‬
‫)‪(G.M.P‬‬
‫ماذا يعني )‪ (G.M.P‬؟‬

‫ھي مختصر لـ )‪ (Good Manufacturing Practice‬وھو نظام عالمي معروف ومعتمد يحدد المتطلبات‬
‫والضوابط الواجب توافرھا في الصناعات الدوائية ويدخل في جميع التفاصيل كاألبنية والبيئة والتوثيق والكوادر‬
‫وطريقة العمل و المتابعة بعد التسويق وجميع تفاصيل العمل في ھذا النشاط الحيوي والمھم ‪.‬‬

‫تعريف التصنيع الدوائي الجيد ‪:‬‬

‫ھو ذلك الجزء من تأكيد الجودة الرامي إلى ضمان تصنيع المستحضرات على الدوام بنوعية مالئمة لما يتوخى لھا‬
‫من استعمال‪ ،‬وحسب إذن السامح بتسويقھا‪ .‬وبذلك فإن الممارسة الجيدة للتصنيع الدوائى تعنى باإلنتاج وضبط الجودة‬
‫على السواء‬

‫شروط التصنيع الدوائي الجيد )‪:(G.M.P‬‬

‫‪ -١‬عامل االدارة ‪:‬‬

‫تعتبر الصناعة الدوائية من الصناعات الدقيقة لكونھا تتعلق بصحة اإلنسان لذلك فأن اإلدارة الحديثة تلعب دوراً‬
‫مھما ً وأساسيا في ھذا المجال وان تأكيد الجودة والجودة الشاملة ھي من أھم مستلزمات الصناعة الدوائية وذلك‬
‫لألسباب التالية ‪:‬‬
‫أ‪ -‬إن الصناعة الدوائية تختلف عن الصناعات األخرى بسبب الحذر من التأثيرات الجانبية‪.‬‬
‫ب‪ -‬إن نجاح إي صناعة وترخيصھا يكون أسھل وأسرع بطبيعته اذا ما قورن بالصناعة الدوائية التي يتطلب أمر‬
‫ترخيصھا التدقيق والتمحيص باإلضافة إلى اختالف الطبيعة البيولوجية عن الطبيعة الكيميائية أو الفيزيائية ‪.‬‬
‫لذلك فإن ضبط الجودة والممارسة الجيدة للتصنيع الدوائي الجيد تعتمد على أربعة عوامل أساسية يرمز لھا‬
‫بالرمز)‪ (4M‬وھي‪:‬‬
‫)‪ (١‬الكوادر الفنية المدربة )‪(Men‬‬
‫)‪ (٢‬الطرق المعتمدة للتصنيع والتحليل )‪(Methods‬‬
‫)‪ (٣‬المواد األولية ومستلزمات اإلنتاج )‪(Materials‬‬
‫)‪ (٤‬األماكن اإلنتاجية والتحليلية )‪(Machinery‬‬

‫‪4M‬‬

‫)‪(4‬‬ ‫)‪(3‬‬ ‫)‪(2‬‬ ‫)‪(1‬‬

‫‪Machinery‬‬ ‫‪Material‬‬ ‫‪Methods‬‬ ‫‪Men‬‬
 ‫‪ -٢‬األبنية‪:‬‬

‫يجب أن يتضمن المصنع الدوائى المساحات واألبنية التالية‬

‫مخزن‬
‫غرفة الماء‬ ‫غرفة حفظ‬
‫المواد‬ ‫اإلدارة‬
‫الخالى من‬ ‫النماذج‬ ‫المختبر‬
‫الفاشلة فى‬
‫األمالح‬
‫التحليل‬

‫القاعة اإلنتاجية‬ ‫تغيير‬

‫المالبس‬ ‫إستراحة‬
‫دش ھوائى‬ ‫العمال‬
‫‪ -‬إعادة الوزن للتدقيق‬ ‫‪+‬‬
‫‪ -‬التحضير‪ /‬الخلط‬ ‫الحمامات‬

‫مخزن‬
‫مخزن‬ ‫قاعة‬ ‫غرفة الوزن‬ ‫المواد‬
‫مواد‬ ‫التعبئة‬ ‫األولية‬
‫التعبئة‬ ‫والتغليف‬

‫مخزن‬
‫المواد‬
‫المنتجة‬

‫غرفة‬
‫التسويق‬
 ‫تكييف المصنع الدوائي‬
‫إن تكييف مصانع األدوية من األمور المھمة التي يجب أن تؤخذ فى االعتبار من اجل صناعة دوائية وفقا ً لشروط‬
‫التصنيع الدوائي الجيد ‪ .‬ويصنف تكييف القاعات إلى ‪:‬‬

‫‪ -١‬تكييف قاعات االنتاج ‪:‬‬

‫وتصنف قاعات االنتاج الى صنفين ‪:‬‬

‫أ‪ -‬القاعات النظيفة )‪:(Clean zone‬‬

‫وھي لتصنيع الحبوب ‪ ،‬الكبسوالت ‪،‬األشربة ‪،‬المراھم الجلدية ‪ ،‬محاليل االستخدام الخارجي ‪ ،‬الفوارات‬
‫والباودرات ‪.‬‬

‫مواصفات القاعات النظيفة ‪:‬‬

‫)‪ (١‬يجب ان يمر الھواء الداخل للقاعة بمراحل الفلترة التالية‪:‬‬

‫‪1-Mesh filter‬‬ ‫‪2 -Wash filter‬‬ ‫‪3 - bag filter‬‬
‫)‪ (٢‬يجب ان تكون قاعات االنتاج المختلفة مفصولة عن بعضھا بأجھزة التكييف‬
‫)‪ (٣‬تكون نسبة الھواء الراجع من قاعات االنتاج ‪ %٧٠‬مطروحا ً منھا ‪ %٣٠‬كھواء عادم ‪ .‬عدا قاعات‬
‫المضادات الحيوية على شكل كبسوالت وحبوب او معلقات فيكون الھواء مطروحا ً بنسبة ‪%١٠٠‬‬

‫ب – القاعات المعقمة )‪(Sterile zone‬‬

‫وھي لتصنيع االمبوالت والفياالت ‪ ،‬وقطرات ومراھم العيون‪.‬‬

‫مواصفات القاعات المعقمة‪:‬‬

‫)‪ (١‬يجب ان يمر الھواء الداخل للقاعة بمراحل الفلترة التالية‪:‬‬

‫‪1-HEPA filter‬‬ ‫‪2-bag filter‬‬ ‫‪3- Mesh filter‬‬ ‫‪4-Wash filter‬‬

‫‪5-HEPA: mean High Efficiency Particulate Air‬‬
‫)‪ (٢‬يجب ان تكون قاعات اإلنتاج المختلفة مفصولة عن بعضھا بأجھزة التكييف‬
‫)‪ (٣‬تكون نسبة الھواء النقي ‪ %١٠٠‬ونسبة المطروح ‪) %١٠٠‬أي ال يوجد راجع(‪.‬‬
‫‪ -٢‬تكييف المختبرات‪:‬‬

‫يجب ان يكون معزوالً تماما ً عن باقي الغرف واليجوز ان يختلط ھواءه مع ھواء باقي القاعات ‪،‬‬

‫‪ - ٣‬تكييف المخازن‪:‬‬

‫يجب ان يكون تكييف المخازن معزوالً عن باقي الغرف‬

‫‪ -٤‬تكييف اإلدارة ‪:‬‬

‫يجب ان يكون معزوالً عن تكييف باقي قاعات المصنع‬

‫والمشروع البحثى التالى يعتبر تطبيقا عمليا على ما تقدم ذكره‬
 ‫الفصل األول‬
‫نظرة عامة على المبنى‬
‫‪Building survey‬‬
‫المشروع عبارة عن تصميم لنظام التكييف المركزى ألحد مصانع األدوية بمنطقة برج العرب بمدينة اإلسكندرية‬
‫يتكون المصنع من طابق واحد‬
‫تم تقسيم المصنع إلى قطاعات ھوائية بحسب درجات النقاء المطلوبة للھواء بكل قطاع كما ھو موضح بالجداول التالية‬

‫حساب األحمال الحرارية‬

‫‪Load calculation‬‬
‫‪ -١‬يتم حساب األحمال الحرارية باستخدام برنامج ) ‪ ( Fridgitech AHU analysis‬حيث يستقبل البرنامج‬
‫المدخالت األساسية المتوافرة كمعلومات لدى المصمم مثل ) درجة الحرارة ونسبة الرطوبة ( ويقوم بتحويلھا‬
‫البيانات المطلوب الحصول عليھا للمساعدة فى اختيار وحدة المناولة المناسبة ‪ AHU‬من الكتالوجات‬

‫‪ -٢‬بناءا على النتائج التى تم الحصول عليھا من البرنامج يتم رسم الـ ‪ Psychometric chart‬للعمليات الحرارية كما‬
‫ھو موضح‬
‫‪ -٣‬تم اختيار عدد )‪ (٦‬وحدة مناولة ھواء لتغطية األحمال الحرارية بالقطاعات المختلفة مع الوضع فى االعتبار‬
‫الشروط التصميمية الداخلية والخارجية المناسبة لمدينة اإلسكندرية كم خو موضح بالجدول التالى ‪:‬‬

‫‪Ser AHU‬‬ ‫‪Section‬‬ ‫‪Tdb r.h‬‬

‫‪1‬‬ ‫‪L‬‬ ‫‪medicine‬‬ ‫‪22‬‬ ‫‪40%‬‬
‫‪2‬‬ ‫‪M‬‬ ‫‪gelatin‬‬ ‫‪22‬‬ ‫‪45%‬‬
‫‪3‬‬ ‫‪N‬‬ ‫‪Corr & washing‬‬ ‫‪22‬‬ ‫‪45%‬‬
‫‪4‬‬ ‫‪O‬‬ ‫‪encapsulation‬‬ ‫‪22‬‬ ‫‪20%‬‬
‫‪5‬‬ ‫‪P‬‬ ‫‪finishing‬‬ ‫‪22‬‬ ‫‪45%‬‬
‫‪6‬‬ ‫‪Q‬‬ ‫‪Fresh air‬‬ ‫‪22‬‬ ‫‪45%‬‬

‫إختيار وحدات المناولة ‪AHU‬‬

‫‪ -‬تم اختيار الـ ‪ AHU‬بناءا على معلومية كل من حجم الھواء وسرعته على وجه الملف‬
‫‪ -‬تم االستعانة بكتالوجات شركة ‪ EGAT‬الختيار وحدات المناولة المناسبة وذلك كما ھو موضح‬

‫‪ -‬تم تدوين نتائج االختيار كالتالي‬

‫‪Chiller selection‬‬
‫باستخدام كتالوج شركة ) ‪ ( YORK‬وبمعلومية اآلتى‪:‬‬
‫‪ -١‬الحمل الكلى للتبريد‬
‫‪ -٢‬درجة حرارة دخول المياه‬
‫‪ -٣‬درجة حرارة دخول الھواء للمكثف‬
‫تم اختيار ‪ chiller‬من نوع ) ‪ ( YCAS 1093 SB‬بقدرة ‪ ٩١٢‬ك‪.‬وات‬
 ‫‪Damper selection‬‬
‫الـ ‪ dampers‬عبارة عن أبواب توضع على خطوط الھواء تفتح وتغلق إما يدويا أو أوتوماتيكيا لغرض التحكم فى‬
‫ضغط وسرعة الھواء المار بھذه الخطوط‬
‫تم اختيار كتالوجات شركة ‪EGAT‬الختيار النوع المناسب من ھذه الـ ‪dampers‬‬

‫‪Number of‬‬
‫‪Number of‬‬

‫‪Position of‬‬ ‫‪Position of‬‬

‫‪Blades‬‬

‫‪Blades‬‬
‫‪in mm‬‬

‫‪in mm‬‬

‫‪in mm‬‬

‫‪in mm‬‬

‫‪drive arm‬‬ ‫‪drive arm‬‬

‫‪H‬‬

‫‪H‬‬
‫‪B‬‬

‫‪B‬‬

‫‪X in mm‬‬ ‫‪X in mm‬‬

‫‪100‬‬ ‫‪100‬‬ ‫‪1‬‬ ‫‪50‬‬ ‫‪650‬‬ ‫‪800‬‬ ‫‪5‬‬ ‫‪400‬‬

‫‪150‬‬ ‫‪150‬‬ ‫‪1‬‬ ‫‪75‬‬ ‫‪700‬‬ ‫‪900‬‬ ‫‪5‬‬ ‫‪450‬‬

‫‪200‬‬ ‫‪200‬‬ ‫‪1‬‬ ‫‪100‬‬ ‫‪750‬‬ ‫‪1000‬‬ ‫‪6‬‬ ‫‪575‬‬
‫‪250‬‬ ‫‪250‬‬ ‫‪l‬‬ ‫‪125‬‬ ‫‪800‬‬ ‫‪1100‬‬ ‫‪7‬‬ ‫‪540‬‬
‫‪300‬‬ ‫‪300‬‬ ‫‪1‬‬ ‫‪150‬‬ ‫‪850‬‬ ‫‪1200‬‬ ‫‪7‬‬ ‫‪600‬‬
‫‪350‬‬ ‫‪350‬‬ ‫‪2‬‬ ‫‪240‬‬ ‫‪900‬‬ ‫‪1300‬‬ ‫‪8‬‬ ‫‪725‬‬
‫‪400‬‬ ‫‪400‬‬ ‫‪2‬‬ ‫‪275‬‬ ‫‪950‬‬ ‫‪1400‬‬ ‫‪c‬‬ ‫‪690‬‬
‫‪450‬‬ ‫‪450‬‬ ‫‪2‬‬ ‫‪300‬‬ ‫‪1000‬‬ ‫‪1500‬‬ ‫‪c‬‬ ‫‪750‬‬
‫‪500‬‬ ‫‪500‬‬ ‫‪3‬‬ ‫‪240‬‬ ‫‪1050‬‬ ‫‪1600‬‬ ‫‪10‬‬ ‫‪875‬‬
‫‪550‬‬ ‫‪600‬‬ ‫‪3‬‬ ‫‪300‬‬ ‫‪1100‬‬ ‫‪1700‬‬ ‫‪11‬‬ ‫‪840‬‬
‫‪600‬‬ ‫‪700‬‬ ‫‪4‬‬ ‫‪425‬‬ ‫‪1200‬‬ ‫‪1800‬‬ ‫‪11‬‬ ‫‪900‬‬
 ‫إختيار مزيل الرطوبة‬
‫‪Desiccant selection‬‬
‫تتميز طريقة إزالة الرطوبة كيميائيا باستخدام الـ ‪ Desiccant‬بالمميزات التالية ‪:‬‬
‫‪ -١‬عدم استخدام الكلوروفلوروكربونات ) الفريونات ( مما يقلل التأثيرات الضارة بالبيئة‬
‫‪ -٢‬تحسين شروط الھواء الداخلى‬
‫‪ -٣‬إمكانية التحكم فى الرطوبة على حدة دون التأثير على درجة الحرارة‬
‫‪ -٤‬استخدام أقل كمية من الـ ‪circulated air‬‬
‫‪ -٥‬تقليل استخدام الطاقة الكھربية‬
‫‪ -‬تم اختيار مزيل رطوبة من نوع )‪ ( KATHABAR‬وھو عبارة عن محلول ملحى ذو تركيز معين له القدرة‬
‫على امتصاص الماء من الھواء المار‬
‫‪ -‬وتعتمد قدرة ھذا المحلول فى امتصاص الرطوبة على درجة حرارته ونسبة تركيزه‬
‫‪ -‬الشكل التالى يوضح العناصر األساسية لدائرة إزالة الرطوبة باستخدام الـ )‪( KATHABAR‬‬
 ‫إختيار مخارج الھواء‬
‫‪Diffuser selection‬‬
‫يستخدم الجدول التالى فى اختيار نوع الـ ‪ diffuser‬المناسب لتحديد معدل التدفق الحجمى للھواء وقدرة الصوت الناتج‬
‫عن مروره‬
‫تم اختيار من النوع ‪ DRL‬يتميز بسھولة التركيب‬
 ‫اختيار الطلمبة‬
Pump selection
‫تم اختيار طلمبة طرد مركزى بناءا على الحسابات التالية‬

FLOW RATE

Q60 /Q50 =N60/N50

Where: Q60=Flow rate at 60Hz

Q50=Flow rate at 50Hz
N60=Speed at 60 Hz
N50=Speed at 50 Hz

Q = mo . cp . ΔT

Where : Q = 910 kW
cp = 4.18 kj/kg.K
ΔT= 6 oC

mo = 36.28 kg/ s
Vo = 36.28 X 3.6 = 130.6 m3/hr
Factor of safety = 15%
We select 2 pump Q=151 m3/hr for each
Number of pump = number of chiller +1 stand by = 3

HEAD

Htotal=H chiller +H pump +H pipe +H fittings +H AHU

H pipe =13 m
H pump =0.5 m
H chiller =5 m
H AHU =2 m
H fittings =6 m

H total =5+0.5+13+6+2 = 26.5 m

For 20% F.O.S

H = 32 m

Each pump: Head =32 m Flow rate =151 m3/hr

For selection from catalogues:
 References

ser References Editor Publisher Date

Lectures of Prof. Dr.
Prof. Dr. ABD EL-HAMID
1 ABD EL-HAMID Alex university 2008
ATTIA
ATTIA
‫محاضرات فى األسس الفنية‬ Prof. Dr. ABD EL-HAMID
٢ Alex university ٢٠٠٢
‫لتكييف الھواء‬ ATTIA
٣ EGAT catalog EGAT EGAT
4 Grundfos catalog Grundfos Grundfos
5 Product catalog York York
‫نخبة من أساتذة تكييف الھواء بالجامعات‬
6 ‫الكود المصرى لتكييف الھواء‬ ‫وزارة اإلسكان والتعمير‬ ٢٠٠٢
‫المصرية‬
7 Carrier catalog Carrier Carrier
Good Manufacturing
U.S. Food and
Practices (GMP) / U.S. Food and Drug
8 Drug ٢٠٠٤
Quality System (QS) Administration
Administration
Regulation

ISO 14644-1 cleanroom American

9 American National Standard ٢٠٠٧
standards National Standard

FEDERAL STANDARD
US FED STD 209E
10 AIRBORNE PARTICULATE FED-STD-209 E ٢٠٠١
cleanroom standards
CLEANLINESS CLASSES

Safe Pharn in
11 Building documentation Safe Pharn in Porg El-Arab
Porg El-Arab
ϖϓ΍Ϯϣ ϑ΍ήηϹ΍ ΔϨΠϟ
Ϊϴδϟ΍ Δϴτϋ ΪϴϤΤϟ΍ ΪΒϋ/Ω.΍
ΔϴϜϴϧΎϜϴϤϟ΍ ΔγΪϨϬϟ΍ ϢδϘΑ έϮΘϛΪϟ΍ ΫΎΘγϷ΍
ΔϳέΪϨϜγϹ΍ ΔόϣΎΟ– ΔγΪϨϬϟ΍ ΔϴϠϛ
 ΔϳέΪϨϜγϹ΍ ΔόϣΎΟ
ΔγΪϨϬϟ΍ ΔϴϠϛ
ΔϴϜϴϧΎϜϴϤϟ΍ ΔγΪϨϬϟ΍ Ϣδϗ

ΔϳϭΩϸϟ "Ύϔλ" ϊϨμϤϟ ϱΰϛήϤϟ΍ ϒϴϴϜΘϟ΍ ϢϴϤμΗ

Ϧϣ ΔϣΪϘϣ

ΩϮϤΤϣ ΡΎΘϔϟ΍ ΪΒϋ ϖϴϓϮΗ ΢ϣΎγ/αΪϨϬϣ

ΔϳήϜδόϟ΍ ΔϴϨϔϟ΍ ΔϴϠϜϟ΍ – ΔγΪϨϫ αϮϳέϮϟΎϜΑ

ϥϮϘϓ΍Ϯϣ ΔθϗΎϨϤϟ΍ ΔϨΠϟ

Ϊϴδϟ΍ Δϴτϋ ΪϴϤΤϟ΍ ΪΒϋ/Ω.΍
ΔϴϜϴϧΎϜϴϤϟ΍ ΔγΪϨϬϟ΍ ϢδϘΑ έϮΘϛΪϟ΍ ΫΎΘγϷ΍
ΔϳέΪϨϜγϹ΍ ΔόϣΎΟ– ΔγΪϨϬϟ΍ ΔϴϠϛ

ϪϤϴόρ ΡΎΘϔϟ΍ ΪΒϋ ΪϤΤϣ/Ω.΍

ΔϴϜϴϧΎϜϴϤϟ΍ ΔγΪϨϬϟ΍ ϢδϘΑ έϮΘϛΪϟ΍ ΫΎΘγϷ΍
ΔϳέΪϨϜγϹ΍ ΔόϣΎΟ– ΔγΪϨϬϟ΍ ΔϴϠϛ

ϰδϳϮτδΒϟ΍ ϒγϮϳ ϝΎϬΘΑ΍/Ω.΍

ΙϮΤΒϟ΍ϭ ΎϴϠόϟ΍ ΕΎγ΍έΪϠϟ ΔϴϠϜϟ΍ Ϟϴϛϭ
ΔϳέΪϨϜγϹ΍ ΔόϣΎΟ– ΔγΪϨϬϟ΍ ΔϴϠϛ
 ΔϳέΪϨϜγϹ΍ ΔόϣΎΟ
ΔγΪϨϬϟ΍ ΔϴϠϛ
ΔϴϜϴϧΎϜϴϤϟ΍ ΔγΪϨϬϟ΍ Ϣδϗ

(ΔϳϭΩϸϟ Ύϔλ) ϊϨμϤϟ ϱΰϛήϤϟ΍ ϒϴϴϜΘϟ΍ ϢϴϤμΗ

ϲϤϠϋ ήϳήϘΗ

ΔϳέΪϨϜγϹ΍ ΔόϣΎΟ– ΔγΪϨϬϟ΍ ΔϴϠϛ ΔϴϜϴϧΎϜϴϤϟ΍ ΔγΪϨϬϟ΍ Ϣδϗ ϰϟ· ΔϣΪϘϣ

ΔΟέΩ ϰϠϋ ϝϮμΤϠϟ ΓέήϘϤϟ΍ ΕΎγ΍έΪϠϟ ˯ΎϔϴΘγ΍

ΔγΪϨϬϟ΍ ϲϓ ήϴΘδΟΎϤϟ΍
ϲϓ
ΔϴϜϴϧΎϜϴϤϟ΍ ΔγΪϨϬϟ΍

Ϧϣ ΔϣΪϘϣ

ΩϮϤΤϣ ΡΎΘϔϟ΍ ΪΒϋ ϖϴϓϮΗ ΢ϣΎγ/αΪϨϬϣ

ΔϳήϜδόϟ΍ ΔϴϨϔϟ΍ ΔϴϠϜϟ΍ – ΔγΪϨϫ αϮϳέϮϟΎϜΑ

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