Airflow Analysis of a Custom “Green”

Air Handling Unit Without a Pre-heater

Performed by M/E Engineering

The CAES Group

22 June 2010
 Background
•  Two years ago, a pharmaceutical client finished construction on a new
LEED certified building in New England.
•  The facility’s air handlers were custom-fabricated and employed
economizers without pre-heaters upstream of the water-based coils.
•  Without pre-heaters, the air handlers were much more energy efficient.
•  The air handler manufacturer believed that their design was capable of
adequately mixing warm RETURN air with 30% cold OUTSIDE air
effectively enough to prevent coil freezing.
•  During the first year of operation, freezestat alarms shut most of the
units down during several cold winter days.
•  The client asked that we model their air handlers to:
–  Understand the issues with the current design, and
–  Provide them with a redesign that would be immune to cold climatic conditions.
 Case 1: Parameters
•  Star CCM+ software was used to model an Economizer/Air Handling
Unit installed on a LEED silver certified building in the
pharmaceutical industry.

•  Given Values:
–  Air Flow CFM = 51,100 CFM
–  30% Outside Air and Temperature = 0ºF
–  Supply Air Temperature Target = 55ºF
•  Assumptions:
–  Return Air Temperature = 70ºF
 Case 1

Custom Air Handler without Pre-Heating

Geometric Elevation View
(Visualization Only)

Actual CFD Model

Supply Fan
Return Fan
Return Air Enters Humidifier Spray Nozzles
Blenders
Outside Air Enters Cooling Coils
Pre-Filters
 Case 1
Custom Air Handler without Pre-Heating
Geometric Plan View

Outside Air Enters

Supply Fan Motor

Supply Fan

Blenders Humidifier Spray Nozzles

Pre-Filters Cooling Coils
 Case 1
Custom Air Handler without Pre-Heating
Geometric Elevation View

Outside Air Enters

Return Air
Enters

Supply Fan
Blenders
Humidifier Spray Nozzles

Pre-Filters Cooling Coils

 Case 1
Custom Air Handler without Pre-Heating
Geometric Isometric View

Outside Air Enters

Return Air
Enters

Supply Fan

Humidifier Spray Nozzles

Blenders
Pre-Filters Cooling Coils
 Case 1
Custom Air Handler without Pre-Heating
Pathlines Isometric View
 Case 1
Custom Air Handler without Pre-Heating
Pathlines Plan View

Blenders Pre-Filters Cooling Coils Humidifier Spray Nozzles

 Case 1
Custom Air Handler without Pre-Heating
Pathlines Elevation View
Blenders Pre-Filters Cooling Coils Humidifier Spray Nozzles
 Case 1
Custom Air Handler without Pre-Heating
Temperature Contour – Isometric View

Cut Plane approx.

thru center of AHU
 Case 1
Custom Air Handler without Pre-Heating
Temperature Contour – Side Elevation View

Cooling Coils
 Case 1
Custom Air Handler without Pre-Heating
Relative Pressure Contour – Side Elevation View
∆P =0.23 in WG ∆P =0.48 in WG

P ≈ 0 in WG
 Case 1
Custom Air Handler without Pre-Heating
Velocity Vectors – Side Elevation View
Blenders Pre-Filters Cooling Coils Humidifier Spray Nozzles
 Case 1
Custom Air Handler without Pre-Heating
Velocity Vectors – Close up Side Elevation View

Blenders Pre-Filters Cooling Coils Humidifier Spray Nozzles

 Case 1
Custom Air Handler without Pre-Heating
Speed Contour & Velocity Vectors –
Side Elevation View
Blenders Pre-Filters Cooling Coils Humidifier Spray Nozzles
 Case 1
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Isometric View

Blenders Pre-Filters Cooling Coils Humidifier Spray Nozzles

 Case 1
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View
Cooling Coils
(min & max values)
 Case 1
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View
Cooling Coils
(cold spots below 35°F)
 Case 1
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperatures at Various Heights

Bottom Coil Middle Coil Top Coil

 Case 1
Custom Air Handler without Pre-Heating
Pre-Filter Face Air Speed – Isometric View

Blenders Pre-Filters Cooling Coils Humidifier Spray Nozzles

 Case 1
Custom Air Handler without Pre-Heating
Pre-Filter Face Air Speed – Front Elevation View
Pre-Filters
 Case 1

Estimated Supply Temperature with perfect mixing

70% Return & 30% Outside Air

Estimated supply discharge temperature

 Case 1

Conclusions
•  The model shows that there’s still a probability of the top cooling coil
to freeze compared to a design without blenders.
–  The temperatures in the supply chamber range from 65ºF down to
26ºF, with an average discharge temperature of 44ºF.
–  A simple mixing model calculates the discharge temperature at
49.2°F. (assuming perfect mixing)
 Case 2: Parameters
•  Star CCM+ software was used to model the Economizer.

•  Given Values:
–  Air Flow CFM = 51,100 CFM
–  30% Outside Air and Temperature = 0ºF
–  Supply Air Temperature Target = 55ºF
•  Assumptions:
–  Return Air Temperature = 70ºF

•  Modified Blender location and interior wall.

 Case 2
Custom Air Handler without Pre-Heating
Geometric Elevation View

Outside Air Enters

Modified interior wall

Return Air
Enters

Supply Fan
New Location for Blenders
Humidifier Spray Nozzles

Pre-Filters Cooling Coils

 Case 2
Custom Air Handler without Pre-Heating
Geometric Isometric View

Outside Air Enters

Modified interior wall

Return Air
Enters

Supply Fan

Humidifier Spray Nozzles

New Location for Blenders
Pre-Filters Cooling Coils
 Case 2
Custom Air Handler without Pre-Heating
Temperature Contour – Side Elevation View

Cooling Coils
 Case 2
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View
Cooling Coils
(min & max values)
 Case 2
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View
Cooling Coils
(cold spots below 35°F)
 Case 2
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperatures at Various Heights

35°

Bottom Coil Middle Coil Top Coil

 Case 2

Estimated Supply Temperature with perfect mixing

70% Return & 30% Outside Air

Estimated supply discharge temperature

 Case 2

Conclusions – Case 2
•  This Economizer model shows that there’s still a probability of the
cooling coils to freeze.
–  The temperatures in the supply chamber range from 63ºF down to
26ºF, with an average discharge temperature of 43ºF.
–  Temperature distribution at coil faces was shifted to slightly higher
temperatures.
 Case 3: Parameters
•  Star CCM+ software was used to model the Economizer.

•  Given Values:
–  Air Flow CFM = 51,100 CFM
–  30% Outside Air and Temperature = 0ºF
–  Supply Air Temperature Target = 55ºF
•  Assumptions:
–  Return Air Temperature = 70ºF

•  Moved the Blender down 5” from the floor.

 Case 3
Custom Air Handler without Pre-Heating
Geometric Elevation View

Outside Air Enters

Return Air
Enters

Supply Fan
New Location for Blenders
(5” from floor) Humidifier Spray Nozzles

Pre-Filters Cooling Coils

 Case 3
Custom Air Handler without Pre-Heating
Geometric Isometric View

Outside Air Enters

Return Air
Enters

Supply Fan

Humidifier Spray Nozzles

New Location for Blenders
(5” from floor) Pre-Filters Cooling Coils
 Case 3
Custom Air Handler without Pre-Heating
Temperature Contour – Side Elevation View

Cooling Coils
 Case 3
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View

Cooling Coils
(min & max values)
 Case 3
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View

Cooling Coils
(cold spots below 35°F)
 Case 3
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperatures at Various Heights

35°

Bottom Coil Middle Coil Top Coil

 Case 3
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View
Comparison of Surface Areas below 35°F

Case 1 Case 3

Case 2
 Case 3

Estimated Supply Temperature with perfect mixing

70% Return & 30% Outside Air

Estimated supply discharge temperature

 Case 3

Conclusions
•  This Economizer model shows that there’s still a probability of the
cooling coils to freeze.
–  The temperatures in the supply chamber range from 58ºF down to
28ºF, with an average discharge temperature of 43ºF.

•  SUGGESTED DESIGN CHANGE

–  Place vanes beneath the outside air damper to skew the cold air
flow rightward.
 Case 4: Parameters
•  Star CCM+ software was used to model the Economizer.
•  Given Values:
–  Air Flow CFM = 51,100 CFM
–  30% Outside Air and Temperature = 0ºF
–  Supply Air Temperature Target = 55ºF
•  Assumptions:
–  Return Air Temperature = 70ºF
 Case 4: Parameters
•  Kept the Blender 5” from the floor
•  Added 9” deep vanes below the outside air damper. (6” gap between
damper and top of vanes, half of the vanes are at 45º to the outside side
walls with the middle vane placed vertically. All vanes are evenly
spaced 1ft apart under the Outside Damper.
•  Added a perturbation airfoil that starts 6” above the opening of the
blenders, protrudes 10 inches upstream and angles back at a 45º to the
wall. This perturbation airfoil extends laterally wall to wall above the
openings of the blenders.
 Case 4
Custom Air Handler without Pre-Heating
Geometric Side Elevation View
Outside Air Enters
Cooling Coils

Added Vanes

Return Air
Enters

Perturbation Airfoil

Blenders Pre-Filters
 Case 4
Custom Air Handler without Pre-Heating
Geometric Front Elevation View

Outside Air Damper

Added 9” Vanes @ 45 º

Return Air Damper

 Case 4
Custom Air Handler without Pre-Heating
Geometric Isometric View

Outside Air Enters

Added Vanes

Perturbation
Airfoil

Supply Fan

Return Air Humidifier Spray Nozzles

Enters

Cooling Coils
Blenders Pre-Filters
 Case 4
Custom Air Handler without Pre-Heating
Temperature Contour – Side Elevation View

Cooling Coils
 Case 4
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View
Cooling Coils
(min & max values)
 Case 4
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperatures at Various Heights

Bottom Coil Middle Coil Top Coil

35°
 Case 4
Custom Air Handler without Pre-Heating
Relative Pressure Contour – Side Elevation View
∆P =0.26 in WG ∆P =0.48 in WG

P ≈ 0 in WG

∆P =0.33 in WG
 Case 4

Estimated Supply Temperature with perfect mixing

70% Return & 30% Outside Air

Estimated supply discharge temperature

 Case 4

Conclusions
•  With the added vanes before the Blenders increases the cooling coil
face temperature up to 35ºF.
•  Still a small possibility that the cooling coils might freeze on the lower
right cooling coil.

•  Recommend mirroring the blade rotation of the right blender to create

a more even temperature distribution on the cooling coils.
 Case 5: Parameters
•  Star CCM+ software was used to model the Economizer.

•  Given Values:
–  Air Flow CFM = 51,100 CFM
–  30% Outside Air and Temperature = 0ºF
–  Supply Air Temperature Target = 55ºF
•  Assumptions:
–  Return Air Temperature = 70ºF
 Case 5: Parameters
•  Kept the Blender 5” from the floor
•  Kept the vanes below the outside air damper.
•  Kept the perturbation airfoil.
•  Mirrored the right blender (when looking downstream towards the
supply fan in the air handling unit.)
 Case 5
Custom Air Handler without Pre-Heating
Geometric Side Elevation View
Outside Air Enters
Cooling Coils

Vanes

Perturbation
Airfoil

Return Air
Enters

Blenders Pre-Filters
 Case 5
Custom Air Handler without Pre-Heating
Geometric Isometric View

Outside Air Enters

Vanes

Perturbation
Airfoil

Return Air
Enters
Supply Fan

Humidifier Spray Nozzles

Blenders
Cooling Coils
Mirrored Blender Pre-Filters
 Case 5
Custom Air Handler without Pre-Heating
Geometric Isometric View
Outside Air Enters

Vanes

Perturbation
Airfoil

Return Air
Enters

Pre-Filters

Blenders
Mirrored Blender
 Case 5
Custom Air Handler without Pre-Heating
Temperature Contour – Side Elevation View

Cooling Coils
 Case 5
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View

Cooling Coils
(35º - max value)
 Case 5
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperatures at Various Heights

Bottom Coil Middle Coil Top Coil

 Case 5
Custom Air Handler without Pre-Heating
Relative Pressure Contour – Side Elevation View
∆P =0.22 in WG

∆P =0.41 in WG

P ≈ 0 in WG

∆P =0.40 in WG
 Case 5

Estimated Supply Temperature with perfect mixing

70% Return & 30% Outside Air

Estimated supply discharge temperature

 Case 5

Conclusions
•  With the added vanes below the outside air damper, a perturbation
airfoil and mirrored rotation of one blender, this model shows that the
minimum temperature across the cooling coil is calculated to be 42ºF.
•  The average supply temperature discharge is calculated to be 46ºF
whereas the theoretical perfect mixing case would be 49.24°F.
•  An added bonus to this design shows that the mirrored blender
enhances the temperature distribution on the cooling coils to be more
symmetrical left to right.
 Case 6: Parameters
•  Star CCM+ software was used to model the Economizer.

•  Given Values:
–  Air Flow CFM = 51,100 CFM
–  20% Outside Air and Temperature = 0ºF
–  Supply Air Temperature Target = 55ºF
•  Assumptions:
–  Return Air Temperature = 70ºF
 Case 6: Parameters
•  Kept the Blender 5” from the floor
•  Kept the vanes below the outside air damper.
•  Kept the perturbation airfoil.
•  Kept the mirrored right blender (when looking down towards the
supply fan in the air handling unit.)
 Case 6
Custom Air Handler without Pre-Heating
Geometric Side Elevation View
20% Outside Air Enters
Cooling Coils

Vanes

Perturbation
Airfoil

Return Air
Enters

Blenders Pre-Filters
 Case 6
Custom Air Handler without Pre-Heating
Geometric Isometric View

20 % Outside Air Enters

Vanes

Perturbation
Airfoil

Return Air
Enters
Supply Fan

Humidifier Spray Nozzles

Blenders
Cooling Coils
Mirrored Blender Pre-Filters
 Case 6
Custom Air Handler without Pre-Heating
Temperature Contour – Side Elevation View

Cooling Coils
 Case 6
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View

Cooling Coils
(35º - max value)
 Case 6
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperatures at Various Heights

Bottom Coil Middle Coil Top Coil

 Case 6
Custom Air Handler without Pre-Heating
Relative Pressure Contour – Side Elevation View
∆P =0.22 in WG

∆P =0.40in WG

P ≈ 0 in WG

∆P =0.38 in WG
 Case 6

Estimated Supply Temperature with perfect mixing

80% Return & 20% Outside Air

Estimated supply discharge temperature

 Case 6

Conclusions
•  With the added vanes below the outside air damper, a perturbation
airfoil and mirrored rotation of one blender, this model shows that the
minimum temperature across the cooling coil is calculated to be 47ºF.
•  The average supply temperature discharge is calculated to be 55ºF.
 Case 7: Parameters
•  Star CCM+ software was used to model the Economizer.

•  Given Values:
–  Air Flow CFM = 51,100 CFM
–  50% Outside Air and Temperature = 35ºF
–  Supply Air Temperature Target = 55ºF
•  Assumptions:
–  Return Air Temperature = 70ºF
 Case 7: Parameters
•  Kept the Blender 5” from the floor
•  Kept the vanes below the outside air damper.
•  Kept the perturbation airfoil.
•  Kept the mirrored right blender (when looking down towards the
supply fan in the air handling unit.)
 Case 7
Custom Air Handler without Pre-Heating
Geometric Side Elevation View
50% Outside Air Enters @ 35ºF
Cooling Coils

Vanes

Perturbation
Airfoil

Return Air
Enters

Blenders Pre-Filters
(5” above floor)
 Case 7
Custom Air Handler without Pre-Heating
Geometric Isometric View

50 % Outside Air Enters @ 35ºF

Vanes

Perturbation
Airfoil

Return Air
Enters
Supply Fan

Humidifier Spray Nozzles

Blenders
Cooling Coils
Mirrored Blender Pre-Filters
 Case 7
Custom Air Handler without Pre-Heating
Temperature Contour – Side Elevation View

Cooling Coils
 Case 7
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperature – Front Elevation View

Cooling Coils
(35º - max value)
 Case 7
Custom Air Handler without Pre-Heating
Cooling Coil Face Temperatures at Various Heights

Bottom Coil Middle Coil Top Coil

 Case 7

Estimated Supply Temperature with perfect mixing

50% Return & 50% Outside Air

Estimated supply discharge temperature

 Case 7

Conclusions
•  With the added vanes below the outside air damper, a perturbation
airfoil and mirrored rotation of one blender, this model shows that the
minimum temperature across the cooling coil is calculated to be 52ºF.
•  The average supply temperature discharge is calculated to be 52ºF.
 Summary
•  Four air handler design variations were evaluated for their resistance to
coil freezing.
•  The proportion of outside air was also evaluated at 20%, 30% and 50%
at two temperatures.
•  The final design variation shows very good resistance to freezing down
to temperatures of 0 °F (-18°C) and below.
•  The new design was implemented on all but one air handler at the
facility.
•  Last winter’s operation saw no freeze-stat alerts for the retrofitted
equipment, but several shutdowns for the unaltered unit.