HVAC Systems — Understanding the basis Table of Contents Introduction to HVAC Systems HVAC System Types HVAC Piping System HVAC Air Distribution Equipments Fans and Pumps HVAC Instrumentation and Control HVAC System Commissioning SS CisIntroduction to HVAC Systems » This article introduces the heating, ventilating and air-conditioning (HVAC) systems. The primary function of HVAC systems is to provide healthy and comfortable interior conditions for occupants; well- designed, efficient systems do this with minimal non-renewable energy and air, and water pollutant emissions.Introduction to HVAC Systems » The purpose of HVAC design is both high indoor air quality and energy efficiency. These dual considerations require an integrated design approach. Rigs heating, ventilation, and air conditioning system (HVAC) creates a climate that allows for maximum comfort by Nsating for changing climatic bns. » Though more costly to installland more complicated to operate, a chiller plant offers a number of benefits over a large number of individual packaged cooling units, including greater energy seul ed better controllability, cheaper overall maintenance, and longer life. Using a comprehensive approach to building design, designers around the world have succeeded at creating highly efficient air-conditioning systems that provide excellent comfort at significant savings.Introduction to HVAC Systems » Heating, ventilating and air- conditioning (HVAC) systems. reduce the environmental impact of rigs/buildings in several NAN SMa nne=1aL ene lalG function of a HVAC systems is to provide the rig/buildings occupants with healthy and comfortable interior conditions. A carefully designed, efficient system can do this with minimal non- renewable energy and air and water pollutant emissions to minimize the environmental impact. Cooling equipment that avoids chlorofluorocarbons and hydro- chlorofluorocarbons (CFCs and HCFCs) eliminates a major cause of damage to the ozone layer.Introduction to HVAC Systems » Even the best HVAC equipment and systems cannot compensate for a faulty rig design. Problems of this type cause inherently high cooling and heating needs and consume unnecessary resources and should be corrected if possible. Conservation of non-renewable energy through an intelligent architectural design offers the greatest opportunity for savings. The most important factors in these designs are careful control of solar gain, while taking advantage of passive heating, daylighting, natural ventilation and cooling. The critical factors in mechanical systems’ energy consumption - and capital cost - are reducing the cooling and heating loads they must handle.HVAC System Types Types of System Designs - There are several major heating, ventilating, and air CoM Compe cul Veen ro eceh Nera ties cma lconie PU eee umem Unie Wataru Mees cueiunt ron er aren ol these categories, or are a combination or variation of them. Each type of system has Ell clef ee lees meted Air cooled = Air cooled Chillers Packaged Unit Evaporator. (cooler) Barrel Figure 4 Alr-Cooled Chiller Package‘Thermal or Electronic Outlet Inlet Expansion Device oded cooler, which has water in the tubes, is also used Figure 5 Refrigeration Cycle Components of an Air-Cooled ChillerAQUA SERIES Air-Cooled Chillers Superior Full and Part-Load Performance Emronmental Leadership Efficiency AquaSnap 30R8» Air Cooled Chiller Advantages ° Lower installed cost * Quicker availability * No cooling tower or condenser pump required * Less maintenance * No mechanical room required» Water Cooled - Sea Water cooled Chillers Stem i lmele) tem ee)» Water-Cooled Chiller advantages * Higher efficiency * Custom selection in larger sizes - Large tonnage capabi * Indoor Chiller location + Longer lifeAir Handling Systems > Purpose of an air handling system Air Handling System Room With Defined Beguine iments)fo) o){-toithes) In the following slides, we will study the components of air handling systems in order to: ' Become familiar with the components Know their functions Become aware of possible problemsOverview components mi a a “Oa ee]Components (1) Ean Ty ta(sta » To prevent insects, leaves, louvre dirt and rain from entering ~ Silencer » To reduce noise caused by air circulation moat) » Automated adjustment of, controller volume of air (night and day, pressure control) ~ Control » Fixed adjustment of volume damper of airComponents (2) ~ Heating unit ~ Cooling unit /dehumidifier ~ Humidifier Baile Ducts bs > a To heat the air to the proper temperature To cool the air to the required temperature or to remove moisture from the air To bring the air to the proper humidity, if too low To eliminate particles of pre- determined dimensions and/or micro-organisms To transport the airAir types 1 | Revtoeen aie: i Ti rsarmncaa ONE EMSRS at ranarua aFilter classesPrimary panel he ondary itiDuct heaters Room HetersMIT e eRe Mele Lam Fire Dampers serge Pps ca Pacis Lael Paarl De-humidificationRegulation of room pressure — pressure differentials concept Annex 1, 17.26Pressure cascade injectables Protection from micro-organisms and particles Hote: Dicectina of doar op telatine w coon pressarePressure cascade solids Protection from cross-contamination ste Divectinn af doer apeaing eelitive y coen peUnit Mounted on GI Base frame for easy Lifting / Handling / Position. Double Skinned Panels Outer Skin — 0.7 mm thk. (PC) Inner Skin — 0.5 mm thk. (Gl) HEPA Filters with Side withdrawal Opposed Blade Dampers for F/A & RIA. Pret Bag Filter with Side Withdrawal. Coll with 1/2” Copper ‘Tubes and Aluminum Fins. Gl Insulated Drain Pan (GI Drain as Standard) in| 2 oa oO Q = s 2 z =x 2 Ss = é Q ¢ 3. * Z| o 3 = nm 8 Z : =iFan) Coil UnitSelf Contain UnitHVAC Air Distribution Equipments » Diffusers ~ eae Fan Design » Fan Performance > Fan-duct Systems > Duct Construction > Air Duct DesignFan Design ‘ 4 » Common types of fans Se eringen rete r-\¢l'-\Pnoa-lcekeUiny-velrlig foil (backward curved), backward inclined, tubular, roof ventilator *« -. || |. t propeller, tube-axial, vane-axial > Fan arrangements * Motor location, air discharge orientation, drive train type (direct drive or pulley drive) * Centrifugal: single width single inlet (SWSI), double width double inlet (DWD!)CENTRIFUGAL FANS AXIAL FANS Inlet Cone or Guide Vane _Inlet Bell wheel Rotor Impeller Rim Whee! Frames Support Inlet Collar Spinner Centrifugal and axial fan componentsAXIAL FANS Cylindrical casing (tube) Hub ClearanceLON MUI OLer Nope) Cylindrical casing Tubular centrifugal fan (Orn tetate Me coLey nen tel Leg (* Note the airflow paths and impeller design.)Arrangement 2 sws! ek or direst drive SWSI or DWDI Belt and direct drive All sacs SwSI Direct drive Smal sizes Be Drive arrangements and motor positions 'SWSI and DWSt Belt or direct dave All sizes Arrangement 8 SWI Belt or direct drive All sizes Arrangement 9 Swst Belt drive ‘Small sizes Arrangement 10) SwsI Belt driv Smal sizesScroll Scroll Inlet Inlet Impeller cone / cone Impeller Single- and double-width centrifugal fansFan Performance » Major parameters « Fan volume flow rate (m’/s or I/s), V, « Fan total pressure Ap,, fan velocity pressure p,, & fan static pressure Ap, (Pa) * Fan power & efficiency Fan power or air power (W) = Ap, x V, Fan power input on the fan shaft (brake horsepower), P) Fan total efficiency: n. = Ap, x V, / P; * Combined aerodynamic, volumetric & mechanical efficiencies Fan static efficiency: n, = Ap,x V,/ P. Air temp. increase through fan. AT. = Ap, /(pc_n)Free delivery wide-openFan Performance Speed (n) Volume flow (V) Total pressure loss (Ap ) Air density (p) For air systems that are geometrically & dynamically similar: (D = impeller diameter) > ¢c.f.: pump laws 7,/v¥, =n,/n, AP2/APy = (n/m, )'(:/0) P/F = (n,/n,) (P3/,) D,/D,)'(n,/m) AP 2 /APy = (D,/D,Y (n/n, (P2/P) P,P =(D./D,) (/m) (P2/P1)Fan Performance » Major issues causing energy losses to a centrifugal fan: * Circulatory flow between the blades * Air leakage at the inlet * Friction between fluid particles and the blade * Energy loss at the entrance * Partially filled passage.Friction between fluid particle and bladeTotal efficiency nao woy fcitestaeree evnerry power curve:© @ © Tube-axial Vane-axial Vane-axial Tube-axialTube-axialieourou ria curves for ontrollable- ever toebat fan Fan velocity pressure — in, of water 02 03 04 06 O08 10 20 3.0 40 60 80 20 20 40 50 60 70 80 90 10 Fan outlet velocity x 1000 FPM Blade position _— 43 in, diameter 40 7 blades 2 é g s Total pressure — Inches of water 0.075 Ibyft? density T aFan-duct Systems Sa » Duct pressure changes (c.f. atm pressure) * Static pressure (SP) * Velocity pressure (VP) = pV’/2g * Jota! pressure (TP) = SP + VP > Fan: a pumping device * Fan (total) pressure = pressure difference between fan inlet and fan discharge * At fan suction/inlet, SP = negative (c.f. atmospheric); at discharge, SP = positiveSTATIC AND TOTAL PRESSURE FLOW » TOTAL PRESSURE IN STATIC PRESSURE NORMAL TO FLOW + DIRECTION OF FLOW STATIC PRESSURE TOTAL PRESSURE U TUBE WATER MANOMETERSPRESSURE (Vp)Fan-duct Systems Sa » Pressure characteristics * SP and VP are mutually convertible (tor!) * TP always decreases in the direction of airflow * For constant-area straight duct sections Velocity and VP are constant TP’ change = SP change * When duct cross-sectional areas are reduced Velocity and VP increase Absolute value of both TP and SP decrease Dynamic losses from elbow, dampers, etc.Fan-duct Systems Se » Fan-duct systems. * Flow resistance R, pressure drop Ap and het e R. y? Eo yo eto (ot a sci ora * Duct sections in parallel: 1 1 1 1 een (CR)Fan-duct Systems we > Fan-duct systems * Terminology Primary air (conditioned air or makeup air) Secondary air (induced space air, plenum air, or recirculating air) Transfer air (indoor air that moves from an adjacent area) * System) curve: volume flow vs pressure loss * System operating pointFan-duct Systems a4 oe » System effect Ap, * Its additional total pressure loss caused by uneven or non-uniform velocity profile at the fan inlet, or at duct fittings after fan outlet * Due to the actual inlet and outlet connections as compared with the total pressure loss of the fan test unit during laboratory ratings Ap,, = Ap,, + Ap,, = Ap,, + Ap,; + AP, = Ap, + C,,(¥4,/4005)° + C,,(v;,,/4005)Fan curve with system effect without system effect System cute, Ap,, = RV, including system effect ——\_ System curve without system v * a3 V, cfm (Ws) J ), Fan system operating point « 7 Ae }Fan-duct Systems we » Modulation of air systems * Constant volume system Volume flow rate remains constant Supply temperature is raised during part load * Variable-air-volume (VAV) system Volume flow rate is reduced to match part load operation Modulation curveModulation Set point of duct static pressure control Ape.Fan-duct Systems we » Fan modulation methods «(vary the opening of the air flow passage) Waste energy * | -- (opening & angle of inlet vanes) Low cost; less efficient than following types ~ Inlet Gone (oar oi=rell rior ele) 1 SIlSe) Inexpensive; for backward curved centrifugal fan. => «; (blade angle of axial fan) * =; -+--« (Using adjustable frequency drives) Most energy-efficient; but usually cost moreSystem curve damper modulation System Speed LN fo modulation _Inlet vane modulationFan spee|Fan-duct Systems we » = (in centrifugal fan) * Occurs when air volume flow is not sufficient to sustain the static pressure difference between discharge & suction Deoneie ren os scUee None Nese M arene Volume flow & pressure fluctuations Create noise & vibration * Surge region; shall avoid operation in it » F15©)|\(in axial fans) * When smooth air flow suddenly breaks & pressure difference across the blades decreases * The fan loses pressure capability drasticallyFe Normal operation Blade pitch angle ¥, cfm Stall and stall region of an axial fanFan-duct Systems we > Fan selection * Select fan type + determine fan size * Important factors: Pressure-volume flow operating characteristics Fan capacity modulation Fanjefficiency, Sound power level Airflow direction Initial costTABLE 15.2 Comparison between Various Types of Funs Backward, airfoil centrifugal fan Forwand-curved centrifugal fan Vane-axial Propeller fan Fan total pressure Ap Flow rate Fan power input Fan modulation Fan total efficiency Sound power level Airflow direction Volume and weight Initial cost Applications Higher 3. All flow rates Nonoverloading Inlet vanes AC inverter 0.7100.86 Lower, higher L, at low frequencies 90° turn High, Large HVAC&R Comparative! x flow rate Medium, higher Ly at low frequencies 90° turn Less Medium Lower pressure, small HVAC&R systems Higher Ap, Low Ay All flow rates Larger flow rate overloading Nonoverloadin; inverter 0.88 0.45 100.6 Medium, difference Higher, higher /., f 1, values is al high frequencies small at various Hz Parallel to axle Parallel to axle Greater Medium volume and lower weight Higher Le Large HVAC&R Low-pressure, high volume flow exhaust systemsDuct Construction » Types of air duct * Supply air duct * Return air duct * Outdoor air duct * Exhaust air » Duct sections * Header or main duct (trunk) ¢ Branch duct or runoutTotal pressure p, (positive) rr ® L Conditioned space (Atmospheric pressure)Duct Construction > Duct systems * Max. pressure difference (between air inside the duct and the ambient air) 125, 250, 500, 750, 1000, 1500, 2500 Pa * Commercial buildings Low-pressure duct system: = 500 Pa, max 12 m/s. Meditim-pressure system: 500-1500) Pa, max 17/5 m/s * Residential buildings: 125 Pa or 250/Pa * Industrial duct system: AP can be higherDuct Construction » Duct material: e.g. UL (Underwriters’ Laboratory) standard * Class 0: zero flame spread, zero smoke developed lron, galvanized steel, aluminum, concrete, masonry, clay tile * Class 1: flame spread = 25, smoke developed = 50 Fiberglass, many flexible ducts * Class 2: flame spread < 50, smoke developed = 100Duct Construction » Shapes of air duct * Rectangular More easily fabricated on site, air leakage * Round Less fluid resistance, better rigidity/strength Sel @e)yZ)) ° Flexible Multiple-ply polyester film w/ metal wire or strips » SMACNA (Sheet Metal and Air Conditioning Contractors’ National Association) standardsTransverse joint reinforcement K., 2001. Handbook of Air Conditioning and Refrigeration)Duct Construction » Duct specification * Sheet gauge and thickness of duct material * Traverse joints & longitudinal seam reinforcements * Duct hangers & their spacing, Damir lol=t-rccwrele| ales) ome [es<1U] cos) ¢ Fire spread and smoke developed * Site-fabricated or factory-/pre-fabricatedDuct Construction » Duct heat gain or loss * Temperature rise or drop * Duct insulation (mounted or inner-lined) Reduce heat gain/loss, prevent condensation, SoU iate ee iicetgUrelelg) Minimum & recommended thickness * See ASHRAE standard or local codes * Temperature rise curves Depends on air velocity, duct dimensions & insulationRound duct Insulation 1.5 in, duet wrap k= 0.30 Btu-in/t-ft?-°F AT = 25°F Length L = 100¢t & g 2 c g a z 1000 2000 Duct velocity », fpm. nentDuct Construction » Frictional losses * Darcey-Weisbach Equation f= friction factor (dimensionless) L =length of duct or pipe (m) D = diameter of duct or pipe (m) V= mean air velocity in duct (m/s)Mode of airflow when air passes over and around surface protuberances of the duct wallDuct Construction » Duct friction chart * Colebrook formula » Roughness & temperature corrections AN cease Nee K,= correction factor for surface roughness K,= correction factor for air temperature K,= correction factor for elevationa be iS) 7 iS S Sutin‘Table 1 Roughness Duct Material Category Uncoated carbon steel, clean Smooth (Moody 194) (0.05 min) PVC plastic pipe (Swim 1982) (0.01 t0 0.05 mm) Aluminum (Hutchinson 1953) (0.04 to 0.06 mm) Galvanized steel, longitudinal seams, Medium 1200 mm joints (Griggs et al. 1987) smooth (0.05 to 0.10 mm) Galvanized steel, continuously rolled, spiral seams, 3000 mm joints (Jones 1979) (0.06 to 0.12 mm) Galvanized steel, spiral seam with 1, 2, and 3 ribs, 3600 mm joints (Griggs et al. 1987) (0.09 10 0.12 mm) Galvanized steel, longitudinal seams, ‘Average 760 mm joints (Wright 1945) (0.15 mm) Fibrous glass duet, rigid Medium Fibrous glass duct line, air side with rough facing material (Swim 1978) (1.5 mm) Fibrous glass duct liner, air side spray coated (Swim 1978) (4.5 mm) Flexible duct, metallic 2 to 2.1 mm when fully extended) Flexible duct, all types of fabric and wire (1.0 0 4.6 mm when fully extended) Concrete (Moody 1944) (1.3 toDuct Construction » Circular equivalent ¢ Hydraulic diameter, D,=4A/P A = area (mm’); PDuct Construction » Dynamic losses * Result from flow disturbances caused by duct- mounted equipment and fittings Change airflow path’s direction and/or area Flow separation & eddies/disturbances ® In dynamic similarity (Same Reynolds number & geometrically similar duct fittings), dynamic loss iS proportional to their velocity pressureDuct Construction » Local or dynamic loss coefficient * Ratio of total pressure loss to velocity local loss coefficient, dimensionless total pressure loss, Pa density, 4 velocity, m/s velocity pressure, PaDuct Construction > Duct fittings * Elbows * Converging or diverging tees and wyes * Entrances and exits * Enlargements and contractions > Means to reduce dynamic losses * jjurning angle, splitter vanes » ASHRAE duct fitting database * Fitting loss coefficientsFITTING LOSS COEFFICIENTS Fittings to support [Examples 9 and {J and some of the more common fittings are reprinted here. For the complete fitting database see the Duct Fisting Database (ASHRAE 194). ROUND FITTINGS (CD¥1 Elbow, Die Stamped, 90 Degree, r/D = LS Damm 78 Be Ta ae (CD33 Ethow, Die Stamped, Domm_78___100 7Region of eddies and turbulences in a round elbow 5-piece 90° round elbowVon ¥bs Por Ay Branch streamEntrance Downstream Upstream rrvvyyAbrupt enlargem Sudden contractionDuct Construction > Flow resistance, R Ceol olrexs0 icc) a Ap, at a specific volume flow Leics Ap, = R:- vy; Re RR Sim Wager ici ee lMlecu Msc iilesse * Flow resistarice in piarallel: L = ttt th sp aif (Re VR VR R,Total pressure lo8 V5 Ap, in. WC Arn= Reig = hy =v} € an i py rte te I / iAme Apo Apr APYAir Duct Design > Optimal air duct design * Optimal duct system layout, space available * Satisfactory system balance * Acceptable sound level * Optimum energy loss and initial cost * Install only necessary balancing devices (dampers), * Fire codes, duct construction & insulation * Require comprehensive analysis & care Tor different transport functionsPepe Meer AP inte i ’ Team Voy iy o 1 ar wt) ViconAir Duct Design » Design velocity * Constraints: space available, beam depth * Typical guidelines: Main ducts: air flow usually = 15 m/s; air flow noise must be checked With more demanding noise: criteria (e:g: hotels), max. air velocity: main duct = 10-12.5 m/s, return main duct = & m/s, branch ducts = 6 m/s * Face velocities for air-handling system components‘Table 10 “Typical Design Velocities for HVAC Components Duct Flement TOUVERS" Iotake 23300 Lis and greater ‘Lexs than 3300 Ls Exhaust 2400 Lis and greater ‘Less thn 2400 Ls FILTERS" Pane! filers ‘Viscous impingement tos Dry-type, extended-surface ‘Rat ow efficiency) Preatec! media (intermedite efficiency) HEPA Renewable media flrs ‘Moving-curiain viscous impingement ‘Moving-curiain dry mecin ‘Blectronic air cleaners lonizing type HEATING COILS Steam and bot water Face Veloity, mis Duct velocity Upto3& min, 8 max. Beetic Open wire Refer to mf. ata Finned tubular Refer to mfg, data DEHUMIDIFYING COILS" Dios "AIR WASHERS® ‘Spray type 11030 Cell type Refer to mfp, data High-velocity speay type 6109 + © ‘AR FLOW PERLOUVER, os ‘Parameters Used to Estableh Figure _ Intake Louver Exhavel Louver | Minimum (reearea(1200™mm squaretwst_ 45 e section), ‘Watar ponetration, uLi\rn?-s) Negigitto (loss than 0.0) Maxrmum state pressure drop, Pa 35 Fig. 18 Criteria for Louver Sizing,Air Duct Design » Reduce dynamic losses of the critical path * Maintain optimum air velocity through duct fittings * Emphasize reduction of dynamic losses nearer to the fan outlet or inlet (high air velocity) ° Proper use:of splitter vanes * Set 2 duct fittings as far apart as possible. > Air duct leakage * Duct leakage classification AISI, SMACNA, ASHRAE standardsAir Duct Design » Fire protection * Duct material selection ¢ Vertical ducts (using masonry, concrete or clay) * When ducts pass through floors & walls * Use of fire dampers * Filling the gaps between ducts & bldg sifucture * Duct systems for industrial applications » Any other fire precautions?Air Duct Design » Design procedure (computer-aided or manual) * Verify local codes & material availability * Preliminary duct layout * Divide into consecutive duct sections * Minimise local loss coefficients of duct fittings * Select duct sizing methods * Critical total pressure loss of tentative critical path * Size branch ducts & balance total pressure at junctions: * Adjust supply flow rates according to duct heat gain * Resize duct sections, recalculate & balance parallel paths * Check sound level & add necessary attenuationAir Duct Design » Duct layout * Symmetric layout is easier to balance Smaller main duct & shorter design path * For VAV systems, duct looping allows feed from opposite direction Optimise transporting capacity (balance points often follow the sun's position) Result in smaller main duct * Compare alternative layouts & reduce fittings * For exposed ducts, appearance & integration with the structure is importantMain duet Branch takeoft Retum ly, return and slots 77 Aichanding any AHU) “Supply stot diffuser Typical supply duct system with symmetric layout & loopingAir Duct Design » Duct liner * Lined internally on inner surface of duct wall * Mainly used for noise attenuation & insulation * Fiberglass blanket or boards » Duct cleaning * Prevent accumulation of dirt & debris * Agitation device to loosen the dirt & debris * Duct vacuum to extract loosened) debris * Sealing of access openingsund power, tering duct Ouct Outer Duct Surtace Cross-sectional Area — Ag Area — Aj Duct breakout noiseHVAC Piping System Leoeno ye eo saa ae ae SECTION eric scnebiaTicHVAC Instrumentation and ControlHVAC System Commissioning The key elements of commissioning include: Installation checks. Ce ta aaa RAAT I eo celal ial euler ts Ca eH Te et ed i pet oe : Pye ea enue ek seen Cee evict re mene a statement of the design intent SS EEE eee bay eet and) clue Bed le training for rig operations: sep au AEH Ca aCe ome ice unsere eice| ensure that equipment and systems continue to Gio eea according to eae ne Correctly implemented, Ce cost-effective, and should improve the delivery process, increase A ee eee EASY Eee