PAC 105 Thesis-1

Design of an Air Conditioning System
for M-2 Hall
SESSION 2003
PROJECT ADVISOR
PROF. DR. ARSHAD HUSSAIN QURESHI
PROJECT COORDINATOR
MR. MUHAMMAD ASLAM
GROUP MEMBERS
MUHAMMED SHOAIB JAMIL SAJJAD AHMED

2003-UET-ME-RCET-02 2003-UET-ME-RCET-28
ADEEL AKHTAR CH. SAJJAD QAISER MEHMOOD
2003-UET-ME-RCET-27 2003-UET-ME-RCET-13
DEPARTMENT OF MECHANICAL ENGINEERING

RACHNA COLLEGE OF ENGINEERING & TECHNOLOGY, GUJRANWALA
UNIVERSITY OF ENGINEERING & TECHNOLOGY, LAHORE
Design of an Air Conditioning System
for M-2 Hall
(USING CANAL WATER)
This report is submitted to Department of Mechanical Engineering at

Rachna College of Engineering & Technology, Gujranwala
For the partial Fulfillment of the requirements for the
BACHELOR’S DEGREE
In
MECHANICAL ENGINEERING
INTERNAL EXAMINER: SIGN: _______________
NAME: PROF. DR. ARSHAD HUSSAIN QURESHI
EXTERNAL EXAMINER: SIGN: _______________
NAME: ________________________________
DEPARTMENT OF MECHANICAL ENGINEERING

RACHNA COLLEGE OF ENGINEERING & TECHNOLOGY, GUJRANWALA
UNIVERSITY OF ENGINEERING & TECHNOLOGY, LAHORE
Dedication
This thesis report is dedicated to
Our beloved parents who brought up us for this stage of learning
And to the
Engineering Profession
in recognition of the pivotal role played by

refrigeration and air conditioning engineering in the analysis and
design of the engineering systems
Acknowledgements
We are graciously thankful to Prof. Dr. Arshad Hussain Qureshi for his valuable
suggestions and supervision. His uniqueness and expertise in the area of Heat & Mass
Transfer, Fluid Mechanics, and Thermal Engineering etc that really proved to be a source
of continuous learning and inspiration for us, causing to work us hard. We wish to thank
also our project coordinator Mr. Muhammad Aslam for his excellent guidance to
complete this project before time.
We are indebted to many of our lecturers, class fellows also who directly or indirectly
helped us in preparing this thesis report, in particular, the present form of it. Various parts
of the manuscripts were copied and distributed to many concerned persons in the college
and outside, they returned with a lot of suggestions and improvements. Discussions with
professors and engineers were of great help to us. We want to mention particularly Prof.
Dr. Riaz Ahmed Mirza, Prof. Dr. Yunas Jamal, and Associate Prof. Mr. Asif Aslam, Mr.
Ali Jibran (Former Lecturer in Rachna College), Mr. Qasim Ali Ranjha (Lecturer), Mr.
Waqar Ahmed Qureshi (Former Lecturer in College) and many others who helped us in
completion this thesis report with their substantial improvements.
Our very special cordial thank goes to Mr. Sheikh Naseem Ahmed, founder of
Siddique Sadiq Trust Hospital Gujranwala, who permitted us to visit the hospital central
air conditioning system for pursuing the basics of HVACR principles. We also like to
thank HVAC Engr. Muhammad Qayyum, PITB Lahore; Engr. Muhammad Riaz of
Rupafil Limited Shiekhupura, who helped us with their polite and cooperative manners
and provides us technical information & permission to use HVAC software.
We also want to thank our non-academic friends like, Muhammad Akram Antal,
Rana Abdul Jabbar, Abdul Haq (computer expert), and many others who helped us in
various aspects.
Furthermore, we wish to thank Mr. Akbar of Lalazar Printers, UET Lahore for his
effective cooperation and great care in printing very efficiently all the crucial sections of
this thesis report.
Group Members
25 May, 2007
PAC-105
Contents
Acknowledgement
Unit 1 Introduction to PAC-105
--Introduction …………………………………..……………………………….......... 1.1
Unit 2 Cooling Load Calculation and Psychrometrics

--Introduction ……………………………..……..………………………………...... 2.1
2.1 Cooling Load Calculation of M-2 Hall.………………………………………… 2.2
2.2 Pschyrometric Analysis of PAC-105 Air Conditioning System………………… 2.4
Unit 3 Design of Air-Handling Unit and Ducting System

--Introduction …………………………………..………………………………........ 3.1
3.1 Function of Air-Handling Unit and Types ……………………………............ 3.2
3.2 Design of PAC-105 AHU ……………………………....................................... 3.2
3.3 Design of PAC-105 Cooling Coil of AHU ………………………………........ 3.3
3.4 Arrangement of Chilled Water Circuits for PAC-105 Cooling Coil …………... 3.12
3.5 Design of Ducting System for Hall M-2 ……………………………................. 3.14
3.6 Indoor air quality (IAQ) and Selection of Air Filter for PAC-105 AHU …….... 3.26
3.7 Fan Selection for PAC-105 AHU ……………………………............................ 3.26
3.8 Suggestions for PAC-105 AHU Fabrication ………………………………........ 3.29
3.9 Design of Condensate Drain Pan of the PAC-105 AHU………………………… 3.31
3.10 Results and Comments………………………………………………………….. 3.34
Unit 4 Design of PAC-105 Refrigeration System

-- Introduction …………………………………..……………………………........ 4.1
4.1 The PAC-105 A Vapor Compression Refrigeration System …………………… 4.2
4.2 Refrigerant and its Selection Criteria for PAC-105 Refrigeration System …….. 4.2
4.3 Graphical Evaluation of the PAC-105 Refrigeration …………………………… 4.3
4.4 Comparison between PAC-105 and Conventional Air-Cooled Chilling System... 4.6
4.5 Designing and Selection of the PAC-105 Compressor …………………………… 4.8
4.6 Results and Comments ………………………………………………………….. 4.20
Unit 5 Design of Water Chiller of PAC-105
--Introduction ………………………………………………...................................... 5.1

5.1 Chiller and Its Types ……………….…………………....................................... 5.2
5.2 Flooded Liquid Chiller of PAC-105 ………………………………………........... 5.4
5.3 Design of PAC-105 Flooded Liquid Chiller ……………………………………... 5.5
5.4 Comments on PAC-105 Flooded Liquid Cooler design ……….......................... 5.10
5.5 Suggestion for PAC-105 Flooded Liquid Cooler ……………………................ 5.10
Unit 6 Design of Water Cooled Open-type® Condenser
i
PAC-105
-- Introduction ………………………………………………..................................... 6.1

6.1 Condensers ……………………………………………….................................... 6.2
6.2 Classification of Condensers …………………………………….................... 6.2
6.3 Water-Cooled Open-type Condenser® of PAC-105 …………………………....... 6.4
6.4 Design of PAC-105 Water-Cooled Open-type Condenser® …………………….... 6.4
6.5 Suggestions for Construction and Installation of PAC-105 Condenser …………. 6.10
6.6 Results and Comments ……………………………………………….................. 6.13
Unit 7 Design of PAC-105 Hydronic System
-- Introduction ………………………………………………..................................... 7.1

7.1 Piping System of the PAC-105 ……………………………………………….... 7.2
7.2 Centrifugal Pump Selection Criteria for PAC-105 …………………………….. 7.3
7.3 Determination of the Pump Head of PAC-105 ………………………………….. 7.4
7.4 Estimation of Centrifugal Pump Power of the PAC-105 ………………………. 7.8
7.5 Results and Comments ……………………………………………………......... 7.10
Unit 8 Design of PAC-105 Control System

--Introduction ………………………………………………...................................... 8.1
8.1 Control System of PAC-105 …………………………………............................ 8.2
8.2 Hydronic and Refrigeration System Control ……............................................... 8.2
8.3 Supply Air System Control…………………...................................................... 8.4
Unit 9 Commissioning and Maintenance of PAC-105 Air Conditioning System
--Introduction ……………………………………………………………………… 9.1

9.1 Fundamental of Commissioning ……………………………………………...... 9.2
9.2 Commissioning Check Lists of PAC-105 ……………………………………… 9.3
9.3 Maintenance and Repair of PAC-105 ………………………………………….. 9.9
9.4 PAC-105 Maintenance and Repairing Schedule………………………………… 9.9
-- Appendix A ………………………………………………………………… A.1

Table A1 Abbreviations
Table A2 Conversion of Units from I-P to SI
-- Appendix B …………………………………………………………………... B.1
Table B1: Table of Thermo physical Properties of Air at Atmospheric Pressure
Table B2: Thermophysical Properties of Saturated Water'
Figure B1: R134a Pressure-Enthalpy Chart (S.I. units)
Table B3: Properties of Refrigerant-134a
Table B4: Local Loss Coefficients, Elbows
Table B5: Loss Coefficients, converging junctions
Table B6: Loss Coefficients, Transitions (Convergent Flow)
Table B7: Loss Coefficients, Diverging Junctions
Table B8: Circular Equivalents of Rectangular Ducts for Equal Friction and Capacity
--References
ii
PAC-105
Unit 1
Introduction to
PAC-105
Introduction
I t is well known fact that energy is the soul of human

activities directly or indirectly. This is why; the
measuring rod of a country’s development is the per
capita use of energy. In this respect we are perhaps at the tail end
and are using only few hundreds of energy units per annum per
head as against about seven thousand in Europe and about ten
thousand in USA. We have to go a long way to attain some
measures of respectability in this respect. During last few years
the situation has deteriorated and we have to resort to
loadshedding which caused a lot of inconvenience to domestic
consumers and industrialists as well. Although we are feeling
well now economically, but still we are standing at the lowest
rung of the ladder micro and macroecnomicaly as compared to
the developed nations. This lack of energy can impart a serious
setback to economic growth of country and can make our
progress shaky.
1.1
Unit 1: Introduction to PAC-105
Pakistan has availability of various kinds of energy resources like oil, coal, natural gas,
etc more and more reservoirs of these energy resources are being explored. These resources are
created by the natural process deep down in the earth after thousands of years and are described
as Non-renewable fuel recourses. However large these resources may be, they are being
consumed at high rate and are more liable to be depleted within few decades. It will seriously
disrupt the normal existence of our energy demanding and energy oriented territory. This problem
of energy crises is world wide accepted and is a challenge for engineers and scientists. It can be
coped by introducing energy audits and better energy management techniques in Pakistan. At the
local edge, solution seems to be main three fold, i.e.
• Discovery of renewable energy resources

• Energy recovery techniques / energy from waste
• Energy management plans etc
As for as the first option is concerned, due efforts are being made by the government to
use the wind power and solar energy across the coastal areas, deserts and nationwide respectively.
Although, they have limited application but the trend is uncourageous. The second option is also
being utilized by installation of incineration plants in various cities like Lahore, Karachi etc
As for as last option of energy saving is concerned this is seem to be more realistic now
a days that Prime Minister Shaukat Aziz has launched Load-shedding Management Plan
LMP on the first of May this year. In an interview he said that “by LMP we could save 500 MW
electricity each month”. This is clear interpretation of energy management plans that how we can
save the energy effectively in this regards?
Our suggestion to solve this energy crisis and make our local resources of energy more
reliable and long-lasting is
• An efficient use of every kind of resources (both renewable and Non-renewable)

This option is of utmost importance. It will impart the independence and self reliance in
energy sector. This suggestion can be implemented by the engineers by designing and introducing
the local energy-efficient systems. This energy-efficient system might be an energy saving system
(related to energy consumption) or a system which utilizes the energy resources (related to energy
generation) more effectively. This suggestion can be applied to any energy resource like solar
energy, wind energy, hydroelectric power and fossil fuels, but especially to the renewable energy
resources. For example flowing canal or river water can be used to drive a water wheel or small
water turbine unit, causing generation of mechanical work, which in turn may rotate an auxiliary
generator for electricity generation. This electricity can be supplied to nearby population or even
to a small industry in accordance with its generation capability.
By careful observation of our surrounding, we can explore numerous ways to use the
energy resources in our local vicinity in more efficient manner. Using above mentioned idea of
designing an energy-efficient system to utilize a local energy resource. We utilized canal water as
follows:
Our institute, Rachna College of engineering and technology Gujranwala (constituent
college of UET Lahore) has a nearby canal about 70 meters away from its main campus building.
During summer season especially in months of July-September the weather becomes more
severe, thus creating problem for all (students, teachers, and managerial staff etc) to continue
their normal activities. It becomes more difficult for “Engineering drawing” students performing
their drawing work in hall M-2, located upstairs on the first floor of admin block. Although the
hall is well furnished with fans, ventilators, window pans provided with curtains to reduce solar
radiation, white washed with a light color, but due to hot climate every thing become insufficient
1.2
and demanding for an air conditioning system for better temperature and humidity control inside
the drawing hall.
Because we belong to the same institute and had faced the same problem of hot climate
and uncomfortable working environment during our Drawing hours. The solution of problem was
to Air condition the hall simply. But the running cost of this summer Air conditioning system was
a major factor to ponder. We started thinking on the problem. Another consideration in our mind
was the availability of low temperature (of order 16 o C) canal water closer to campus. Then, we
conceived an idea that
“Is there any way to condition this hall at lower running cost using this low
temperature canal water flowing idler?”
The answer was YES, and was explored by the study of vapor compression cycle that is
an approximation to reversed Carnot cycle.
In vapor compression cycle the purpose of compressor is to compress the vapor
refrigerant up to such an extent so that the refrigerant may easily reject its heat of condensation to
some cooling medium like air or water. Higher is the temperature of cooling medium, higher will
be the compression needed to reject heat and vice versa. Thus more compression work needed for
given capacity of refrigeration machine and temperature limits in the former case. That means a
large size compressor will be needed. Hence resulting in more energy consumption and higher
running cost accordingly. Using this idea we utilized the low temperature canal water as a heat
sink and designed a complete air conditioning system for summer Comfortable Air Conditioning
(CAC) of hall M-2 and operating at lower running cost. The detailed discussion is provided in
unit 4 of this thesis report. There it is mathematically proved that, “how much energy can be
saved using this suggested way of Air conditioning for hall M-2”? The aspect of energy
efficiency is shown by too high COP (Coefficient of Performance) of the refrigeration machine.
Thereof it is:
“1st, final year Project of design of an Air
Conditioning system at RCET which was conceived and
initiated in year 2005”
Therefore, it was patented as PAC-105. Throughout the thesis report, this system will be
called by its patent name i.e. PAC-105 and most of the equipments also will be discussed headed
by this name i.e. patent name until specified or mentioned. Because it is an energy conservation
project, therefore a concept of energy saving has been strictly followed during design of each and
every component of this air conditioning system (referred to as PAC-105 shortly), rendering it
more uniqueness.
Another feature of this system is that it has greater capability to cope with seasonal
variations in climatic temperatures. For example during peak loading hours like in months of
June-July when outside temperature rises to even 40oC - 45oC of locality, conventional systems
(air cooled systems / systems other than PAC-105) will be running at their extreme upper loading
condition. This severe climatic change may lead the conventional system to malfunctioning or
tripping. But PAC-105 will be running at its normal pace because such sever climatic change can
never rise the temperature of bulk cooling water of canal only by few degrees that will be
negligible for the system performance. It shows that offset between the performance curves of
PAC-105 and conventional refrigeration system will increase at worst climatic temperatures
range. Thus it can be inferred that higher climatic temperatures will be conducive towards the
better performance of PAC-105 refrigeration system, which is quite impossible in case of any
conventional air cooled systems.
1.3
It is important to realize here that in each unit of this thesis report, the information is given purely
related to the PAC-105 equipments otherwise unless specified or mentioned. All the illustrations
regarding PAC-105 air conditioning system are constructed or produced in the Computer Aided
Drafting and Design, CADD with own self which is a clear interpretation of the hardware
equipments. There may be a little variation in the drawings and dimension during the fabrication
of the hardware equipments of the PAC-105 air conditioning system. It is also important to
mention here that we also employed the few engineering software in the determination of the
properties of the air and water, which are provided to us from our friends working in the fields of
HVAC&R. We are much pleasure to mention here that about most of the text material which is
added in each unit concerning PAC-105 is not yet copied or transferred massively, except major
concepts; so we are adding learning concepts, which we learnt during study of the course.
At the start of the each unit a short introduction is given related to the concerned unit, which has
key information about the unit that “what approach or idea is behind it”?
Note:
An objection by some of our friends and colleagues on this system was that our suggested system
has its limited application, because it is based on the utilization of natural water resource. Our
answer was always the same and was as follows,
1. “Our objective and suggestion is to use every resource of energy in an efficient way. In
our case it was canal water and we used it. For other applications and locations any other
available source of energy can be utilized” Also,
2. “It is a sort of Case study, and Case study is always related to some specific area of
research”
Result:
Finally it is suggested that, for all systems having vapor compression cycle (VCC) based
refrigeration systems and nearby natural water source it is recommended that they must be
designed in a way to avail the opportunity to reduce their energy consumption and making it more
economical. If possible, during site selection for a refrigeration unit like cold storage units, ice
plants, industrial refrigeration systems, or even a commercial air conditioning system employing
VCC, due importance should be given to availability of low temperature water resource.
1.4
PAC-105
Unit 2
Cooling Load
Calculation and
Psychrometrics
Introduction
I n this unit we are discussing two basic portions of HVAC system

design procedure. In the first portion we will discuss the Cooling
load calculation of M-2 Hall and in the second portion, the
Psychrometrics analysis of PAC-105.
In the first portion of this unit, we will calculate the cooling load of M-2
hall, which is the amount of heat that must be removed from the Hall, to
maintain comfortable level of temperature and humidity of the air. In the
cooling load calculation, we shall calculate the heat gain into the Hall
due to all possible factors. At the end of the unit there is a cooling load
table for M-2 Hall, in which all the calculations are shown in the form of
a table.
In Psychrometrics analysis portion, we shall evaluate the total volume of
supply air, which must be delivered to the M-2 hall at design temperature
through ducting in order to maintain the indoor design conditions. The
design indoor and outdoor conditions for the M-2 hall will be set to be an
optimum value, which is a perfect balance between energy and the
occupant’s satisfaction.
2.1
Unit 2: Cooling Load Calculation and Psychrometrics
2.1 Cooling Load Calculation of Hall M-2
T he air inside a building receives heat from a number of sources during the cooling
season. If the temperature and humidity of the air are to be maintained at a comfortable
level, this heat must be removed. The amount of heat that must be removed is called the cooling
load.
The cooling load must be determined because it is the basis for selection of the proper size air con-
ditioning equipment and distribution system. It is also used to analyze energy use and conservation.
For determination of cooling load of a building it is very crucial to identify its construction type.
Therefore before proceeding, first of all we shall try to explore the construction type of hall M-2.The
architectural plane is shown in figure 2.1. The walls are 9 in. common brick type with ½ in plaster on
both the sides. There are 18 windows on the South Wall and 10 ventilators and 2 Doors on the North
wall (as shown in architectural plan). So the net conduction area of these walls will be calculated by
subtracting the areas of the windows, ventilators and doors from the total area of walls. Also the South
and East Walls are exterior walls and North and West walls are interior walls. The entire building
exterior is covered with light color weather sheet (I.e. white washed).
GROUND FLOOR PLAN

6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5"
WIN. WIN. WIN. WIN. WIN. WIN. WIN. WIN.
1'-8" 6'-101"
2
M-2 HALL
ADMIN BLOCK, FIRST FLOOR
78'X18'
4'-9" 4'-9" 4'-9" 4'-9" 4'-9" 4'-9"

4'-9" 4'-9"
VENT. VENT. VENT. VENT. VENT. VENT. VENT.
4'-2"
4'-2" 2'-9"
STREET 8'-0" 8'-0"
4'-2" 4'-2"
OTHER BUILBING, CLASSROOMS

TOILETS
Figure 2.1 Architectural Plan of Hall M-2 (First Floor, Admin Block RCET Gujranwala Campus)
There are a few different, acceptable procedures for calculating cooling loads that take into account
the phenomena we have discussed. All of them are more accurate than past methods and are often re-
quired in state energy codes and standards. These methods often lead to use of smaller equipment and
sometimes result in less energy use.
The cooling load calculation procedure that we will be using is called the CLF/CLTD method. This
procedure is relatively easy to understand and use. The CLTD values for roof and wall constructions
and the values of U, LM, CLTD and all of other technical parameters are available from respective
Tables in ASHRAE Fundamentals Handbook 2005 OR principles of air conditioning by ADWARD
G. PIITTA .All the walls used for the M-2 Hall are of medium construction, so the value of U for
walls is 0.45 and that for roof is 0.13 and for floor is 0.26
The CLF/CLTD method can be carried out manually or by using a computer. In actual practice the
use of computers and cooling load calculation software are very common to use now a days. The
2.2
complete summary of load calculation for hall M-2 is given table 2.1
Table 2.1 Cooling Load Calculation

Room: M-2 Hall Admin Block, First Floor
Location: Rachna College of Engineering and Technology, Gujranwala, Pakistan
DB WB W´
RH%
F F gr/lb Daily Range: 50-55 F Average:52.5 F
Design Out Door 108 56 Day: July/ August Time:12 PM
Conditions Room 77 50 Latitude: 32° North
Area ft2 CLTD, F SCL

Conduction Dir. Color U
BTU/hr
Gross Net Table Corr.
South 1.04 310.5 14 37.5 12109.5
North 1.04 95 26 2568.8
Glass
0
0
South D 0.45 586.5 24 43.5 11480.738
East D 0.45 207 32 55.5 5169.825
Wall
West D 0.45 103.5 63.5 2957.5125
North D 0.45 744.63 10 24 8041.95
Roof/Ceiling D 0.13 1404 40 65.5 11955.06
Floor D 0.26 1404 15 5475.6
Partition 0
Door North 1.04 57.375 26 1551.42
Solar Dir. Sh. SHGF Area SC SLF

South no 60 103.5 1 0.58 3601.8
North no 44 152.4 1 0.86 5765.87
Glass
0
0
Lights 600 W x 3.41x 1.25 BF x 1 CLF 2557.5

Fan 250 x 10 W x 3.41x 1 CLF 5115 LCL
People 255 SHG x 60 nx 1 CLF 15300 BTU/hr
255 LHG x 60 n 15300
0
Equipment 0
*Infiltration 1.1x CFMx TC 0
0.68x CFMx gr/lb 0
Subtotal 88174.975 15300
SA Duct
gain
2.3
SA Duct leakage
Total CL,
SA Fan Gain(draw thru) BTU/hr
Room Cooling
88174.975 15300 103474.98
Load
SA Fan Gain (Blow thru)
**Ventilation 1.1x CFMx TC
0.68x CFMx gr/lb
RA Duct
gain
RA Fan
Gain
Cooling Coil
88174.975 15300 103474.98
Load
Pump gain
Refrigeration
103474.98
load
8.70Tons/
30.65 kW
* Infiltration will not be considered for Hall M-2, because during normal operation of system hall
will be pressurized slightly above the atmospheric, thus causing no infiltration.
Note: For simplicity additional heat gains like return duct heat gain, fan/ Blower heat gain,
ventilation heat gain etc are not considered here. (The reason will be explained at the end of this unit)
2.2 Psychrometrics Analysis of the PAC-105 Air Conditioning System

o
Room temperature = 77 F =25 o C
Relative humidity = RH =50%
o
From psychrometrics chart, at 77 F and 50% RH
Specific humidity or humidity ratio = w = 60 grains / lb of d.a
Room sensible cooling load (RSCL) = 26.16 KW =89181.8 BTU/ hr
Room latent cooling load (RLCL) = 4.486 KW =15293.18 BTU/ hr
Room total cooling load (RTCL) = RSCL+ RLCL= 30.65 KW= 8.707 TR
2.2.1 Coil Entering and Leaving Conditions

o
Temperature of air entering the coil = 26 o C =78.8 F
o
Temperature of air leaving the coil = 13.33 o C = 56 F
Coil by pass factor
Tc − Tb
BPF =
Tc − Ta
Where
Ta = The DB temperature of the air entering the coil
Tb= The DB temperature of the air leaving the coil
Tc = The mean effective temperature of the coil surface
2.4
Now,
RSCL
Room sensible heat factor = RSHF = = 0.8536 ≅ 0.85
RTCL
Using value of room sensible heat factor (RSHF), draw a line called coil process line on
psychrometrics chart as shown in the figure 2.2. This coil process line intersects the curved line on
chart with complete saturation at 11.1 o C . This point of intersection is called the coil or apparatus dew
point (ADP). This is the temperature that must be maintained to cool and dehumidify the air
according to desired conditions of entry and leaving from cooling coil. As
The temperature of water entering the coil = 6 o C
The temperature of water leaving the coil = 14 o C
Tw,i +Tw,o 6+14
Therefore the mean temperature of water = = = 10 o C
2 2
The actual (ADP) required for designed cooling and dehumidification is found to be 11.1 o C . But
most of coil surface will be at mean temperature of water. Therefore, Let we select mean temperature
of water as (ADP). Thus putting values in above relation we get,
T -T 10-13.3
BPF= c b = =0.206
Tc -Ta 10-26
It shows that the coil configuration is such that 20.6 % quantity of air will be by passed.
2.2.2 Determination of Supply Air Quantity
In order to find the quantity of air required to maintain desired room conditions using relation 2.12 for
sensible heat of air
(
qsen = m.a c
pd )
+ wc ps T = m.a c paT .
All the parameters in above relation have been defined in unit 2.the modified form of relation is
qsen = 1.1 × CFM × (TR −TS )
The above relation relates all parameters in British system of units. So,
qsen 88174
CFM = = = 3817 *
1.1×(TR −TS ) 1.1×(77 −56)
In SI units using density of air as 1.1614 kg/m3 at 26 o C , the corresponding mass flow rate of air is
2.0937 kg/sec.
*this is the maximum value of the supply air CFM, which must be maintained during the peak load
season, so in the unit 3 for the duct design purposes we shall take a value of 3790CFM, which is an
optimum value of the supply air so the fan/blower will attain this value in the season automatically.
2.2.3 Condensate Formation during Air Conditioning Process
Now from psychrometrics chart in figure 2.2, at leaving conditions of air the relative
humidity of supply air is
w = 54 lb/ kg of d.a
S
Thus mass of water vapor condensed = m.w = m.a ( wR − wS )
= 2.1963 (60-54)
= 13.1778 grains /sec=13.1778/7000 =1.8825lb/sec=3.0735kg/hr
2.5
ASHRAE PSYCHROMETRIC CHART NO.1
55 60
NORMAL TEMPERATURE
R
BAROMETRIC PRESSURE: 29.921 INCHES OF MERCURY R
OD
Copyright 1992 90
AMERICAN SOCIETY OF HEATING, REFRIGERATING AND AIR-CONDITIONING ENGINEERS, INC.
50 .028
SEA LEVEL 60
∞ 1.0 1.0 -∞
85
15.
5000 0.8 .026
0
2.0 -2000
3000
0.6 SENSIBLE HEAT Qs 4.0 -1000
8.0
TOTAL HEAT Qt -∞ 45
0. 5 -
-48.0.0 85
-2. 0 WE .024
0.4 0 T
200
-1. BU
0
0 LB
TE 55
M
0.3
PE
- 0. 4
RA
-0.
50 80
5
TU
-0.3
0
0.2
-0.2
E-
-0.1
0 .022
0.1
40 °F
15
00
80
1000
.020
ENTHALPY ∆h
HUMIDITY RATIO ∆W 75
35 50
14.
.018
5
75
R
AI
Y
F
DR
-°
RE 70 .016
F
30
O
U
D
AT
UN
R
PO
PE
M
R
45
TE
PE
70 .014
N
TU
IO
65
-B
AT
HUMIDITY RATIO - POUNDS MOISTURE PER POUND DRY AIR

R
PY
TU
AL
25
SA
TH
EN
.012
65
14.
60 M
0V
%
90
OL
UM
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80
E-
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CU
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. PE
55 .008
50
RL
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60
B. D
13.
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45 50
5
15
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AIR
.006
DRY BULB TEMPERATURE - °F

40
45 35
40%
35
40
.004
13.
35 30%
0
20%
.002
12.
VE HUMIDITY
10% RELATI
5
30
100
105
110
115
120
35
40
45
50
55
60
65
70
75
80
85
90
95
10 15 20 25
ENTHALPY - BTU PER POUND OF DRY AIR
For calculating maximum condensate formation in PAC-105 air conditioning process can be
calculated by mixing of 5% outdoor air quantity in the return air from the M-2 hall. So if the outdoor
air which is taken inside the AHU is at the DB= 44 0C, RH65, w =38.81 g/kg then the condensate
flow rate is
= ma. × ( wo − ws ) = 2.1964 × ( 38.81 − 7.637 )
= 68.468g/sec = 4.108 kg /min also 0.903GPM
In this case condensate may be significant problem, so therefore a proper drain pan should be
carefully designed to collect this condensate, in order to minimize or mitigate the bacterial and
microorganisms growth etc.
2.8
PAC-105
Unit 3
Design of Air-
Handling Unit
and Ducting
DDC
C o n tro l
P anel
System
Introduction
O
ne of the most important function of an Air-conditioning
system is to reduce the temperature of an air stream. It is
accomplished by the use of air handling units, which
mainly contain an air cooling coil. Various types of AHUs are used
depending upon the applications. This unit is concerned with the
design of an air handling unit for PAC-105. An air-handling unit
consists of cooling coil, air filters and blower for treatment of air.
First of all we shall design the most important component
of AHU i.e. chilled-water cooling coil. Convection correlations
developed by Zhukauskas for bundle of tubes in cross flow will be
used to find the air-side coefficient. The water-side convection
coefficient will be found by using Dittus-Boelter and colburn
correlation. Using these coefficients and appropriate fouling
factors, finally the required heat transfer area will be found for
cooling coil. After arranging the tubes in rows, specific paths
(technically called circuits) of chilled water via coil will be
planned.
Secondly, other important component called fan will be
selected. Its selection is based on the head loss of air stream in
ducting system. Therefore before fan selection we have to design
the ducting system for M-2 hall by using Cost Optimization-T
Method, supply ducting system will be designed and then finally
we shall design an air handling unit for PAC-105.
3.1
Unit 3: Design of Air Handling Unit and Ducting System
3.1 Function of Air-Handling Unit and Type
A n air-handling unit (AHU) is the primary equipment in an air system of a central

hydronic system; it conditions the air and distributes it to conditioned space. In an
AHU, the required amounts of outdoor air and recirculating air are often mixed and conditioned.
The temperature of the discharge air is then maintained within predetermined limits by means of
control systems. After that, the conditioned supply air is provided with motive force and is
distributed to various conditioned spaces through ductwork and space diffusion devices.
Many air-handling units are modular so that they have the flexibility to add components
as required. An AHU basically consists of an outdoor air intake and mixing box section, a fan
section including a supply fan and a fan motor, coil section with water cooling coil, a filter
section and a control section. A return or relief fan, a heating coil, a precooling coil, and a
humidifier may also be included depending on the application. Supply volume flow rates of
AHUs vary from 2000 to 63,000 cfm (945 to 29,730 l/s).
Whether a return fan or a relief fan should be added to an air system depends on the con-
struction and operating characteristics of the air system and the total pressure loss of the return
system. A heating coil is mainly used in the air-handling unit that serves the perimeter zone or for
morning warm-up in the heating season. Humidifiers are employed for processing air
conditioning and health care facilities where space humidity must he controlled. Air handling
units used commercially may fall into any of the following categories
• Horizontal or Vertical Unit

• Draw-Through Unit or Blow-Through Unit
• Outdoor Air (Or Makeup Air) AHU or Mixing AHU
• Rooftop AHU or Indoor AHU
• Factory-Fabricated AHU or Field-Built AHU, Custom-Built or Standard Fabrication
• Single-Zone AHU or Multizone AHU
3.2 Design of PAC-105 AHU

Before going into details of design and selection of components for PAC-105 AHU, first of
all we have to specify its location. The suggested location for AHU is “Along the eastern wall of
hall M2 on ground floor”.
The location of PAC-105 AHU is shown in figure 7.1, it would be an optimum selection of location
for air handling unit, because this place assures the easy supply and delivery of chilled water
from/to the refrigeration system located at canal bank. Also this location provides better outdoor
area, easy installation and maintenance, supply & return ducts connections and minimum
condensate flow problems. After selecting an adequate location, the next step is to select an
appropriate type of air handling unit. Because hall M2 is on the first floor, therefore the supply and
return ducts from/to the PAC-105 AHU will run upward/downward direction respectively. For such
a location it is better to use a vertical type AHU.
As for as the physical sequence of fan and coil in AHU is concerned, we shall select a
draw-through configuration for blower and coil. In blow-through units air stream suffers excessive
pressure drop while passing through the cooling coil, thus require larger fan and thus more energy
consumption. Also in blow-through units the air stream is more liable to carry condensate or mist
droplets with it. The schematic of PAC-105 AHU is shown in figure 3.1.
The design of PAC-105 air handling unit consists of following steps.
• Design of cooling coil
• Design of ducting system
• Selection of an air filter
3.1
• Selection of blower/fan
Supply Air Duct

Flexible Connection
b/w Fan and Supply
Supply Air Fan Duct
(Direct Drive )
Return Air
Duct
Cooling Coil
Saddle for fan
Air Filter, Air Mixing
HEPA Box
Guide Vanes for Air
Fresh Air
DDC
Dampers
Control
Panel
Coil Section Exchaust Air

Foundation Condensate Pan Dampers(Optional)
Figure 3.1 the Schematic of PAC-105 Air Handling Unit
3.3 Design of PAC-105 AHU’s Cooling Coil
Known parameters
Amount of heat rejected by coil=Cooling load of hall M-2 = 30.65 Kw (neglecting

return duct heat gain)
Mass flow rate of air =2.077 kg/sec
Temperature of air entering cooling coil=26 o C
Temperature of air leaving the cooling coil=12 o C
Temperature of water entering the cooling coil=6 o C
Temperature of water leaving the cooling coil=14 o C .
Assumptions
1. First of all we shall select proper tubing for coil. Let we use copper tubing of type K
with outer diameter as 12.7mm and inner diameter as 10.2 mm.
2. Usually cooling coils consists of an array of tubing arranged in a special way. Let the
cooling coil of PAC-105, consists of an array or bank of tubes arranged in staggered
3.2
arrangement, With 30 tubes in each row and 10 circuits of chilled water.
Properties
1. All the properties of air will be evaluated from table B-1 at air mean temperature, Ta , m
Ta ,i +Ta ,o 26+12 o o
T = = = 19 C ≅ 20 C
a ,m 2 2
2. All the properties of water will be evaluated from table B-2 at water mean temperature,
Tw,m
Tw,i +Tw,o 6+14 o
T = = = 10 C
w,m 2 2
Design Procedure
Using equation, which relates the heat transfer of any heat exchanging device with its
surface area and temperature,
Q = UAΔT
lm
Where,
Q = Total heat transfer rate Kw
U = Over-all heat transfer coefficient W/m2 .K
A= Total heat transfer area m2
ΔTlm = Log-mean temperature difference K
The relation for finding value of U is of form[a],
1
=
1
+
1
+
R f ,o R f ,i ln D d
+ +
( )
UA hi Ai ho Ao Ao Ai 2π kl
Where, l is required length of a single tube in array, k is conductivity of copper = 400 W / m.k , d
and D are inner and outer diameters of tubing. R f ,i , R f ,o are the fouling factors of inner and outer
sides of tubing, and there values are taken as,
R f ,i =0.0002 m2.K/W (for chilled water side, [a])
R f ,o =0.0005 m2.K/W (For air side)
⎛D⎞
ln⎜ ⎟
⎝d ⎠
The term , accounts for conductive resistance of the copper tubing.
2π kl
Because the outer surface of tubing is exposed to higher temperature, Therefore, U will be based
on outer surface area of tubing
Now modified form of above expression for tube array is as under,
D
ln ⎛⎜ ⎞⎟
1 1 D 1 D ⎝d ⎠
= × + + R f ,i × + R f ,o + ×D
U o hi d ho d 2k
All parameters in above relation have been defined except,
hi = Chilled water side heat transfer coefficient W/m 2 .K
ho = Airside heat transfer coefficient W/m2.K

Now we shall find these parameters one by one.
3.3
Determination of Air-side Heat Transfer Coefficient
As convection heat transfer coefficient is very strong function of velocity of fluid,

therefore first we shall find the velocity of air flowing over the cooling coil. According to
.
continuity equation, for air flowing over cooling coil ma = ρ a AF Va
Where,
.
ma = Mass flow rate of air kg/sec
ρa = density of air kg/m3
AF = Face area of cooling coil m2
Va = face velocity of air m/sec
.
From table B-1 ρ a = 1.2034 kg/m3 at 20ºC. In above relation only two parameters ma & ρ a are
known. In order to find the face velocity of air, the face area of coil must be known. Let the
length of coil is 1m.Now the next step is to find the height of coil. As we have already assumed
that coil consists of successive no. of rows, with 30 tubes in each row. Assuming staggered
arrangement of tubes in each row, as shown in [d].From geometry of staggered tubes array the
height of each row can be correlated as,
Height of each Row = H = ⎡⎣ ( NT ×D)+( NT −1) A1 ⎤⎦
Where,
NT = No. of tubes in each row
D = Outer dia. of tube m
A1= gap b/w successive tubes m
Now the next step is to choose an appropriate value of parameter A1 , let we take
A1 =21mm=0.021m
Thus
Height of each row = H = ⎡⎣ ( NT ×D )+( NT −1) A1 ⎤⎦
Height of each row = H = ⎡⎣ (30×0.0127)+( 30−1)0.021⎤⎦
H = 0.990m
Therefore the face area of coil will be AF = length(l ) × Height ( H ) ⇒ 1 × 0.990 = 0.990m 2
.
Now, using above relation ( ma = ρ a AF Va ) to find the velocity of air
.
ma 2.077
Va = = = 1.755m / sec
ρa AF 1.2034×0.990
Now, for assumed configuration of tubes array the transversal pitch (center to center distance of
tubes in a row, in vertical direction) will be,
Transversal pitch ST = D + A1 = 0.0127 + 0.021 = 0.0337 = 33.7 mm = 0.0337 mm
The next step is to specify the longitudinal pitch (center to center distance b/w successive rows of
tubes, in horizontal direction) Let[d],
3.4
Longitudinal pitch S L = 2 D = A1′ + D
⇒ S L =2×12.7=25.4 mm=0.0254m
⎛S ⎞
2
Hence, Diagonal pitch = S D = S L2 +⎜ T ⎟ = 30 mm
⎝ 2 ⎠
Now we have completely described the configuration of tubes array, the next step is to find the
value of convection heat transfer for the assume geometry of tubes array, using Zhukauskas
relation [d], for average Nusselt number. Nu Of tubes
0.25
Nu = CReD, m ( Pr )0.36 ⎛⎜ Pr ⎞⎟
max ⎜ Pr ⎟
⎝ s⎠
All of the parameters used in above relation stand for their usual notations, now from [d]
S
For Staggered tubes with T = 1.35 < 2
SL
1
⎛ ST ⎞ 5
C = 0.35 ⎜⎜ ⎟⎟ = 0.37 & m = 0.6
⎝ SL ⎠
The relation for Reynolds’s no based on max. Velocity of air will be as under,
ρ V D
ReD, = a max
max μ a
−
μ a = viscosity of air at mean temp. of air = 181.6 × 10 7 Pa.sec
S +D
Now, because S D = 30 mm ? T = 23.2 mm
2
So,
Vmax (Max. velocity of air) occurs at A1 and is:
⎛ S ⎞ ⎛ 33.7 ⎞
Vmax = ⎜⎜ T ⎟⎟ Va = ⎜ ⎟ × 1.755 = 2.816m / sec
⎝ ST − D ⎠ ⎝ 33.7−12.7 ⎠
Thus,
ρ V D 1.2034×2.816×0.0127
ReD, = a max = = 2369.9 ≅ 2370
max μ a 181.6×10−7
And, from table B-2

Pr At mean temp. Of 20 o C (293K) = Pr293 = 0.7085
And Prs = prandtle no. at surface temperature of tubing = Pr = 0.713
283K
Putting all values in relation for Nusselt no,
0.7085 0.25
Nu = 0.37 × (2370)0.6 × (0.7085)0.36 ( )
0.711
Nu = 34.577
h D
Nu = a
ka
k
⇒ ha = a × Nu
D
Where, ka = Thermal conductivity of air at mean temp = 0.026w/m.k
3.5
0.026
= × 33.54 = 69.5
0.0127
⇒ ha = 70.788W/m 2 .K
Determination of Water-side Heat Transfer Coefficient

As Q. = mw. C p ΔT
Q. 30.75×103
So, mw. = = = 0.91Kg/s
C p ΔT 4.18×103(14−6 )
mw. = Total mass flow rate of water required in Kg/s
Assuming 10 no. of circuits for cooling coil, then mass flow rate of water through each circuit
Will be,
. w. 0.91
mw = w = = 0.091Kg / s
10 10
per tube
4 m.w
per tube
Now, Re,w =
π d μw
Where,
μ w = viscosity of water at mean temp. of air Tw,m = 1.31 × 10−3 Pa.s
So,
4×0.091
Re,w = = 8671
π ×0.0102×1.31×10−3
As Re,w > Rc (i.e. 2000), so flow is turbulent
Therefore, Dittus-Boelter relation [g] using for turbulent flow between 0.6>Pr>100
0.8
Nu = 0.023 ( Re,w ) ( Pr )0.4
More recent information by Gnielinski [n] suggest that better results for turbulent flow in smooth
tubes may be obtained from the following relations:
Nu = 0.0214 ( Re 0.8 − 100 ) Pr 0.4
for 0.5<Pr<1.5 and 10 4 < Re < 5 × 106 or
Nu = 0.012 ( Re0.87 − 280 ) Pr 0.4
for 1.5<Pr<500 and 3000 < Re < 106
The power of Pr is taken as 0.4 considering relation [g]because water in the tube is being heated.
From table B-2 the value of Pr is 9.39
Solving above relation we get,
Nu = 79.66
h d
Nu = w = 79.66
Kw
Where,
K w = thermal conductivity of water at Tw,m = 0.585 W/mK (From table B-2)
K K 0.585
⇒ hw = Nu × w = 79.66 × w = 79.66 × = 4568.7
d d 0.0102
3.6
So,
hw = 4568.7w/m 2 .k
Determination of Overall Heat Transfer Coefficient
Now the modified form of relation for overall heat transfer coefficient, Uo is
⎛D⎞
1 1 Ao R fi Ao ln⎜⎝ d ⎟⎠ Ao
= + +R + +
U o ho hi Ai fo Ai 2π KL
⎛ 12.7 ⎞
ln ⎜ ×π D
1 1 12.7 0.0001×12.7 10.2 ⎟⎠
Or, = + + 0.000044 + + ⎝
U o 70.788 10.2×4568.7 10.2 2π ×400
= 0.014 + 2.72 × 10−4 + 0.000044 + 1.245 × 10−4 + 3.4 × 10−6 = 0.0150
1
Uo
⇒ U o = 69.233W / m2 .K
Determination of Log-Mean Temperature Difference and Surface Area of Coil
Also, let we use the counter flow arrangement for coil[e] i.e. warm air with warm water and
cooler air interacts first with cooler water. Thus
( 26−14 )−(12−6 )
ΔT = = 8.656o C
lm ⎛ 26−14 ⎞
ln ⎜ ⎟
⎝ 12−6 ⎠
So,
Q 30.65×103
A= = = 51.146m2
UoΔTlm 69.233×8.656
Also,
A = NT × N L × π Dl
A
NL =
NT ×π Dl
As the length of coil was selected as 1 meter, therefore
A 51.146
NL = = = 42.73 Rows
NT ×π D 30×π ×0.0127
The no. of rows is too large. It will make the assembly of air handling unit, bulky and larger in
size thus creating problem. Therefore the coil with must be reduced to some optimum value. The
overall size of coil can be reduced by increasing rate of heat transfer per unit surface area of coil,
and the need of increasing heat transfer rate leads us to the use of extended surfaces. Need and
significance of extended surfaces is given as under.
Determination of Efficiency of Single Fin
For finding the efficiency of surface ( η ), we select the appropriate dimensions of fins.
Then, after finding the fin efficiency ( η f ), the surface efficiency (η o ) will be found. Now ,
considering the configuration of tubes array used previously, we come to know that spacing
available for extended surface on tubes in transversal and longitudinal direction is
3.7
S −D S −D
A1 = T = 10.5mm and A1′ = L = 6.35mm respectively. From availability of space, it is
2 2
wise to use the rectangular fin of dimensions as under,
Length (along transversal direction) = D+2(10) =12.7+2(10) =32.7mm
Width (along longitudinal direction) = D+2(5) = 12.7+2(5) = 22.7mm
Assuming thickness of fins as 0.25mm
Thus using relation for corrected fin length [j]
t 0.25
Lc = L + = 10 + = 10.125mm =0.010125m
2 2
Now the corrected fin profile area [j] is
AP = Lct = 2.53 × 10−6 m 2
1
1.5 ⎛ ha ⎞ 2
So, Lc ⎜⎜ ⎟⎟ = 0.35
⎝ KAP ⎠
Where,
ha = Heat transfer coefficient of air side of tubing
K = conductivity of fins material (Al) = 237 W/m.K
1
1.5 ⎛ ha ⎞ 2
Now, from [j] for straight fin and above found value of Lc ⎜⎜ ⎟⎟ , the corresponding fin
⎝ KAP ⎠
efficiency (of straight rectangular fin) is
η f = 89%
Determination of Overall Surface Efficiency of a Single Tube of Array
Normally for air cooling coils, it is common practice to use 12 or 14 fins per inch of tube
length [Edward G. Pitta]. Now, let we use 14fins / inch (No of Fins per unit length N = 551
fins/m length of tube). The surface Area of one fin ( Af ):
⎡
Exposed surface area of single fin=A f = ⎢( L×W )−
π D 2 ⎥⎤ × 2 (Neglecting Area at perimeter)
⎢⎣ 4 ⎥⎦
Solving we get,
A
f
= 1.23122/1000 m2 =0.00123122 m2
Now, considering a single tube of first row of array having 1 m length (it must be noted that
previously we selected tubes array of length 1 meter) and with fin configuration as discussed
before, Total surface area of tube ( At ) will be:
At = Fined Area + Base or prime Area
π Dl ⎛ N ×t ⎞
At = NA + 1−
f 1000 ⎜⎝ 1000 ⎟⎠
Putting values and solving we get,
At = 0.6784+0.034
At = 0.7128 m2
So, total surface (base and finned) area of tubes/length = 0.7128 m 2 /m
And, for length l the Total Area = 0.7128l m 2
Now, using relation for Overall Surface Efficiency[j], the overall surface efficiency (η o ) will be:
3.8
NA f
At (
ηo =1− 1−η f )
551×0.00123122
ηo = 1 − (1−0.89 ) = 90.48%
0.7128
Determination of Overall Surface Area of Cooling Coil
Now by using the same configuration of fins as discussed already, the value of U o will be:
⎛ D⎞
1 1 1 R fo R fi ln⎜⎝ d ⎟⎠
= + + + +
Uo Ao ηoho Ao hi Ai ηo Ao Ai 2π KL
Where,
hw = 70.788 W/m 2 K (as found previously)
ha = 4568.7 W/m2K (Using 6 no of water circuits)

At = 0.7128l (total outside surface area of fined surface)
ηo = overall surface efficiency
D
ln⎛⎜ ⎞⎟× Ao
1 1 Ao R fo R fi Ao ⎝ d⎠
= + + + +
U o ηoho hi Ai ηo Ai 2π Kl
Now putting the values we get,
⎛ 0.0127 ⎞
ln⎜ ⎟×0.7128×1
1 1 0.7128×1 0.0000444 0.0001×0.7128×1 ⎝ 0.0102 ⎠
= + + + +
Uo 0.905×70.788 4568.7×π ×0.0102×1 0.905 π ×0.0102×1 2π ×400×1
1
= 0.023 ⇒ U o = 43.3 W/m 2 .K
Uo
So U o = 43.3 W/m 2 K
Thus,
Q 30.65×103
A= = = 81.77 m2 .
U oΔTLMTD 43.3×8.656
For used configuration of tubes and Finns, this area can be adjusted in successive rows as
following,
Ao = NT × N L × 0.7128l
Ao 81.77
NL = = = 3.82 ≅ 4 rows
NT ×0.7128l 30×0.7128×1
As for same configuration of tubes, previously the no. of rows was 42.73. Now using fins the no.
of rows has been reduced to approximately 4 rows. It shows that using the fins, the heat transfer
rate is enhanced per unit area or unit length of tube/coil. It depicts the advantage of using fins or
extended surface on the tubing of cooling coil.
1st Iteration
3.9
The above calculations show that, if we use 30 tubes in each row, the corresponding no of
successive rows will be 4 as shown above. Now if we analyze the situation then, we come to the
fact that the no. of rows seems to be insufficient to treat air according to desired conditions.
Therefore the coil depth must be increased by 2-3 rows or at least by 1 row.
Now actually we shall have to adjust the above calculated surface area in rows greater
than 4. It can be done by changing the face area of coil and then transforming this deduced area in
form of more rows. Using above mentioned suggestion the adjustment can be made very easily.
But another point which is very important to note is that, at the very beginning of our problem we
fixed the face area of coil, because the face velocity of air was based on that fixed face area. Now
any change in face area will change the face velocity of the air, hence changing the convection
coefficient of air side, and similarly the value of overall heat transfer coefficient. It mean now we
have to proceed via the same profile of calculations as before. First we have to find the new
values of air side heat transfer coefficient and the overall heat transfer coefficient. Then using
these values the required heat transfer area and corresponding no of rows will be calculated.
Now the face area of coil can be changed either by changing the length or height of coil. Let we
assume that there are 20 no of tubes in each row. i.e. NT =20
Thus the height of coil row with NT =20 and length l =1m will be
Height of each Row=H = ⎡⎣ ( NT ×D)+( NT −1) A1 ⎤⎦
Putting values we get, H = ⎡⎣ (20×0.0127)+(19 )0.021⎤⎦ = 0.653m
And the face area will be AF = 0.695 × 1 = 0.653m2

And the new face velocity of air will be
.
ma 2.077
Va = = = 2.48m / sec
ρa AF 1.2034×0.653
Again for same configuration of coil, the maximum velocity of air will occur at A1 and will be,
⎛ S ⎞ ⎛ 33.7 ⎞
Vmax = ⎜⎜ T ⎟⎟ Va = ⎜ × 2.48 = 3.979m / sec
S
⎝ T − D ⎠ ⎝ 33.7 −12.7 ⎟⎠
Thus the value of Reynolds’s no. will be,
ρ V D 1.2034×3.979×0.0127
ReD, = a max = = 3348.66
max μa 181.6×10−7
And,
Pr At mean temperature of 20 o C (293K) = Pr293 = 0.7085
And Prs = Prandtle no. at surface temperature of tubing = Pr 283K = 0.713
Putting all values in Zhukauskas relation for Nusselt no,

0.7085 0.25
Nu = 0.37 × (3348.66)0.6 × (0.7085)0.36 ( )
0.711
Solving we get, Nu = 42.55
Let we assume the no of rows as 7, thus from table[d]. For staggered tubes array with 7 rows the
correction factor for Nu will be 0.95. Thus the corrected value of Nu will be
Nu c = 42.55 × 0.95 = 40
Thus,
3.10
h D
Nu c = a
ka
k
⇒ ha = a × Nu c
D
Where, ka = Thermal conductivity of air at mean temp=0.026w/m.k
0.026
= × 40 = 81.889 ≅ 82
0.0127
⇒ ha = 82W/m 2 .K
Putting the above value, with all other terms unchanged. The new value of U o will be
U o =47.93w/m 2 .K
Now using this value of U o , we proceed for finding the required surface area and finally no. of
rows,
Q 30.65×103
A= = = 73.89m 2
UoΔTlm 47.92×8.656
And the corresponding number of rows (NL) will be,
Ao 73.89
NL = = = 5.18 rows
NT ×0.7128l 20×0.7128×1
The number 5.18 is meaningless for rows, let we round it off as 5. Therefore for 5 no of rows the
corresponding length of coil can be adjusted now easily as,
Ao
l=
NT ×0.7128× N L
Ao 73.89
l= = = 1.036 m = 1036mm
NT ×0.7128× N L 20×0.7128×5
So the final dimensions of coil will be,
1
Height of coil= H = 653 + ST = 669.85mm = 26.37 inches(approx.)
2
Length of coil= l =1.036m=1036mm=41 inches (approx.)
Thickness/depth of coil
Depth = [(no of rows)D+(no of rows -1) × A1′ ]
=[(5 × 0.0127)+(4)0.0127]= 0.1143m
3.4 Arrangement of Chilled Water Circuits for PAC-105 Cooling Coil

As found previously that PAC-105 cooling coil consists of 5 no of successive rows
with 20 numbers of tubes in each row, and 10 no of water circuits. The arrangement of
chilled water circuits will be such that , only 10 tubes in the first row will be tube feeds and
will connect to the return header. Hence making ½serpentine[k] arrangement for PAC-105
cooling coil. Each of the water circuit will run through 10 passes as shown in figure 3.2a,
Note:
1. In figure 3.2a supply and return headers are shown. The hidden circles in supply header show the
connection between supply header and copper tubing of PAC-105 cooling coil. Similarly for
return header the connections are shown by hidden circles. Thus 10 chilled water circuits run from
supply header to return header from where it will be directed towards chiller. In order to inter-
connect the tubes bends will used on both the sides’ i.e. front and back. Bends on front side have
3.11
been shown by solid thick lines while the bends on back side (behind the plane of paper) are
shown by dashed / hidden lines.
2. For simplicity fins are not shown in drawings. Actually there will be 551 Finns per meter of
tubing as discussed in design calculations.
Stainless
Steel Sheet
Feeding
Connections
for coil
Chilled
Water Outlet
Supply Header
Return Header
Chilled
Water Inlet
U-Bends
for Tubes
(a)
Supply Header Chilled Water Tubes
Return Header
(b)
3.12
Figure3.2 PAC-105 Cooling Coil (A) End View Showing Circuits’ Arrangement (B) Top
View
3.5 Design of Ducting System for Hall M-2
Location: M-2 Hall, Admin-Block First Floor.

(Rachna College of Engineering and Technology Gujranwala)
Total CFM Handled By the System: 3790 CFM
Method Used for Duct Design: Cost Optimization T-Method
System of Units: FPS British System
Schematic Layout of the Ducting System for M-2 Hall (Admin Block First Floor)
T-method optimization (Tsal et al. 1988) is a dynamic programming procedure based on the tee-
staging idea used by Bellman (1957), except that phase level vector tracing is eliminated by
optimizing locally at each stage. This modification reduces the number of calculations but
requires iteration.
Optimization Basis. Ductwork sizes are determined by minimizing the objective function:
E=Ep(PWEF)+ Es
Where
E = present-worth owning and operating cost
Ep = first-year energy cost
Es = initial cost
PWEF = present worth escalation factor (Smith 1968), dimensionless
The objective function includes both initial system cost and the present worth of energy. Hours of
operation, annual scalation and interest rates, and amortization period are also required for
optimization.
The following constraints are necessary for duct optimization (Tsal and Adler 1987):
• Continuity. For each node, the flow in equals the flow out.
• Pressure balancing. The total pressure loss in each path must equal the fan total pressure; or, in
effect, at any junction, the total pressure loss for all paths is the same.
• Nominal duct size. Ducts are constructed in discrete, nominal sizes. Each diameter of a round
duct or height and width of a rectangular duct is rounded to the nearest increment, usually 25 or
50 mm, or according to ISO standards where applicable. If a lower nominal size is selected, the
initial cost decreases, but the pressure loss increases and may exceed the fan pressure. If the
higher nominal size is selected, the opposite is true—the initial cost increases, but the section
pressure loss decreases. However, this lower pressure at one section may allow smaller ducts to
be selected for sections that follow. Therefore, optimization must consider size rounding.
• Air velocity restriction. The maximum allowable velocity is an acoustic limitation (ductwork
regenerated noise).
• Construction restriction. Architectural limits may restrict duct sizes. If air velocity or
construction constraints are violated during an iteration, a duct size must be calculated. The
pressure loss calculated for this preselected duct size is considered a fixed loss.
Calculation Procedure. The T-method comprises the following major procedures:
• System condensing. This procedure condenses a multiple-section duct system into a single
imaginary duct section with identical hydraulic characteristics and the same owning cost as the
entire system. By Equation (1.41) in Tsal et al. (1988), two or more converging or diverging
sections and the common section at a junction can be replaced by one condensed section. By
applying this equation from junction to junction in the direction to the root section (fan), the
entire supply and return systems can be condensed into one section (a single resistance).
3.13
• Fan selection. From the condensed system, the ideal optimum fan total pressure Pt opt is
calculated and used to select a fan. If a fan with a different pressure is selected, its pressure Popt
is considered optimum.
• System expansion. The expansion process distributes the available fan pressure Popt throughout
the system. Unlike the condensing procedure, the expansion procedure starts at the root section
and continues in the direction of the terminals.
78ft W
AHU A-A B-B C-C D-D E-E
M2 Hall 15.6 X18ft 5A/G
4Beams
5A/D 18ft
Silencer
D D
Street
1st floor
Plane View Classrooms
Relief Fan S/D

R/G 2.5ft
Return Ducts 11.5ft

M-2 Hall
Admin Block, First Floor
Hall Elevation
4 Beams Construction Type: -A/D Adjustable Damper

Concrete Plane Roofing -A/G Adjustable Grill
DIM: 14 X 18 in. -AHU Air Handling Unit
False Ceiling vineerboard -Rectangular duct
formica laminated type -False cieling with
Polystyrene or GI sheet
(a)
3.14
FIRST FLOOR PLAN

6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5" 6'-10.5"
WIN. WIN. WIN. WIN. WIN. WIN. WIN. WIN. 1"
6'-102
1'-8"
21 FT
FAN OUTLET ADMIN BLOCK, FIRST FLOOR 78 x 18 FT
FO M-2 HALL
9 8 7 6 5
3790 CFM 758 CFM 758 CFM 758 CFM 758 CFM 758 CFM
13 FT
9 FT
4'-9" 4'-9" 4'-9" 4'-9" 4'-9" 4'-9" 4'-9"
VENT. VENT. VENT. VENT. VENT. VENT. VENT.
1 3032 CFM 2 2274 CFM 3 1516 CFM 4
8 FT 16 FT 16 FT 16 FT
72 FT 6 FT
(b)
Figure 3.3 (a) the Ducting System of the M-2 Hall (Schematic Architectural Plane of A/D
Dampers) (b) Layout of Supply Ducts with Dimensions in Feet
Note: This layout is not according to scale, but it is showing the exact location of the main duct and branches.
FO: Fan-outlet, CFM: cubic feet per minute
Constructional and Operational Characteristics
ρ= density of air = 0.075 lb/ft3

υ=viscosity of air= 1.59×10-4 ft2/sec
Tsup = 54 0F
ε= absolute roughness= 0.0003 ft
ηmotor = 0.8, ηfan = 0.7*
Ciu= $3.5/ft2
Er= Electrical energy cost =$0.067/KWh
Cid = Installation cost=$3.25/ft2
i (1 + i )n
CRF =capital recovery factor =
(1 + i )n − 1
Where,
I = interest rate
n = no. of year considered
Assumption for CRF is as follows
n= 10 (year plan), i= 12 %( annually)
0.12(1 + 0.12)10
CRF= = 0.1532
(1 + 0.12)10 − 1
tan= annual operating hours

10 hrs 24 days 7months
tan = × ×
day month year
3.15
hrs
tan = 1680
year
For secure design criteria (SDC), let tan= 2000 hrs / year.
For The First Iteration, start with the round duct section 4-5, which may be the last section of
the design critical path. Assume a diameter of 1.2475 ft, and an air velocity of 1300 fpm. Assume
also that the local loss coefficient of the straight-through stream of the diverging tee Cc, s =0.15
and for elbow Co=0.22. The Reynolds number based on diameter D is
VD 1300×1.2475
R = =
eD ν 60×1.59×10−4
=169994.7
Now using the relation for friction factor [m]
0.25
f =
2
⎧⎪ ⎡ ε 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎪⎩ ⎣ (3.7 D ) 0.9 ReD ⎦ ⎪⎭
0.25
=
2
⎪⎧ ⎡ 0.0003 5.74 ⎤ ⎪⎫
⎨log ⎢ + ⎥⎬
⎩⎪ ⎣ 3.7×1.247 (0.9×169994.7) ⎦ ⎭⎪
f= 0.015709
Now calculate the optimum pressure drop from the relation given below[m]
0.82 0.18 ⎛
⎡ LCiuηmotorη fan ⎤ ⎡ fL ⎤ 1 ⎞
Δp f 4−5 = 108 ⎢ ⎥ ⎢( +∑ C D ) ρ ⎥ ⎜⎜ ⎟⎟
⎢⎣ (1/ CRF ) Er tan ⎥⎦ ⎣ D ⎦ ⎝ V .0.46 ⎠
0.82
⎡ ⎤ 0.18
⎢ 25×3.5×0.7×0.8 ⎥ ⎡⎛ 0.015709×25 ⎞ ⎤ ⎛ 1 ⎞
= 108 ⎢ ⎥ × ⎢⎜ + 0.37 1.2475 ⎟0.075⎥ × ⎜⎜ ⎟⎟
⎢ 1 ×0.0167×2000 ⎥ ⎣⎝ 1.2475 ⎠ ⎦ ⎝ 7580.46 ⎠
⎢⎣ 0.1532 ⎥⎦
=0.22938 in. W
⎡ ⎛ fL
0.22
⎞ ⎤
D4−5 = 0.0511 ⎢⎜ +∑ C D ⎟ ρ ⎥ × V .0.44 Δp −0.22
⎣⎢ ⎝ D ⎠ ⎦⎥ f
0.22
⎡⎛ 0.015709×25 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ + 0.37 1.2475 ⎟0.075 ⎥ × 758 × 0.22938
⎣⎝ 1.2475 ⎠ ⎦
D4-5=0.86702 ft.
Duct section 3-4 is one of the sections of the critical path. For this section, if we assume that
∑ C = .4 and the diameter is 1.3ft, and air velocity is 1400 fpm then calculated friction factor is
3.16
First check the flow condition
VD 1400×1.3
R = =
eD ν 60×1.59×10−4
=190775.68
Now friction factor, f
0.25
f =
2
⎪⎧ ⎡ ε 5.74 ⎤ ⎪⎫
⎨log ⎢ +
⎪⎩ ⎣ (3.7 D ) 0.9 ReD ⎥⎦ ⎬⎭⎪
0.25
=
⎧⎪
2
⎡ 0.0003 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎩⎪ ⎣ 3.7×1.3 (0.9×190775.68) ⎦ ⎭⎪
=0.01548
Pressure drop in the section 3-4 then,
⎡ LCiuηmotorη fan ⎤
0.82 ⎡ 0.18 ⎛
fL ⎤ 1 ⎞⎟
Δp = 108 ⎢ ⎥ × ⎢( +∑ C D ) ρ ⎥ ⎜
f 3−4 ⎣⎢ (1/ CRF ) Er tan ⎦⎥ ⎣⎢ D ⎦⎥
⎜
⎝V .0.46 ⎟
⎠
0.82
⎡ ⎤ ⎡⎛ 0.01548×16 ⎤
0.18 ⎛ ⎞
16×3.5×0.7×0.8 ⎞
= 108 ⎢ ⎥ × ⎢⎜ + 0.4 1.3 ⎟0.075⎥ × ⎜⎜
1
⎟⎟
⎢ 1 ×0.0167×2000 ⎥ ⎣⎝ 1.3 ⎠ ⎦ ⎝ 15160.46 ⎠
⎣ 0.1532 ⎦
=0.07785 in. W
Diameter D of section 3-4 is,
⎡ ⎛ fL
0.22
⎞ ⎤
D3−4 = 0.0511 ⎢ ⎜ +∑ C D ⎟ ρ ⎥ × V .0.44 Δp −0.22
⎢⎣ ⎝ D ⎠ ⎥⎦ f
0.22
⎡⎛ 0.01548×16 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ + 0.4 1.3 ⎟0.075⎥ × 1516 × 0.07785
⎣⎝ 1.3 ⎠ ⎦
D3-4=1.165 ft.
Duct section 2-3 is again one of the critical paths. For this ∑ C=0.4. Let us assume that velocity is
1400fpm, D=1.35 ft, L=16 ft.
Now calculate the friction factor as
As usual check first flow condition
VD 1400×1.35
R = = =198113.2
eD ν 60×1.59×10−4
Friction factor, f
0.25
f =
2
⎪⎧ ⎡ ε 5.74 ⎤ ⎪⎫
⎨ log ⎢ + ⎥⎬
⎩⎪ ⎣ (3.7 D ) 0.9 ReD ⎦ ⎭⎪
3.17
0.25
=
⎧⎪
2
⎡ 0.0003 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎩⎪ ⎣ 3.7×1.35 (0.9×198113.2) ⎦ ⎭⎪
f=0.01535
0.82 ⎡ 0.18 ⎛
fL ⎤ 1 ⎞⎟
Δp = 108 ⎢ ⎥ × ⎢( +∑ C D ) ρ ⎥ ⎜
f 2−3 ⎣⎢ (1/ CRF ) Er tan ⎦⎥ ⎣⎢ D ⎦⎥
⎜
⎝V .0.46 ⎟
⎠
⎛ ⎞
⎜ ⎟ ⎡ 0.18 ⎛ ⎞
× × × ⎤
Δp = 108 ⎜
16 3.5 0.8 0.7 ⎟ × ⎢⎛ 0.01487×16 + 0.4 1.35 ⎞0.075⎥ × ⎜⎜
1
⎟
f 2 −3 ⎜⎛ 1 ⎞ ⎟ ⎣⎝ ⎜ ⎟ 0.46 ⎠⎟
0.0167 × 2000 1.35 ⎠ ⎦ ⎝ 2274
⎜ ⎜ 0.1532 ⎟ ⎟
⎝⎝ ⎠ ⎠
Δ f 2 −3 =0.06469 in. W
Diameter D of section 3-4 is,
⎡ ⎛ fL
0.22
⎞ ⎤
D2−3 = 0.0511 ⎢ ⎜ +∑ C D ⎟ ρ ⎥ × V .0.44 Δp −0.22
⎢⎣ ⎝ D ⎠ ⎥⎦ f
0.22
⎡⎛ 0.01535×16 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ + 0.4 1.35 ⎟0.075 ⎥ × 2274 × 0.06469
⎣⎝ 1.35 ⎠ ⎦
D2-3=1.453 ft.
Duct section 1-2 is also one of the critical paths. So for that section let we assume
V=1550 fpm, D=1.40 ft, and ∑ C = 0.2
The Reynolds number is
VD 1550×1.4
R = = =227463.31
eD ν 60×1.59×10−4
Friction factor, f
0.25
f =
2
⎧⎪ ⎡ ε 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎩⎪ ⎣ (3.7 D ) 0.9 ReD ⎦ ⎭⎪
0.25
=
2
⎧⎪ ⎡ 0.0003 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎪⎩ ⎣ 3.7×1.4 (0.9×227463.31) ⎦ ⎪⎭
f=0.015123
3.18
0.82 ⎡ 0.18 ⎛
fL ⎤ 1 ⎞⎟
Δp = 108 ⎢ ⎥ × ⎢( +∑ C D ) ρ ⎥ ⎜
f 1−2 ⎢⎣ (1/ CRF ) Er tan ⎥⎦ ⎢⎣ D ⎥⎦ ⎜ .0.46 ⎟
⎝V ⎠
⎛ ⎞
⎜ ⎟ ⎡ 0.18 ⎛ ⎞
× × × ⎤
Δp = 108 ⎜
16 3.5 0.8 0.7 ⎟ × ⎢⎛ 0.015123×16 + 0.2 1.4 ⎞0.075⎥ × ⎜⎜
1
⎟
f 1− 2 ⎜⎛ 1 ⎞ ⎟ ⎣⎝ ⎜ ⎟ ⎟
0.46 ⎠
0.0167 × 2000 1.4 ⎠ ⎦ ⎝ 3032
⎜⎜ ⎟ ⎟
⎝ ⎝ 0.1532 ⎠ ⎠
=0.05246 in. W
The diameter of sized duct section 1-2 is
⎡⎛
0.22
⎞ ⎤
× V .0.44 Δp −0.22
fL
D1−2 = 0.0511 ⎢ ⎜ +∑ C D ⎟ ρ ⎥
⎣⎢ ⎝ D ⎠ ⎦⎥ f
0.22
⎡⎛ 0.015123×16 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ + 0.2 1.4 ⎟0.075⎥ × 3032 × 0.05246
⎣⎝ 1.4 ⎠ ⎦
D1-2=1.5715 ft.
Duct section FO-1 is one of the critical paths. So for that section let we assume
V=1750 fpm, D=1.6 ft, and ∑ C = 0.4
The Reynolds number is,
VD 1750×1.6
R = = =293501.04
eD ν 60×1.59×10−4
Friction factor, f
0.25
f =
2
⎧⎪ ⎡ ε 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎪⎩ ⎣ (3.7 D ) 0.9 ReD ⎦ ⎭⎪
0.25
=
2
⎪⎧ ⎡ 0.0003 5.74 ⎤ ⎪⎫
⎨log ⎢ + ⎥⎬
⎪⎩ ⎣ 3.7×1.6 (0.9× 293501.04) ⎦ ⎪⎭
f=0.01458
Pressure drop in the section FO-1 then,
0.82 ⎡ 0.18 ⎛
fL ⎤ 1 ⎞⎟
Δp = 108 ⎢ ⎥ × ⎢( +∑ C D ) ρ ⎥ ⎜
fFO−1 ⎢⎣ (1/ CRF ) Er tan ⎥⎦ ⎢⎣ D ⎥⎦ ⎜ .0.46 ⎟
⎝V ⎠
⎛ ⎞
⎜ ⎟ ⎡ 0.18 ⎛ ⎞
× × × ⎤
Δp = 108 ⎜
42 3.5 0.8 0.7 ⎟ × ⎢⎛ 0.01458×42 + 0.4 1.6 ⎞0.075⎥ × ⎜⎜
1
⎟
fFO −1 ⎜⎛ 1 ⎞ ⎟ ⎣⎝ ⎜ ⎟ 0.46 ⎠⎟
0.0167 ×2000 1.6 ⎠ ⎦ ⎝ 3790
⎜ ⎜ 0.1532 ⎟ ⎟
⎝⎝ ⎠ ⎠
Δp = 0.1437 in.W
fFO−1
3.19
The diameter of sized duct section FO-1 is
⎡⎛
0.22
⎞ ⎤
× V .0.44 Δp −0.22
fL
DFO-1 = 0.0511 ⎢ ⎜ +∑ C D ⎟ ρ ⎥
⎣⎢ ⎝ D ⎠ ⎦⎥ f
0.22
⎡⎛ 0.01458×42 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ + 0.4 1.6 ⎟0.075⎥ × 3790 × 0.1437
⎣⎝ 1.6 ⎠ ⎦
DFO-1= 1.659ft.
Duct section 4-6, is the branch duct section from the junction 4 so now we have
f = 0.01639 , D=1 ft. V=1400 fpm, ∑ C = 0.37 , L=9 ft
Pressure drop in the section 4-6 is,
0.82 0.18 ⎛
Δp = 108 ⎢ ⎥ × ⎢( +∑ C D ) ρ ⎥ ⎜⎜ ⎟⎟
f 4−6 ⎢⎣ (1/ CRF ) Er tan ⎥⎦ ⎣ D ⎦ ⎝ V .0.46 ⎠
⎛ ⎞
⎜ ⎟ ⎡ 0.18 ⎛ ⎞
× × × ⎤
Δp = 108 ⎜
9 3.5 0.8 0.7 ⎟ × ⎢⎛ 0.015709×9 + 0.37 1 ⎞0.075⎥ × ⎜⎜
1
⎟
f 4 −6 ⎜⎛ 1 ⎞ ⎟ ⎣⎝ ⎜ ⎟ 0.46 ⎟⎠
0.0167× 2000 1 ⎠ ⎦ ⎝ 758
⎜ ⎜ 0.1532 ⎟ ⎟
⎝⎝ ⎠ ⎠
=0.116029 in. W
Now the sized duct diameter of branch section 4-6 is
⎡ ⎛ fL
0.22
⎞ ⎤
D4−6 = 0.0511 ⎢⎜ +∑ C D ⎟ ρ ⎥ × V .0.44 Δp −0.22
⎣⎢ ⎝ D ⎠ ⎦⎥ f
0.22
⎡⎛ 0.015709×9 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ + 0.37 1 ⎟0.075⎥ × 758 × 0.116029
⎣⎝ 1 ⎠ ⎦
D4-6=0.7429 ft.
Now repeat the same procedure for branch duct section 3-7,
Let us assume that, the velocity is 1300fpm in the section 3-7, D=1.1 ft, ∑ C = 1
Check the flow condition,
VD 1300×1.1
R = = =149895.17
eD ν 60×1.59×10−4
Friction factor, f
0.25
f =
2
⎧⎪ ⎡ ε 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎩⎪ ⎣ (3.7 D ) 0.9 ReD ⎦ ⎭⎪
3.20
0.25
=
2
⎪⎧ ⎡ 0.0003 5.74 ⎤ ⎪⎫
⎨log ⎢ + ⎥⎬
⎩⎪ ⎣ 3.7×1.1 (0.9×149895.17) ⎦ ⎭⎪
f=0.016139
Pressure drop in the section 3-7 is,
0.82 0.18 ⎛
Δp = 108 ⎢ ⎥ × ⎢( +∑ C D ) ρ ⎥ ⎜⎜ ⎟⎟
f 3−7 .0.46
⎣⎢ (1/ CRF ) Er tan ⎦⎥ ⎣ D ⎦ ⎝V ⎠
⎛ ⎞
⎜ ⎟ ⎡ 0.18 ⎛ ⎞
9×3.5×0.8×0.7 ⎤
Δp = 108 ⎜ ⎟ × ⎢⎛ 0.016397×9 +1 1.1 ⎞0.075⎥ × ⎜⎜
1
⎟
f 3−7 ⎜⎛ 1 ⎞ ⎟ ⎣⎝⎜ 1.1
⎟
⎠ ⎦ ⎝ 7580.46 ⎟
⎠
⎜ ⎜ ⎟ 0.0167×2000 ⎟
⎝ ⎝ 0.1532 ⎠ ⎠
Δp f 3− 7 = 0.134736 in. W
Or we can also find out the pressure drop by adding all the pressure losses of the duct section 3-4
and 4-6.so proceeding in this way we know that
Δp
f 3−7 = Δp f 4−6 + Δp f 3−4
So now estimate the diameter of the sized duct section 3-7

⎡ ⎛ fL
0.22
⎞ ⎤
D3−7 = 0.0511 ⎢ ⎜ +∑ C D ⎟ ρ ⎥ × V .0.44 Δp −0.22
⎢⎣ ⎝ D ⎠ ⎥⎦ f
0.22
⎡⎛ 0.016139×9 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ +1 1.1 ⎟0.075⎥ × 758 × 0.134736
⎣⎝ 1.1 ⎠ ⎦
D3-7=0.86295 ft.
Duct section 2-8 is another leg from junction 2. Let we assume that, D=0.75 ft, V=1248 fpm and
∑ C = 1.2
The flow condition is
VD 1248×0.75
R = = = 98113.2
eD ν 60×1.59×10−4
Friction factor is,
0.25
f =
2
⎧⎪ ⎡ ε 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎩⎪ ⎣ (3.7 D ) 0.9 ReD ⎦ ⎭⎪
0.25
=
2
⎪⎧ ⎡ 0.0003 5.74 ⎤ ⎪⎫
⎨log ⎢ + ⎥⎬
⎪⎩ ⎣ 3.7×0.75 (0.9×98113.2) ⎦ ⎭⎪
f=0.01766
3.21
The pressure drop in the duct section 2-8.
The section 2-8 must have the sum of the total pressure loss of the duct section 2-3 and 3-7, or we
have
0.22
⎡⎛ 0.01766×9 ⎞ ⎤ 0.44 −0.22
Δp = 0.0511 ⎢⎜ +1.2 0.75 ⎟0.075⎥ × 758 × 0.01766
f 2−8 ⎣⎝ 0.75 ⎠ ⎦
Δp f 2−8 = 0.13545 in.W
So now the sized duct diameter is
⎡⎛
0.22
⎞ ⎤
× V .0.44 Δp −0.22
fL
D2−8 = 0.0511 ⎢ ⎜ +∑ C D ⎟ ρ ⎥
⎣⎢ ⎝ D ⎠ ⎦⎥ f
0.22
⎡⎛ 0.01766×9 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ +1.2 0.75 ⎟0.075⎥ × 758 × 0.13545
⎣⎝ 0.75 ⎠ ⎦
D2-8=0.86748 ft.
Now size the last branch 1-9 from junction 1. Let us assume that D=0.7 ft, V=1300 fpm and with
local loss coefficient as in section 2-8 that is ∑ C = 1.74 ,
First of all check the flow condition in the duct section 1-9, that is
VD 1300×0.7
R = = = 95387.84
eD ν 60×1.59×10−4
Friction factor is,
0.25
f =
2
⎪⎧ ⎡ ε 5.74 ⎤ ⎪⎫
⎨log ⎢ +
⎩⎪ ⎣ (3.7 D ) 0.9 ReD ⎥⎦ ⎭⎬⎪
0.25
=
2
⎧⎪ ⎡ 0.0003 5.74 ⎤ ⎫⎪
⎨log ⎢ + ⎥⎬
⎪⎩ ⎣ 3.7×0.7 (0.9×95387.84) ⎦ ⎪⎭
f=0.017889
For calculating pressure drop in this section, it must have the sum of the total pressure loss of the
duct sections, which are following it, that is
Δp = Δp + Δp
f 1−9 f 2−8 f 1−2
=0.25188 in. W
Calculating now the diameter of section 1-9, that is
⎡⎛
0.22
⎞ ⎤
× V .0.44 Δp −0.22
fL
D1−9 = 0.0511 ⎢⎜ +∑ C D ⎟ ρ ⎥
⎣⎢ ⎝ D ⎠ ⎦⎥ f
3.22
0.22
⎡⎛ 0.017889×9 ⎞ ⎤ 0.44 −0.22
= 0.0511 ⎢⎜ +1.74 0.7 ⎟0.075⎥ × 758 × 0.25188
⎣⎝ 0.7 ⎠ ⎦
D1-9=0.808 ft.
The results of the first iteration are given in the Table 3.1a, the result are rounded to standard
sizes and provide the information for the selection of the diverging tees and wyes and the
determination of the local loss coefficients.
For the branch take-offs 4-9 to 1-9, select the proper diverging tees and wyes and therefore, the
Cc,b values based on the air velocity of the sized sections. Vary the size of the duct sections if
necessary so that their Δpt values are approximately equal to the Δpt of the section 4-5 for
branch duct 4-6 and the Δpt of the sum of the sections 4-5, and critical path sections total losses.
Now recalculate the total pressure loss of the sections 4-6 to 1-9 according to the rounded
diameters.
After the diverging tees and wyes are selected, recalculate the optimum total pressure losses and
diameters for duct sections 4-5, 3-4 and back to 1-2 from the equations mentioned above in the
first iteration.
So after the two iterations the final results are given in the Table 3.1b.
With the succeeding iterations the final sizes of the duct sections are listed in the Table 3.1b given
below. Note that the duct sizes, which are calculated in the following pages, are in round shape. Their
equivalents can be found from the Table of equivalent sizes for the round duct, which are given in the
table B8 in appendix B at the end of this thesis report.
The method employed for sizing of the ducts section is Cost Optimization T-Method, which is based
on the ideology that the minimum cost raised on the installation with optimized pressure drop inside
the duct (see for further detail ASHRAE Handbook 2005 Fundamentals).
Because we know that, the higher the pressure drop in the ducts smaller the sizes and thus reducing
the total marginal cost on the material of the ducts but on the other hand this increases the capacity
(size) of the blower and energy consumption. This method facilitates us in choosing the correct sizes
and optimum pressure drop in the system i.e. providing the total pressure drop to an optimum value,
where cost raised on the system is lower.
The Table 3.1 shows the sized diameter of the duct section of the figure 3.3.
3.23
Table 3.1a: Results of the Computations of the Supply-Duct Sizes and Total Pressure Loss in M-
2 Hall Ducting System
First iteration
Volume Air Friction
Duct section flow V, Diameter Rounded velocity factor
cfm ft in. in. FPM fps f
4-5 758 0.867 10.40 11 1300 21.67 0.015709
3-4 1516 1.165 13.98 14 1400 23.33 0.01548
2-3 2274 1.453 17.43 17 1400 23.33 0.01535
1-2 3032 1.5715 18.85 19 1550 25.83 0.015123
FO-1 3790 1.659 19.91 20 1750 29.16 0.01458
4-6 758 0.7429 8.915 9 1400 23.33 0.01639
3-7 758 0.863 10.35 10 1300 21.67 0.016139
2-8 758 0.8675 10.41 10.5 1248 20.8 0.01766
1-9 758 0.808 9.696 10 1300 21.67 0.017889
Therest of the results of the calculations are given in the following table.
Table 3.1a (continued...)
Duct Section ∑C Δpt

In. WC Velocity ratio
K Z
4-5 0.37 0.22938 1.07
3-4 0.4 0.07785 1
2-3 0.4 0.06469 1.107
1-2 0.2 0.0524 1.13
FO-1 0.4 0.1437
4-6 0.37 0.11603 1.07
3-7 1 0.1347 0.93
2-8 1.2 0.13545 0.89
1-9 1.74 0.2519 0.84
3.24
Note: In the Table 3.1a & b the ducts sizes are in round shapes their equivalent can be found from the Table B8 in the
Appendix B.
vs vb
K= and Z = . Here K and Z are the velocity ratios.
vc vc
Table 3.1b: Final Sizes of the M-2 Hall Supply-Ducting System
Final Iteration
Diameter
Duct section Volume Flow V, cfm Air velocity, fpm
Ft in.
4-5 758 1300 0.867 10.40

3-4 1516 1400 1.175 14.1
2-3 2274 1400 1.437 17.24
1-2 3032 1550 1.579 18.948
FO-1 3790 1750 1.659 19.91
4-6 758 1440 0.818 9.816
3-7 758 1300 0.863 10.35
2-8 758 1248 0.88 10.56
1-9 758 1300 0.86 10.32
Designing of Return Ducting System
Now it is very important to design i.e. estimate the sizes of the return ducting system as
shown in the figure 3.3a in order to maintain the desired indoor conditions of the M-2. The
methods employed for the designing of the return ducting is “Equal Friction Method”, with this
method, “the same value friction loss rate per unit length of duct is used to size each section of
duct in the system”. In the following table we shall give only the sizes of the designed ducting
dimensions after succeeding calculations.
Table 3.1c: Designed Sizes of the M-2 Hall Return-Ducting System
Final Iteration
Diameter Friction Loss

Duct section Volume Flow V, CFM Air velocity, FPM in. in. W / 100ft
A-A 3790 1300 23 0.1

B-B 3032 1250 21 0.1
C-C 2274 1150 19 0.1
D-D 1516 1050 16.25 0.1
E-E 758 875 12.5 0.1
Note:
• In the design we didn’t include the air leakage in the total supply CFM i.e. 3790 CFM. The reason for that is
the total length of the ducting does not exceed to a 115ft so there is not a problem. The ducts are well insulated with a
thermopore sheets along with vapor barriers. For further detail on the insulation see the table in the appendix B.
• The ducts are well equipped with the hangers on the walls, with spring damper greatly reducing the vibrations
and noise. The blower, which is rotating at more than 3000rpm, is producing tremendous vibration that is transferred to
the duct fittings, finally reducing the life of the ducting system.
• In the design of the return ducting system, it is assumed that return ducting system is of low velocity (less than
2500FPM).
3.25
• In the Table 3.1a, b & c the ducts sizes are in round shapes their equivalent can be found from the Table B8 in
the Appendix B.
The length of the each section i.e. A-A is 36Ft, and remaining sections i.e. B-B, C-C, D-D and E-
E is 15.2 Ft.
3.6 Indoor air quality (IAQ) and Selection of Air Filter for PAC-105 AHU
It is evident that the poor air quality inside the building causes health problem. Therefore
it must be given special importance in designing an air conditioning system.Uptill hall M2 has
been used as a drawing hall for engineering students. Some times it has to be used as a conference
hall, Lecture hall, examination centre, etc.During working hour’s students or other concerned
people spend about 60 % of day time in the hall. Their presence may cause the generation of
following types of air pollutants or contaminants.
Biological contaminants
These include bacteria, viruses, mites, pollen and fungi.
Environmental tobacco smoke (ETS)
It includes the mixture of substances emitting from the burning of tobacco, breathed in by
occupants. In order to get the better working environment it is preferable to use a high efficiency
air filter, mostly used in commercial buildings.
3.7 Fan Selection for PAC-105 AHU

For HVAC applications centrifugal fans are preferred. Therefore we shall use a
centrifugal fan with backward inclined (BI) curved blades and single width single inlet (SWSI)
for PAC-105.
After selection of an appropriate type of fan, the next step is to find the size and RPM of the fan.
For this we need the static pressure loss of the whole ducting system. This pressure loss is due to
the frictional resistance of duct surface or other restrictions in air flow like dampers, branch take
offs etc. discussion on duct design is provided in previous section First we shall find the total
pressure loss of air in air cooling coil, air filter, supply duct, return duct and in air handling unit
due to transition in face area, then a proper fan will be selected.
Maximum Pressure Drop of Air Flowing Across PAC-105 Cooling Coil
Using relation for pressure drop of air flowing over a compact heat exchanger [L]
G 2vi ⎡⎛ ⎛v ⎞ v ⎤
ΔP = ⎢⎜1+σ 2 ⎞⎟⎜ o −1⎟+ f φ m ⎥ ...
2 ⎣⎢⎝ ⎠⎝ vi ⎠ vi ⎦⎥
Where, from table B-1
⎣ ⎦
1 1 1
vi = = = =0.8610m3 / kg
ρ ρ o
a,i a at 26 C 1.1614
1 1 1
vo = = = =0.7469m3 / kg
ρ a,o ρa at 12 C
o 1.3387
v +v 0.8610+0.7469
vm = i o = = 0.8039
2 2
3.26
2
G = mass velocity of air=ρaVmax kg/m 2 .sec = 1.2034×3.979=4.788=kg/m .sec
( ρ a = viscosity of air at mean temperaure (Tm =20 o C) )
Also we know that for PAC-105 cooling coil,
AF = l × H = 1.036 × 0.653 = 0.72m 2
And recalling from previous sections, we know that the total surface area of coil is
AT = 75.34m 2
Only the parameter required to find the pressure drop is free flow area of coil and is
formulated as,
A f f = Free flow area of coil=face area of coil - area of coil restricted to free flow of air
The above relation gives the physical interpretation of free flow area, mathematically
A = AF − ⎡⎣( NT ×D )+( N ×l×t ) ⎤⎦
f f
Where,
N = total no of finns per unit length of tube
t = Thickness of single fin=0.25mm=0.00025 m
All other values in above relation have been defined already, now putting values in above
relation,
A = 0.72 − ⎡⎣( 20×0.0127 )+( 551×1.036×0.00025) ⎤⎦
f f
A f f = 0.3233m 2
Thus,
Af f Free flow area of coil 0.2333
σ= = = = 0.449
AF face area of coil 0.72
φ = AT = total heat transfer area of coil = 75.34 =233
Af f Free flow area of coil 0.3233
Now we have all values except friction factor f . Its value for standard configurations
can be found from work of Kays and London. For our configuration of PAC-105 cooling
coil an appropriate value can be selected. The values of f mostly lie in range 0.02-0.06, Let
we select the upper limit of (maximum Value) of f . Then pressure drop relation will give the
maximum pressure drop of air for assumed configuration of coil.
Putting values in above relation
(4.788)2×0.8610 ⎡ ⎛ ⎞⎛ 0.7469 −1⎞+0.06×233 0.8039 ⎤
ΔP = ⎢ ⎜1+(0.449)2 ⎟⎜ ⎟ ⎥
2 ⎣⎢ ⎝ ⎠⎝ 0.8610 ⎠ 0.8610 ⎦⎥
Solving, we get
ΔP = 127 Pa= 0.51 inch of water column.
Hence the maximum pressure of air while passing over the PAC-105 cooling coil is 127
Pascal. Or 0.51 inch of water column. Actually the pressure drop will never attain this value
because we selected the max value of friction factor for coil, therefore we assume that both
cooling coil and air filter produce the above calculated pressure drop of air stream flowing.
Pressure Loss of Air in Return Duct
3.27
The length of return duct can be calculated from layout of ducting system shown in
figure3.3.and is 20.2034 ft. Standard charts are available which give the value of friction factor
for given cfm and velocity and diameter of round duct [m]. For 3790 cfm and round duct of 22.5
inches diameter, the velocity of air in return duct is 1410 fpm. The corresponding value of friction
factor is 0.135 in of WC per 100 feet of length. Thus
0.135
The frictional loss in return duct =Δ Pr.d = × 20.2034 = 0.02727 in WC
100
Note: The pressure loss of air in supply ducts can be calculated easily by adding pressure drops
listed in table 3.1for main and each of the branches for their corresponding cfms and velocities. It
was1.2061 in WC. Thus Δ Ps.d = 1.2061in WC
Pressure Loss of Air in Return Duct Rectangular Mitered (Having Vanes) Elbow
The air handling unit will be on ground floor, therefore return duct from hall M-2 will
have to be turned at right angle using 90o elbow with vanes to reduce the head loss. Thus
V 2
The dynamic loss in return duct mitered elbow = Co ( ) in WC
4005
Where V is velocity of air in fpm, and Co is local loss coefficient for mitered elbow. Its
value ranges from 0.12 to 0.18 [m] let we use the upper value of 0.18. Thus
1410 2
The dynamic loss in return duct mitered elbow=Δ Pr.e = 0.18( ) =0.22 in WC
4005
Pressure Loss of Air in AHU Rectangular Mitered (Having Vanes) Elbow
The air handling unit for PAC-105 is shown in figure 3.4. Now because of change in
cross sectional area the air stream coming from return duct and entering in the AHU will suffer a
change in its velocity. Now from table B-9 for cfm equal to 3790, the velocity of air in the
equivalent round duct of diameter 39.5 ′′ , corresponding to rectangular duct of dimensions
29.5′′ × 43.5′′ is 550 fpm. Thus,
550 2
The dynamic loss in AHU mitered elbow =Δ PAHU .e = 0.18( ) =0.00339 in WC
4005
Total Pressure Loss of Air in Ducting System
The total pressure loss is summation of all above found losses. Thus,
The total pressure loss =Δ PT = Δ Pr. + Δ Ps. + Δ Pr.e + Δ P + Δ PAHU .e
d d coil & filter
The total pressure loss =Δ PT =0.02727+1.2061+ 0.022+ 0.51+ 0.00339=1.76876 in WC
We have not calculated the pressure loss in mixing box section, fan inlet and in transition
from fan outlet to supply duct. These losses are usually very small. Let we assume that
including these parameters the total pressure loss approaches to value 2 in WC. Thus,
The total pressure loss =2in WC
Now from table (By Trane international inc. USA) see in the References, the AHU fan has the
specifications which are given in the Table 3.2 below. These values are not directly available
form tables of TRANE Fan Manufacturer’s catalogue, so they are found by interpolation
technique for the backward-curved inclined (B.I.) fan.
3.28
Table 3.2: Specification of the PAC-105 AHU Fan

Fan Type Wheel Design Air RPM Motor E.S.P. Manufacturer
diameter Flow H.P. In. WC
in. Quantity
CFM
*B.I. 20 3790 1252 1.75 2 **TRANE
* Backward Inclined (B.I.) Curved Blade Fan.
** See the reference or web source of the concerned product in detail.
Since we are mentioning here the characteristics curves, graphs and tables so they can be found in
detail in the TRANE® Company’s product brochures for B.I. fan or one shall contact with us.
3.8 Suggestions for PAC-105 AHU Fabrication
1. The recommended material for fabrication of air handling unit is double sheet-metal
panel, with inner insulation layer such as glass fibers and mineral wool and perforated
metal liners. The casing and back door for maintenance must be air tight. Inner surface of
casing must be smooth and well insulated. Outer surface of casing must painted with a
light color.
2. Because the fan is small therefore it would be direct-driven. The fan must be connected to
supply duct using a canvas or rubber connection to reduce the vibration transmission to
duct. Also the rubber pad vibration isolators must be used for fan saddle.
3. Connections of supply and return duct must be secure and insulated to reduce air leakage
and heat loss respectively.
4. During design of cooling coil we used the K-type copper tubing with inner and outer
diameter as 10.2mm and 12.7mm respectively. Thus the head loss of chilled water
passing through cooling coil will be found as following.
Total mass flow rate of chilled water = 0.91kg/sec =14.5 GPM
Now from Table [n] the value of friction factor for 14.5 GPM, K-type copper tubing the
value of friction factor is 18 ft per 100 ft of length of tubing. Now,
The length of each circuit =(no of passes × length of coil)+eqivalent length of 11 U-bends
From [n] the equivalent length of each U-bend is 1.6 ft. Thus,
The length of each circuit =(10 × 3.39 ft)+(11 × 1.6 ft)=51.58 ft
18
thus head loss of water per circuit = × 51.58 = 9.28 ft of Water
100
Thus the head loss for 10 water circuits will be 92.8 ft of water column, which is too high and
must be reduced to minimize the operating cost of chiller pump. Now, if we select L-Type
copper tubing with outer diameter as 0.75in then for same flow rate of chilled water through
cooling coil the friction factor will be 0.8 ft per 100 ft of length. In this case the head loss of
water in cooling coil will be
0.8
head loss of water for cooling coil = ×515.8=4.1264ft of Water
100
It reveals the importance of proper selection of tubing for coil and other components like
chiller, hydronic system etc. Using 0.75in diameter L-type copper tubing the height of
cooling coil will increase and will be 796.85mm approx. Therefore the height of coil section
(750mm) of AHU must be changed accordingly to some suitable value.
3.29
Door for Cleaning

and Maintenance
1250 X800
DDC
Control
Panel
(a)
3.30
Fan Motor
(b)
Figure 3.4 the PAC-105 AHU Dimensional View Front Face Showing the Mixing Box Detail (a)
Front view (b) Mixing box end view
Note: Figure 3.4 shows the detailed drawing of PAC-105 air handling unit (AHU), Small variations can be made in the
above dimensions during fabrication. Also the dimensions can be round off later on. All the dimensions are in
millimeters. The door of the PAC-105 AHU is provided at the opposite end of the mixing box for maintenance and
cleaning from sludge. The dimensions of this door are 1250 mm height and 800 mm width; this is an air tight door
which can sustain a thrust force of higher magnitude and prevents from leakage.
3.9 Design of Condensate Drain Pan of the PAC-105 AHU
The condensate drain pan is also an important part of any AHU, in which condensate
flow should be collected effectively and then it must be drained to the outside of the coils so that
IAQ should be maintained inside the space by minimizing the bacterial and microorganisms
growth. The condensate pan of the PAC-105 AHU is shown in the figure 3.5 with all of its
accessories and dimensions. The designed of this pan is standardized by TRENT and TRENT®
and IAQ standards (See for further details references at the end of this thesis). In our case the
total condensate flows as given in the unit 2. So suitable port size and other necessary dimensions
are taken from chart given in the figure 3.5.
3.31
So it is important to note here that higher the latent load, higher is the condensate flow
volume so critical should be the design of the pan. The drain trap is installed as shown in the
figure 3.5, U-tube is filled with water and the height of the water column in the tube should be 2
in. WC than the highest vacuum or negative pressure recorded behind the coils in case of draw-
through type AHU as PAC-105 AHU in order to isolate the coils from the surroundings. The total
mass flow rate of the condensate in case of the full recirculation of air (see unit 2):
3.0735 kg / hr
So after mixing with the outside air at 440 C, RH 65%, and leaving air from the AHU at 13.330C,
the mass flow rate of condensate is:
3.916kg / min or 0.879GPM (Maximum Condensate Flow Rate)
While designing the drain pan we must take the higher condensate flow rate value as given above
after mixing of outside air rather than small one. In the following graphs in figure 3.6a and b, the
drain pan and port of the pan is designed as shown in figure 3.7.
Figure 3.5 Contamination problems created by wide Drain Pans.
Since the PAC-105 AHU coil is rectangular and 1020 mm long so Drain Pan is longer in size than
width. The drain pan is specially designed with state of art techniques as shown in the figure 3.8. In
the figure the plan of the drain pan is shown, so where we can well estimate the bacterial and
3.32
microorganisms presence. In the design of the pan we have taken all the standard methodologies to
improve the IAQ by minimizing the condensate carry over. So designed coil inlet velocity is very
important to choose, in PAC-105 coil designing the face velocity is 2.48 m/sec where condensate
carry over does not occur (for further detail, see the key reference).
In the figure 3.6 with increasing condensate GPM and pan width, we must optimize the port size so
that there should be a minimum depth of the condensate in order to overcome the surface tension and
viscosity effect.
Figure 3.6 Pan Widths suitable for units with various Flow Rates and for commonly used port sizes.
3.9 Results and Comments
1. For calculating the value of Nusselt No for coil in first iteration, we assumed that the coil
consists of 7 rows. Then from [d] we used the corresponding value of correction factor
for Nusselt No as 0.95. After calculation of area, the actual no rows was 5, for which the
value of correction factor is 0.92. Therefore our assumption generates an error of 3.15%
in calculation of surface area of coil, which is acceptable.
2. The value of air side convection coefficient was calculated for bank of tubes without fins,
and same value was used in area calculation. Actually due to fins the value of convection
coefficient will increase. But we used the lower value of convection coefficient, making
our design safer.
3. The reference [a] shows that recommended value of U o for finned tube heat exchanger is
25-50 W/m2.K. Our calculated value of U o is 47.92 W/m2.K, It shows the agreement
between recommendation and our calculations.
4. The reference [a] shows the value of fouling factor for seawater 0.0001m2.K /W. we
used that value in calculations. But the actual value of fouling factor will be less than
above value, because we shall use tab-water in chiller with fouling inhibitors instead of
sea water.
5. In area calculation, we used rectangular fins in form of small strips. Actually continuous
rectangular fins will be used, providing more heat transfer area than assumed fins.
3.33
6. In order to get good result from air, it is recommended to place the cooling coil in counter
flow arrangement with air, i.e. warmest air interacts with warmest water and coolest air
with coolest water.
3.34
Table 3.3: Specification Table of PAC-105 AHU
Cooling
E.S.P. Capacity Power Mo- Dimension
In. KW Coil Fan Supply to r Filter Casing mm
WC/Pa
Air Air
Chilled Drain Disc-
Flow 10 Water Port Thick-
m3/h harge
pipes Without Fins Pipe Size Drive V/ph/ Input ness
(CFM) per mixing Type / in. in. In. Type Type Hz. Kw Material mm Type L D H
circuit
6444 2 30.65 Cu 14 1/2 1 Aero- Direct Vertical 440/ 0.408 Nylon 90 G.I. with 2312 1104 1604
(3790) /Al Foil Drive 3/50 Filter/ in 3 Fiber
Fins High H.E.F stages Glass
Stgd.* Efficiency Insulation
Note:
• The PAC-105 vertical draw-through type AHU is double-wall sheet-metal casing in which insulation material us sandwiched b/w two sheet-metal panels of 2 in. (50 mm) with a
u value of 0.18 Btu / h. ft2. 0F. the insulation material preferred is mineral wool (inert) which has better resistance towards moistures and heat. The outer surface of the AHU is
coated with an ultraviolet–resistance epoxy paint and interior surface with a light color paint which increases the ability to spot the debris and microbial growth.
• The mixing box of the PAC-105 AHU can be dismantled easily for repairing and cleaning purposes. The servomotors (Servos) can be controlled through a structured
programming from DDC unit.
• The condensate trap is mounted at the side-end of the condensate pan (as shown in the figure 3.5), with a maximum height of water (Head) in the U-tube is taken as 1.5 to 2 in.
WC greater than the highest vacuum or negative pressure behind the AHU fan to isolate the coil section from the atmosphere air (see in the figure 3.4).
* Stgd. Staggered arrangement
Unit 3: Design of Air Handling Unit and Ducting System 3.36

100
1050 Part A Detail

20
1
4" per Ft 16
200
Part B Detail 30
B 6
15 30
50 100 Drain Port Size 200
Ø1" 30
160
Height of
U-Tube
Male Drain Port Condensate Drain Trap
Ø1" Ø1"
50 Mild Steel Sheet with Minimum Thickness of 2mm
,boted on the AHU floor
The minimum depth of condensate water in the Pan
is 18in. so that it must overcome the Surface Tension.
Figure 3.5 Drain Pan of the PAC-105 AHU

All the accessories shown in the figure 3.5 are according to the standards of TRENT & TRENT ® Inc. all the dimension are in millimeters unless specified on the figure.
Unit 3: Design of Air Handling Unit and Ducting System 3.34

PAC-105
Unit 4
Design of PAC-105
Refrigeration
System
Introduction
I n the previous units we have been analyzed the supply conditions of

the air supplied to the M-2 hall. Because as we know that PAC-105 is
a vapor compression central air-water cooling system, in which air is
being supplied to the hall after removing heat to the chilled water, which
is coming from the chiller (See Unit 5). The water carrying this heat
rejects into the chiller to the refrigerant, which is the primary source of
heat rejection in our PAC-105 system.
The system performance or effectiveness directly depends upon the
chiller, that how it removes heat from the return chilled water returning
back from the AHU. So it is very important to design an efficient chilling
system. In this unit shall analyze the design and selection of the
refrigeration equipments, e.g. design and selection of compressor, which
is a backbone for any refrigeration system, selection of the thermostatic
expansion valve (TEV), and selection of the refrigerant for the PAC-105
system. We would also give a general comparison of PAC-105
refrigeration system and conventional air-cooled system of same capacity
at same design conditions.
4.1
Unit 4: Design of PAC-105 Refrigeration System
4.1 The PAC-105 A Vapor Compression Refrigeration System
R efrigeration is defined as the “process of extracting heat from a lower-temperature heat

source, substance, or cooling medium and transferring it to a higher-temperature heat
sink”. Refrigeration maintains the temperature of the heat source below that of its
surroundings while transferring the extracted heat and any required energy input, to a heat sink,
atmospheric air, or surface water.
The refrigeration system of the PAC-105 is a vapor compression system, there are number of the other
systems which are being used in the actual practice with varying coefficients of performance, COP and
type of input energy. There are given below as:
¾ Absorption systems
¾ Air or gas expansion systems etc
In the vapor compression system, compressors activate the refrigerant by compressing it to a higher
pressure and higher temperature level after it has produced its refrigeration effect. The compressed
refrigerant transfers its heat to the sink and is condensed to liquid form. This liquid refrigerant is then
throttled to a low-pressure, low-temperature vapor to produce refrigerating effect during evaporation.
Vapor compression systems are the most widely adopted refrigeration systems in both comfort and
process air conditioning. This system has high coefficient of performance (COP), but the crisis of the
energy available and utilization is the main cause for diverting the attention of the engineers and
technologists to produce such systems which are energy efficient and reliable.
We are yet using this system because of:
• Very low temperature source available (channel water)
• Perfect availability of design approaches and techniques.
• Ease in part manufacturing and availability of the local sources for installation and
maintenance.
In the refrigeration system design of the PAC-105, we are designing and selecting/estimating the
following mechanical refrigeration system equipments:
1. Refrigerant selection
2. Refrigeration i.e. Refrigerating effect, capacity of the PAC-105 water chiller,
refrigerant mass flow rate ( mr. ) and COP (theoretical and actual) etc
3. Refrigeration compressor type and estimation of the capacity and sizes
4. Thermostatic expansion valve (TXV)
5. Vapor and liquid lines selection and sizes for the PAC-105 water chiller circuit
4.2 Refrigerant and its Selection Criteria for PAC-105 Refrigeration System
Since it is already have been mentioned that PAC-105 is a central air-conditioning vapor
compression system that the air is being supplied to the M-2 hall after conditioning in the AHU,
so chilled water is a secondary working fluid in the system. The chilled water which is circulating
in the chiller losing heat to another working fluid or substance which is known as refrigerant or
primary working fluid, So both working fluids should have capability of absorbing as much as
possible heat and rejecting it to the surroundings at the given atmospheric conditions i.e. ambient.
As for as PAC-105 refrigeration is concerned, we have selected a refrigerant HFC-134a of which
chemical name is tetraflouroethane. The Hydrofluorocarbons (HFCs) contain only hydrogen,
fluorine, and carbon atoms. They contain no chlorine atoms, therefore are environmentally safe,
and cause no ozone depletion. They are designated by the prefix HFC. HFC-134a is an attractive,
long-term alternative to replace CFC-12 in reciprocating, scroll, screw, and centrifugal
compressors; and a long-term alternative for HCFC-22. It has a low 0.28 HGWP. HFC-134a is
nonflammable, has an extremely low toxicity, and is classified as AI in ANSI/ASHRAE Standard
34-1997 safety rating.
4.2
HFC-134a has a molecular mass of 102.3 instead of CFC-12's molecular mass of 120.93. At a
condensing temperature of 100°F (37.8°C), HFC-134a's condensing pressure is 138.83 psia (957
kPa abs.), whereas CFC-12's is 131.65 psia (908 kPa abs.). A larger impeller of higher speed is
needed for a centrifugal chiller to provide the same cooling capacity. Parsnow (1993) reported a
capacity loss of direct conversion from CFC-12 to HFC-134a of 8 to 10 percent, and an
efficiency loss of 1 to 2 percent. In Lowe and Ares (1995), in the conversion from CFC-12 to
HFC-134a in the Sears Tower centrifugal chillers, the compressor's speed increased about 8.5
percent, there was a cooling capacity loss of 12 to 24 percent, and efficiency was 12 to 16 percent
worse.
HFC-134a has a poor mutual solubility with mineral oil because of a higher interfacial tension
between them. Polyolester-based synthetic lubricants should be used. Polyolester-based synthetic
oils are hygroscopic, so monitoring of the moisture content of the refrigerant is important.
Halocarbons, including HFC-134a, are compatible with containment materials. Concerning
nonmetallic or elastomer (such as gaskets) compatibility, Corr et al. (1993) reported that HFC-
134a, an ester-based synthetic oil mixture, has a smaller volume change of elastomer than CFC-
12 and mineral oil. HFC-134a may become one of the most widely used single-chemical-
compound refrigerants during the first half of the twenty-first century. So we therefore considered
it best in the modern chilling system saving environmental voluntarily. For further information
see the reference at the end of this thesis.
Replacement of the R-12 with R-134a

Refrigerants R-12 R-134a
Condensing pressure 908Kpa 957 Kpa abs

Condensing Temperature 37.80C
Capacity loss 8-10%
Efficiency loss 1-2 %
ODP 0.00
So from the above table, conversion of the R-12 to R134a is not conducive toward performance
but it has 0 ODP, which is neither saving environment but also a good replacement. So therefore
we are using it as a refrigerant in the PAC-105 shilling system (see unit 5).
4.3 Graphical Evaluation of the PAC-105 Refrigeration
Graphical Method: Before calculating the refrigeration, we must have a sufficient

knowledge of the P-h chart and T-s diagram of the HFC-134a. Referring to the P-h chart shown in
the figure 4.1, the change in pressure can be clearly illustrated on the P-h diagram. Also both heat
and work transfer of various processes can be calculated as the change of Enthalpy and are easily
shown on P-h diagram given below. The property tables of the HFC-134a are given in the table
B3 in Appendix B.
The PAC-105 refrigeration process is shown with the numbers 1-2-3-4. So now let us starting
from state point 1 to the point 4.
State 1-2 shows the isentropic compression in the compressor, so we have from Equation 4.1
(P-h diagram in figure 4.1)
Heat of Compression = h3 − h2 ……..4.1
per kg of the refrigerant (kJ /kg)
The compressor designed inlet or suction conditions i.e. state point 2 are
T2= 0 o C , P1=P2 =0.2005 Mpa (Evaporator Pressure)
4.3
Entropy, S2 = 1.765 kJ /kg
Since process 2-3 is the isentropic process so S2 = S3
Now at temperature 0 0 C and P2 =0.2005 MPa (superheated) the
h = 401.21 kj/kg
2
ρ 2 =9.54 kg/m3
S = 1.765 kj/kg
2
Saturated conditions at state point S2 are
0
T = −10 C , P = 0.200 Mpa
s s
h f =186.78kj / kg ,
h = 392.75kj / kg
g
Now at the discharge of compressor, i.e. state point 3 (superheated), the conditions are
h = 432 kj/kg
3
S3 =1.765 kj/kg
Saturated conditions of the vapors at point S3 are
0
T = 34 C , P = 0.8625 Mpa
s s
h f = 247.46 kj / kg ,
h = 416.85kj / kg
g
From equation 4.1, we have
Heat of Compression = 432 - 401.21= 30.79 kJ /kg
So from equation 4.2, the refrigerating effect
qrf = hlv − hen
qrf = h2 − h1 …..4.2
The conditions at state point 1 can be seen from the p-h chart as
h1=236 kj/kg
q = 401.21 − 236
rf
= 165.21 kj/kg
The refrigeration capacity, Qrc of the chillers can be found from the energy balance equation as
Q absorbed refrigerant = Q rejected
water
.
Q absorbed refrigerant = m × c × ΔT
w pw w
. 0
Qabsorbed refrigerant = m × c × ΔT c = 4.20kj / kg. C
w pw w pw
For factor of safety or secure design criteria, SDC♣ of the PAC-105 refrigeration system
Qrc = 45.65 kw
Note: Because chilled water is traveling to a long distance of 70 m, there might be a significant rise in
temperature of water so therefore Qrc should be taken larger than calculated
From equation 4.3, mass of refrigerant required is
4.4
Figure 4.1 Pressure-Enthalpy chart of R134a
4.5
m.r = rc .........4.3
Q
qrf
45.65
= = 0.2763kg/sec
165.2
Now calculating the capacities of the compressor, condenser, and evaporator as
W = m .r ( h 3 − h 2 ) . . . . . . . . . . . . . . . . . . . . 4 . 4
in
= 0 .2 7 6 3 (4 3 2 − 4 0 1 .2 1 )
= 8 .5 0 7 2 k w
Now calculating the capacity of the condenser with the same procedure
Q = m .r ( h 3 − h 4 ) . . . . . . . . . . . . . . . . . . . . . . . . . 4 . 5
cond
= 0 .2 7 6 3 (4 3 2 − 2 3 6 )
= 5 4 .1 5 k w
And for the capacity of the evaporator we have
Q = m .r ( h 2 − h1 ) ...............4 .6
rl
= 0 .2 7 6 3 ( 4 0 1 .2 1 − 2 3 6 )
= 4 5 .6 4 7 k w
The coefficient of performance, COP of the system can be calculated from equation 4.7 such as
refrigerating effect
COP =
ref work input
q rf h −h
= = 2 1 .........................4.7
win h3 −h2
165.21
= 5.365
=
30.79
Refrigerating capacity, or cooling capacity, Qrc, (KW), is the actual rate of heat extracted by the
refrigerant in the evaporator. In practice, the refrigeration capacity of the equipment selected is
often slightly higher than the refrigerating load. This is because the manufacturer’s specifications
are a series of fixed capacities. Occasionally, equipment can be selected so that its capacity is just
equal to the refrigeration load required.
4.4 Comparison between PAC-105 and Conventional Air-Cooled Chilling

System
Let us compare PAC-105 refrigeration system with a conventional air-cooled chilling
system with a condensing temperature of 60oC and evaporating temperature same as in the PAC-
105 i.e., -10 oC.
The Vapor compression cycle of this system is shown in the above P-h chart (Figure 4.1) with
alphabets A-B-C-D, now proceeding in the same way as above we have,
At temperature –10 oC (saturated temperature) and PA =0.2005Mpa
hA = hD = 288kj/kg
At state point B
hB = 392.75kj/kg
Now at state point C (superheated)
PB=1.6815 Mpa
B
4.6
hc = 437kj/kg
So we know that Heat of compression = hC − hB = 437-392.75 = 44.25 kj/kg
Now calculating refrigerating effect (R.E.), qrf as
q = hB − hA =392.75-288
rf
qrf =104.75 kJ / kg
Mass flow rate of refrigerant, mr. can be calculated from the relation
Qrc
mr. = Since Qrc = 45.65Kw
qrf
Now putting above we have
45.65
= = 0.4358kg/sec
104.75
m.r = 0.4358kg/sec
Heat of condensation or heat rejected in the condenser is
q = h − h = 437 − 288
cond C D
qcond = 149kj/kg
Now calculating capacities (i.e. sizes of chiller and condenser)
Qrl = mr. × qrf = 45.65Kw
Q = m.r × q = 64.93 kw
cond cond
The work input to the compressor
Win = m.r (hC − hB ) = 0.4358 ( 44.25) = 19.28 kw
Now calculating coefficient of performance, COP of the system
q 104.75
COP= rf = = 2.367
w
in
44.25
COP = 2.367
Energy use index (EUI) in KWPT (kW / ton) indicates the electric power consumption of a
refrigerating compressor per ton of refrigeration output. It is a clear and widely used energy
index.
For a hermetic refrigeration compressor as of conventional air cooled system, it can be calculated
as
3.516 × W
kw / ton= in ................4.8
q × ηisen × ηmotor
rf
3.516
=
COP
ref
3.516
= = 1.485
2.367
From table 4.1, it is cleared that the PAC-105 refrigeration system is efficient in all the aspects of
performance. It is efficiently rejecting heat to the canal water thus saving a lot of energy and
capital annually.
4.7
This was an idea in our mind before initiating this projects that, “how we can harness the
natural resources around us”? This can even cut off the dependence on the energy in the future.
Power saving in PAC-105 as compared with a conventional system can then be estimated as
w in PAC-105 − w in conventional
%age saving in power =
w in conventional
19.28-8.507
= ×100
19.28
= 55.87%
Or on another way, we can also estimate as
EUI PAC-105 -EUI conventional
=
EUI conventional
Note: where EUI is in kw/ton

1.485−.655
% age saving = × 100 = 55.89%
1.485
From above results, we can perceive that the PAC-105 is saving more than a half of energy per
unit time or annually.
Table 4.1: Comparisons of PAC-105 and a Conventional System
PAC-105 Water-Cooled Chilling System

Tcond=34 0C , Tevap=-10 0C
qrf qcond mr. * Q rc Q cond Q rl Win EUI
kj/kg kj/kg kg/s Kw Kw Kw Kw kw/ton COP

165.21 196 0.2763 45.65 54.15 45.65 8.507 0.655 5.365
Conventional Air-Cooled Chilling System

Tcond=60 0C , Tevap=-10 0C
qrf qcond mr. * Q rc Q cond Q rl Win EUI
kj/kg kj/kg kg/s Kw Kw Kw Kw kw/ton COP

104.75 149 0.4358 45.65 64.93 45.65 19.28 1.485 2.367
*Both equal capacities mean that systems are working in the same environment and at the same place.
4.5 Designing and Selection of the PAC-105 Compressor

Analytical Method: We can also approximate the power by thermodynamics relations.
The design suction and discharge conditions for the compressor are given in the following pages:
T2 = 00 C , p2 = 0.2005Mpa , mr. = 0.3038 kg/sec , h2 = 401.21kj/kg , ρ 2 = 9.8kg/m 3 ,
vs 2 = 0.10204m3 / sec , hs 2 =392.75kj/kg
Where vs2 = Sp. Volume of the suction vapor (m3 / kg), hs2 = saturated enthalpy at pressure 0.2005
Mpa i.e. evaporator pressure, (from P-h chart).
The design compressor discharge conditions are:
T3 = 480 C , p3 = 0.8625MPa, ρ3 = 40kg/m 3 , h3 = 432kj/kg, hs 3 = 418kj/kg
4.8
By using thermodynamic relations as:
γrR
c pr = ………….4.9
γ r −1
We also know that
( ) ( )
Win = m.r h3 − h2 = m.r c pr T3 − T2 or h3 - h2 = c pr T3 - T2 ( ) ………4.10
where c pr = Avg. Sp. heat at constant pressure of the refrigerant
By putting values in the Equ.4.10 we have c pr = 0.625 kJ /kg. K, since P.R. = 4.3125
Where P.R. = Pressure ratio of the compressor
By using following relation of thermodynamics we know that,
T2 ⎛ P2 ⎞
( γ r −1) / γ r
=⎜ ⎟ → γ r = 1.124
T1 ⎜⎝ P1 ⎟⎠
The value of the R (avg. Refrigerant gas constant) can be estimated from the above relation 4.19
as R=0.06937 kJ /kg, so now putting all these values in the equation 4.11 below we have
Indicated Power (I.P. ) input to the compressor as
γr
I.P = mr. R (T3 − T2 ) ...............4.11
γ r −1
1.124
= × 0.2763 × 0.06937 ( 321 − 273) = 8.34kw
1.124 − 1
So the I.P. calculated above is same as calculated graphically in the table 4.1.
As isentropic efficiency of the compressor with respect to P.R = 4.3125 is 0.85and take
mechanical efficiency as 0.96 the actual power input to the compressor can be estimated as
BHP= 13.7 hp (10.22 KW)
4.5.1 Selection of the PAC-105 Compressor
The operational and designed parameters of the PAC-105 compressor are as follows:
P.R. = 4.3125, MFR (refrigerant) =0.2763 kg/sec or VFR (refrigerant) = 101.5 m3 /hr,
With a density of the suction vapors of R-134a refrigerant from P-h chart (Figure 4.1) can be
estimated as
ρ 2 = 9.8 kg/m 3
P2 =0.2005Mpa, and P3 = 0.8625Mpa with corresponding temperatures of 0 0C and 48 0C
respectively. The reciprocating compressor is selected for PAC-105 refrigeration system, which is
matching with our requirements, is of the following characteristics:
The compressor of the PAC-105 is reciprocating air-cooled i.e. same vapors of the refrigerant are
being fed to the motor which can significantly reduce the temperature of the winding of the
motor. We have been selected the single stage compressor with four cylinders in the v-
configuration designed at a speed of 1425 with 50 Hz frequency 3-Phase.
The BOCK® COMPANY of the refrigerant compressors is a leading manufacturer in the world
which is producing all types of refrigerant compressors with HI-TECH control and reliability. So
in the following pages we shall give the selected compressor’s technical specs as given in the
table 4.2 and few of its functional characteristics.
4.9
Table 4.2: Specification of the PAC-105 Reciprocating Compressor

Number of Displacement Winding Max. Max. Max.
cylinders / 50 Hz (1450 divided working power Motor Protection Weight permissible Connection Connection
Bore / ¹/min) Voltage into current consumption Protection terminal (KG) pressure suction discharge
Stroke 1) 2) 2) 2) box HP line SV line DV
4 / 55 mm / 107,50 380- 66% / 31,0 A 15.90 kW MP10 IP 54 224 kg 28 bar 42mm - 1 28 mm - 1

49 mm m³/h 420 V 33% 5/8 " 1/8 "
Y/YY -
3 - 50
Hz PW
Oil type R134a,

R404A, R407C, Oil type R22 (R12,
Lubrication R507 R502 Oil charge Oil sump heater Manufacturer Model
FUCHS Reniso FUCHS Reniso SP 4,5 Liter 230 V - 1 - 50/60 Hz, Bock compressor inc. HA6/1240-4
Oil pump
Triton SE 55 46 80 W
-This signifies: 25 °C suction gas temperature without liquid sub-cooling
-Conversion factor for 60 Hz = 1.2
-The performance data are based on ISO-DIS 9309 (DIN 8928) with a 50Hz power supply frequency.
The model selected above for PAC-105 refrigeration system is air cooled, single stage semi-hermetic compressor. Carefully note that in the above table 4.2, the
volume flow rate of the refrigerant for PAC-105 refrigeration system is 101.5 m3 /hr, but selected compressor VFR is 107.5 m3/hr which means that the chiller
capacity may shoot up to a higher value. Such problems may normally arise in the design problems, so it is better to use always a little more capacity for safer
design.
The alternative models of the compressors are also available from various compressor manufacturers with exact VFR. So we also suggested the other types of the
compressor i.e. Refcomp® Italy inc. model no. SP- 4L2500 or just log on to www.refcomp.it for further detail.
Other mode preferred for the PAC-105 refrigeration system is of frascoled compressor®, i.e. V-25-103Y with a VFR 102.83m3/hr, for further detail see the
references.
In the table 4.3, at the various condenser and evaporator temperatures the refrigeration capacity and their corresponding power input to the compressor are given.
Carefully note that at higher condensing and evaporator temperature, the power consumption to the compressor is maximum thus lower COP. So while designing
the PAC-105 refrigeration system we have been taken all these measures in consideration. The HA6/1240-4 compressor of the PAC-105 is operating in between
these suggested limits thus saving a much quantity of the energy, which is very economical for the design.
4.10
Figure 4.2: the PAC-105 single-stage Compressor (Actual and dimensional views, dimensions
are Millimeters)
The PAC-105 compressor [HA6-1240-4] optionally can be equipped with ERC, ESS and EFC,
BCM2000 system optionally, which can enhance the functional reliability and performance of the
compressor in all the working conditions and save a lot more
Table 4.3: Capacity versus Power Consumption of the PAC-105 at various Evaporator
Temperatures
Q=Refrigeration Capacity (W), P= Power Consumption, (KW)
Evaporative Temperature Te [°C]

Tcond
[°C] 12,5° C 10° C 7,5° C 5° C 0° C -5° C -10° C -15° C -20° C -25° C -30° C
30° C Q 36844 33673 30698 27910 22866 18484 14705 11472 8725 6406 4458
P 6,44 6,21 5,98 5,77 5,37 4,98 4,62 4,26 3,89 3,50 3,10
40° C Q 33160 30273 27568 25038 20475 16524 13128 10228 7765 5682 3920
P 7,25 6,97 6,70 6,44 5,94 5,46 4,98 4,52 4,04 3,54 3,02
50° C Q 28823 26257 23862 21629 17623 14181 11244 8754 6653 4882 * 3383 *
P 8,09 7,75 7,42 7,10 6,48 5,87 5,28 4,68 4,07 3,44 2,78
60° C Q 23760 21555 19507 17610 14239 11382 8981 6979 5316 * 3934 * 2775 *
P 8,96 8,55 8,15 7,76 6,99 6,24 5,50 4,75 3,98 3,19 2,37
70° C Q 17901 16094 14433 12910 10249 8055 6268 * 4830 * 3682 *
P 9,85 9,37 8,89 8,42 7,49 6,57 5,65 4,73 3,79
4.11
energy during the part-load operation (see for further detail product brochure or log on to
www.bock.de).
The performance curves for the compressor are shown at various condenser and evaporator
temperatures showing the possible operational characteristics during the summer peak and normal
operation. In table 4.3 at different evaporator temperatures and condenser temperatures the
refrigeration capacities and their corresponding power consumption of the compressor of PAC-
105 is given, which is very important in pursuing the peak conditions in full loaded condition of
the chiller. The conditions of the loading can also be seen in the figure 4.3 and 4.4 where
compressor must perform carefully in order to avoid over heating of coils of motor and
breakdown of power.
Figure 4.3 Operating Characteristic at various Condenser (tc, 0C) and Evaporative (to, 0C)
temperatures for PAC-105 Reciprocating Compressor
The Bock software gives performance data for other operating points.
Unlimited application range
Supplementary cooling or reduced suction gas temperature *
Compressor operation is possible within the limits shown on the diagrams of application. Please
note the colored areas. Compressor application limits should not be chosen for design purposes or
continuous operation.
4.5.2 Selection of the Thermostatic Expansion Valve (TXV) for the Refrigeration
System of the PAC-105
In a refrigeration system like PAC-105 refrigeration system, the expansion valve is an

adjustable throttling device through which the refrigerant at condensing pressure is throttled to
evaporating pressure or interstage pressure. At the same time, the expansion valve regulates its
opening to feed the required amount of refrigerant to the evaporator to meet the refrigeration load
at the evaporator.
In the following pages we shall find the refrigeration expansion valve which could meet our
required capacity i.e. 45.65 KW. We have selected the thermal expansion valve (TEV) of the
standard manufacturing company i.e. like Sporlan Valve Company USA.
4.12
4.5.2.1 Operational Characteristics for PAC-105 Chilling System
Refrigerant selected: R-134a

Mass flow rate of the refrigerant, mr. = 0.2763 kg/sec
Condensing pressure, p3 = 0.8625 MPa, Condensing temperature, T3 = 34 0C
Evaporator pressure , p2 = 0.2005 MPa, Evaporating temperature, T2 = -10 0C
Refrigerant liquid entering temperature to the expansion valve = 25.55 0C
(Subcooled liquid see figure 4.1)
Degree of superheat at the suction of the compressor = h2 − h2 s = 401.21 − 392.75 = 8.46kj/kg
This is the maximum superheat value at suction of the compressor when system will run in the
peak loading conditions in the summer. Now as liquid line of the refrigerant circuit is shown in
the following figure 4.4. Let us proceed in the way that
B 3 Std.
Elbows
Filter & Solenoid Fuse plug A

Dryer valve
B Liquid
Sight Refrigerant
glass Reciever
A
Pressure
guage K-type
Thermostatic Copper
Expansion Refrigerant liquid circuit of PAC-105 system Tubing
Valve insulaton:
Subcooling Temperature of Liquid : 25.55 0C
Nitrile
foam with
Ducts
Insulation
Tape
Figure 4.4 Liquid-line Circuit of the PAC-105 Refrigeration System
Now at section A-A:
L = 10 ft (Designed length from condenser to receiver as shown in the figure 4.6)

D = 28 mm and Net flow diameter Di = 25.27 mm, (K-type copper tubing)
Total accessories in the section A-A = 2 std. Elbows = 28 mm
Velocity of the liquid refrigerant in the section A-A = Vr A-A = 0.459 m/sec (90.349 FPM)
From table
The equivalent length of the elbow
= 2 × 2 = 4 ft.
Total length of section A-A = 10 + 4 = 14 ft.
Head loss = 1.25 ft / 100 ft
So total loss in section A-A = 1.25 × 14 × 1/ 100 = 0.175 ft. of water
Now at section B-B:
L = 0.82 ft. (250 mm)

D = 22 mm, Net flow diameter = 18.92mm (K-type copper tubing)
Velocity of the refrigerant in section B-B = 0.818967 m/sec (161.17 FPM)
Since by using figure
4.13
3 Std. Elbows 3 × 1.55 = 4.65 ft

1 Solenoid Valve* 1 × 0.95 = 0.95ft
1 Sight glass 1 × 1.55 = 1.55ft
1 Dryer & Filter 1 × 10 = 10 ft
Total equivalent length 17.15 ft
* Since this valve is acting as a gate valve during the normal operating mode of system so we are taking the loss the
gate valve with the corresponding data of the section B-B
Total length T.L. = 0.82 + 17.15 = 17.97 ft ≈ 18 ft
So now calculating head loss from the chart per 100 ft of the length as:
= 18 × 4.4 / 100 ft = 0.792 ft. of water
So now the total pressure loss of the accessories and fitting of both the sections as given below:
Δp* = Δ pA− A + Δ pB − B
= 0.175 + 0.792 =0.967 ft.w
Δ p * = carefully we are mentioning here that this the total pressure loss of the liquid flowing
through the copper K-type tubing, this is pressure drop of the water not for the R-134a liquid
refrigerant of the PAC-105 system. since this is clear to us that the pressure drop in any flow
system is strong function of the shape, fluid velocity, material of the conduit. So as at subcooling
temperature of 25.55 0C, the R-134a refrigerant has the density of the 1200 kg/m3 as compared
with the density of the water as 1000 kg/ m3. Other corresponding properties can be found from
the table given in the Appendix A for R-134a. We could multiply this pressure drop by a
correction factor (CF) equivalent to the specific gravity (Sp. gr.) of the R-134a at temperature of
25.55 0C, that is
C. F. = 1.2
So now total pressure drop for the R-134a liquid refrigerant is = 1.2 × 0.967 = 1.1604 ft. w
So now estimating the capacity of the TEV as
Design evaporator temperature . . . . . . . . . . . ..14°F

Design condenser temperature . . . . . . . . . . . . 93 °F
Refrigerant liquid temperature . . . . . . . . . . . . 78 °F
Design system capacity . . . . . . . . . . . . . . . . . 12.98 ton
Available pressure drop across TEV:

Condensing pressure (psig) . . . . . . . . . …….125.095
Evaporating pressure (psig) . . . . . . . . . . ….. 29.08
Liquid line and accessories loss (psi) . ….. . – 0.5
Net total pressure (psi) 95.515 (0.6585527MPa)
By using tables from 4.3 a to 4.3 c, we can estimate the capacity of the TEV for PAC-105
refrigeration system by relation given below:
TEV Capacity = TEV rating x CF liquid temperature x CF pressure drop……4.12
4.14
Where CF = correction factor for liquid temperature entering to the TEV and pressure drop in
across the TEV.
Now proceeding in the following way as:
Table 4.4a: Thermostatic Expansion Valve (TEV) Capacities for Refrigerants (R-134a)
4.15
Table 4.4b: Recommended Thermostatic Expansion Valve Charge for R-134a
Since our PAC-105 refrigeration system is a commercial refrigeration system with evaporating
temperature as 14 0F, we shall use charge for TEV bulb as JC see the table 4.4b.
So hence from the table 4.3a, corresponding to the refrigerant R-134a and nominal capacity of 12
ton, evaporator temperature 20 0F, TEV charge JC the TEV capacity is given as
TEV capacity = 14.0 ton
CF for Liquid temperature entering TEV corresponding to 80 0F = 1.14
CF for pressure drop across TEV corresponding to 100 psi and evaporator temperature 14 0F =
1.12
Now calculating the capacity of the TEV by using above relation given in the equation 4.12, so
we have
*TEV = 14.0 × 1.14 × 1.12 = 17.8752 TR
*So this is true TEV estimated capacity for the PAC-105 refrigeration system for R134a expansion device with a least
error of 10%.
Table 4.4c: Specification of the H-type TEV for Refrigerants (R-134a)
4.16
So now selected valve corresponding to the refrigerant R-134a and operating parameters
is given below:
HJE - 12 - JC - 7/8” × 1-1/8” × 1/2”ODF × *8”
HJE – H-type body with external equalizer i.e. E letter at the end shows that this valve uses
external equalizer if this letter E comes H then the valve is internally equaled see for further detail
the references at the end of the thesis
J—color coding letter of R-134a (Blue)
12 – Nominal capacity of TEV in tons
7/8”—inlet connection in inches ODF
1-1/8”—outlet connection in inches ODF
1/2”—external equalized connection in inches ODF
8”—length of the capillary tube in feet
ODF Solder indicates a female connection on the valve of proper diameter to receive copper tubing of corresponding
OD size. Thus, 7/8” ODF will receive 7/8” OD tubing.
* Since the recommended length of the capillary tube for the TEV selected is 5 ft, we are recommending the 8 feet
length as per suggested by the experts and valves manufacturers.
The selected PAC-105 TEV is given in the figure 4.5 and material detail and construction is given
in the table 4.4 as:
(a) Cross-sectional View of PAC-105 TEV (b) Accessories & Fittings
Figure 4.5 PAC-105 TEV (a) Cross-sectional View (b) Assembled View & Accessories
4.17
Table 4.5: Material Detail and Construction of the PAC-105 TEV
Valve Body Seat Pin Pin Pushrod Type Connection Inlet

Type Carrier Of Strainer
Joints
Knife
H Machined Stainless Stainless Brass Stainless Edge At Solder Coarse
Brass Bar Steel Steel Steel Element Flange Mesh
And Strainer
Bottom Disc
Cap
Gasket
At Seat
Cap
Note: Courtesy of the Sporlan Valves Company USA, the authors are using the material provided by the sporlan
despite of knowing the local availability of the this product, so simply alternative product on this place can be used
after redefining the calculation and conditions that were taken in the design of this product for the PAC-105
refrigeration system.
The complete assembled view of the PAC-105 chilling system is shown in the figure 4.6 here
that is clarifying the thermostatic expansion valve circuit. The figure 4.6 is a true illustration of
the PAC-105 system after manufacturing of this particular product (see also units 5 and 6 for
complete overview of the PAC-105 refrigeration system).
4.18
Vapors to Condenser
Check Valve
Superheat
Fuse Plug Sensor
Solenoid Valve
Refrigerant Reciever
Sight Glass Through-type, Hi Working Pressure
8.625MPa, Temp. 25.55oC Liquid Line
TEV PAC-105
Reciprocating Water
Chiller Cap. 13TR
Purging Valve
Figure 4.6 The PAC-105 Water Chiller Refrigerant Circuit (An assembled view)
In the above illustration of the figure 4.6, the compressor is HG4-465-4 of the Bock compressor® so it is important to realize at this stage, don’t get confuse from the illustration.
Because actually the model of the compressor is HA6-1240-4 of the same manufacturer’s company (see Table 4.2).
4.19
At the Compressor Suction End i.e. State Point 2:

1. It is impossible to connect the suction pipe to the compressor suction with providing any
extra length or mechanical freedom i.e. it is practically difficult to place a compressor
just after the evaporator coils without providing any extension or extra pipe length.
Provision should be made to reject a considerable part of the degree of superheat at the
suction end of the compressor ( h2 − hs 2 ) say 90 % must be inside the evaporator coils of
the chiller, because this is conducive towards the refrigeration system performance.
Since saturated vapors leaving from the evaporator coils before reaching to the
compressor chamber has a temperature of 0 0C, so there is a significant temperature
gradient between the refrigerant and chilled water leaving the chiller, such of the heat can
be rejected to the saturated vapors while changing them to superheated vapor at the
suction of the compressor. If let us assume that, the 90% degree of superheat (DSH) is
made to reject inside the evaporator coils, then the COP becomes
0.9 DSH 90% + hs 2 − h1

COP 90% =
win …….1.13
where 0.9 DSH 90% = 0.9 ( h2 − hs 2 )
Now above equation can also be written in the form as
0.9 ( h2 − hs 2 ) + hs 2 − h1 0.1hs 2 + 0.9h2 − h1

= = ….4.14
win ( h3' − h2 )
90%
(
Since h3' − h2 ) 90%
= ( h3' − h2 ) , because there is no change in the pressure ratio but only
the change in the entropy.
0.1( 392.75 ) + 0.9 ( 401.21) − 236

COP 90% = = 4.356
( 438.94 − 401.21)
It is clear above that the COP calculated above at 90% degree of superheat rejected into
the chiller coils is less than the ideal value of COP for PAC-105. This is the fact that all
heat does not reject into the evaporator coils, this is virtually possible if we made an
evaporator of infinite length.
2. Superheating inside the tubes is somewhat more economical and increase the life of the
compressor but large superheating inside the tubes will decrease the volumetric
efficiency of the compressor, because less volume of the refrigerant will enter into the
chamber of the compressor due to increase in the specific volume of the refrigerant
vapors. It may reduce the capacity of the refrigeration system of the chiller at full
compressor loading conditions. This situation can be well perceive by the following
mathematical impression as
4.20
m.r × vs 2
Vr. = .............4.15
ηv
where vs2 = specific volume of the suction vapors
Vr. =cylinder displacement volume in m3/sec
VD 60Vr.
=
cycle N ×ηv
also
VD × N ×ηv
Vr. = ..........4.16
60
Now equating equations 4.15 and 4.16, by taking volumetric efficiency as 1 we have
.
VD × N ×ηv mr × vs 2
= Q ηv = 1
60 ηv
60mr. × vs 2
VD = .........4.17
N
whereN = revolution per minute of crank shaft
VD = cylinder displacement volume in m3
So now it is very clear from the Equ. 4.17, that for a given rpm and mr. cylinder
displacement volume is directly proportional to the specific volume, it means that for
maintaining desired mr. , either we must increase the revolution of the crank shaft or we
must reduce the specific volume of the suction vapors. Or in other way for delivering
designed mr. , (in order to meet the refrigeration capacity of the chiller), we must increase
the dimensions of the compressor i.e. diameter, stroke length, which is again a loss of
energy due large friction between the cylinder wall and the piston-liner.
3. Carefully noting at the suction side i.e. state point 2, the higher the super heat
(i.e. h2 − h2s ) higher is the specific volume of the refrigerant vapors as given by the Equ.
4.15, which means large should be the size of the compressor in order to maintain the
desired cooling capacity of the system or on the way other consumption of more electric
energy and adverse economics of the system. one thing also noting at this stage that for
very lower evaporating temperature the evaporating pressure is too low than the
surroundings so greater drop should be needed across the TEV, it is controversial that
specific volume of the vapors are low and hence less VFR of the refrigerant is needed as
given by the Equ. 4.15 so small is the size of compressor but practically it is not a true
statement, therefore a sophisticated design is needed.
At Compressor Discharge End i.e. State Point 3:

4. From the p-h chart which is shown in the figure 4.1, that the state points 3 and 4
represents the inlet and outlet conditions for the condenser ideally. In the actual practice
it is impossible to place a compressor at just close to the condenser, so degree of
superheat (see figure 4.1) at the discharge end of the compressor given by
4.21
(h'
3 − hs 3 ) shows that, if it is possible, provisions should be made to reject as much as
possible this must be rejected in the hot-gas line before entering into the condenser into
condenser coil, because this is very conducive towards refrigeration system performance,
it also minimize the cost of the condenser.
5. At the discharge of the compressor the refrigerant temperature is 48 0C, which is greater
than the ambient temperature, Tamb (43 0C, this is designed temperature at the location of
the hall in the summer at Day 21 July), and the channel water temperature as 15 0C, so
heat degree of superheat at the discharge must be removed partially in the ambient air
through convection till thermal balance, then whole of the heat must be removed in the
channel water to a saturated temperature i.e. 34 0C.
6. In actual practice, pressure drop occurs from the discharge pressure (0.8265MPa),
because of the friction present inside the tubes, higher vapor velocity in narrower tubes
etc, so therefore it is important at this stage to realize that pipe length and size should be
carefully optimized so that a small variation in pressure results. Rejecting heat inside the
condenser is more economical, but greater pressure drop is expected in case of
multipass/multitubes condensers as in PAC-105 condenser.
7. The pressure drop inside the tubes may be estimated by darcy-wiesbach Equation (se
reference at the end), let us say it is denoted by p f , then net pressure at the TEV
(thermostatic expansion valve) is
p4' = p −p
disf
'
So p4 is the pressure at the TEV, which is less than the pdis by an amount of p , so
f
'
therefore now refrigerant subcooled liquid is allowed to expands from p4 to p1 , this will
significantly reduce the temperature of the refrigerant after expansion.
8. We can slightly minimize the pressure drop inside the condenser by rejecting much
portion of the heat into the discharge pipe, if condenser is multipass, multi-circuit as that
of shall and tube type condenser. Minimizing pressure drop can be conducive towards
refrigeration system performance. The heat rejection can be estimated by the Dittus
boelter equation as
hi Di
Nu = = 0.023Pr n Re0.8
D …………..4.18
Ki
Inside the tubes and outside the tubes some empirical relation can be found from the
Handbook of Heat Transfer, with an average velocity of the wind and direction in the
summer.
9. The state point 4 for the refrigerant is not inside the condenser coils. In the actual
conditions it is just before the thermostatic expansion valve, TEV as shown in the figure.
The refrigerant is subcooled at state point 4, its temperature is 25.55 0C. The subcooled
liquid refrigerant (T4 =25.55 0C) is much less than the atmospheric temperature (43 0C),
so the liquid line coming out of the condenser should be well insulated including
receiver, TEV, and chiller tank.
10. After expansion in the TEV, the refrigerant is partially liquid and partially vapors as seen
in the figure 4.6
x1 =
( h1 − hs1 ) = h1 − hs1 ………….…..4.19
( hs 2 − hs1 ) h fg1
4.22
So amount of vapors entering into the chiller are
n = x1m.r = 0.2763 x1 → kg/sec …4.20
If the external equalizer is used as shown in the Figure 4.6, which is used to extract these
vapors from the liquid-line before entering into the chiller coils after expansion. Because
these vapors will get superheated in the very initial length of the evaporator coils of the
chiller and occupy whole of the space of the chiller tank which neither add useful cooling
but also increase the risk of leakage of the refrigerant, which is very dangerous and
detrimental to the system and environmental safety.
Now net refrigerating capacity of the chiller is evaluated as follows
Qrc net
= (1 − x1 ) mr. ( h2 − h1 ) 90% …..4.21
Work input to the compressor is
Win = mr. ( h3' − h2 ) Q ( h3' − h2 ) = ( h3' − h2 )
90% 90%
So
(1 − x1 ) mr. ( h2 − h1 ) 90%
COP actual = ……………4.22
mr. ( h3' − h2 )
Where
( h2 − h1 ) 90% = 0.9 ( h2 − hs 2 ) + hs 2 − h1
Here
h2 at 90% is = 0.9 ( h2 − hs 2 ) + hs 2
Now calculating actual power input to the compressor as
Win = mr. ( h3' − h2 ) ×ηv−1 = 0.2763 ( 439.7 − 401.21) × 1.176 = 12.51kw
Now refrigerating capacity of the chiller on an idea of 9 can be calculating as

Using Equ.4.19, the quality of refrigerant after expansion is
Since h1 = 236 kj/kg, hs1 = 186.78 kj/kg, hs 2 =392.75 kj/kg
236 − 186.78
x1 = = .239
392.75 − 186.78
Now COP actual can be calculated by using Equ. 4.22
(1 − 0.239 ) 0.2763 × ⎡⎣0.9 ( 401.21 − 392.75) + 392.75 − 236 ⎤⎦

COP actual =
12.26
0.21026 (164.364 )
COP actual −PAC-105 = = 2.8189 ; 2.82
12.26
4.23
From Equ.4.22, it is evident that if after expansion in the TEV there is all liquid
refrigerant (i.e. x1=0), so then COP calculated above will be same as calculated from
equation 4.7 by neglecting 90% heat of superheat at suction end i.e. ( h2 − hs 2 ) rejected
inside the evaporator coils. Practically such a system cannot be manufactured because
subcooling of in any condenser coils cannot be met to a large extent i.e. sate point 4
should lie far beyond the saturated liquid line on the left of p-h chart, so that after
expansion of the refrigerant the state of the refrigerant should be liquid (i.e. point S1).
Explaining in a way other, condenser coils should be infinite long, which is no doubt is
impossible in actual practice so COP calculated from Equ.4.22 will always be less than
COP calculated from Equ.4.7 i.e.
COP 90%−actual < COP Hypothetical
COP 90%−actual
≅ 0.50 − 0.60
COP Hypothetical
So the actual COP will always be less than the COP calculated hypothetically from the p-
h chart due to various reasons discussed above from 1 through 9.
Dr. Riaz Ahmad Mirza [Chairman: Mechanical Engineering Department, UET Lahore],
said in a meeting with us that the actual COP of any refrigerating system is always about
half (50-60%) of the hypothetical COP as calculated in section 4.3 It has been proved
above in 9 that how this COP is half than the hypothetical one?
11. As compared to compression ratio of 4.3, the isentropic efficiency and the volumetric
efficiency of the reciprocating compressor (From standard Tables of Reciprocating
Compressors given by the ASHRAE Handbook, see in the Key-references), are
ηisen = 0.80, ηv = 0.85
We know that from the relation given below, the standard leaving conditions of the
superheated vapors from the compressor discharge by ignoring the pressure drop in the
evaporator tubes as
mr. ( h3 − h 2 ) ( h3 − h 2 )
ηisen = =
mr. ( h3' − h 2 ) ( h − h2 )
'
3
0.80 =
( 432 − 401.2 )
(h '
3 − 401.2 )
h3' = 439.7kj/kg
So now actual discharge temperature of the superheated vapors leaving the compressor is
rather than 480 C so with this situation actual load on the condenser may vary slightly i.e.
condenser duty etc. but in case of PAC-105 refrigeration system, the source available for
rejecting heat is at very low temperature, so system capacity does not shoot-up suddenly.
4.24
PAC-105
Unit 5
Design of
PAC-105 Water- BOCK Germany
Chiller
PAC-105
Reciprocating Water
Chiller
Introduction
T he chiller is a major component of any commercial air conditioning

system. In domestic air conditioning systems it is replaced by an
evaporator. In commercial air conditioning systems its function is to
generate a continuous supply of secondary refrigerant (water or any other) at
a desired temperature. It involves the boiling of refrigerant in the tubing or in
a shell, depending upon its configuration. Design of water chiller involves
selection of an appropriate configuration, and determination of required heat
transfer area for attaining the desired temperature and flow rate of liquid,
which is being chilled.
This unit presents the various types of chillers, with emphasis on
PAC-105 chiller. In the forgoing sections of this unit, using convection
correlations developed by Rohsenow, boiling heat transfer convection
coefficient will be found for pool boiling of R-134a in chiller shell. Then
using Dittus-Boelter Convection correlations, heat transfer coefficient will
be found for liquid (water) being chilled in the tubes bundles. Finally the
overall heat transfer coefficient will be determined for flooded liquid chiller
of PAC-105 leading to the calculation of required heat transfer area.
The hydronic system associated with this unit i.e. chilled water
transportation from the chiller to the AHU coils, piping design and pump
will be discussed in the unit 7.
5.1
Unit 5: Design of PAC-105 Water Chiller
5.1 Chiller and Its Types
C hiller is a device (also called liquid cooler) which is used to generate a continuous supply
of cooling fluid, (often called secondary refrigerant)that is directed towards the cooling
coil of air handling unit or fan coil unit depending upon the configuration and size of the cooling
equipment. The term chilling differs from that of cooling in this sense that, chilling means the cooling
up to temperature of the order 3 or 4 oC .Practically various configurations are used for liquid chillers,
mostly the followings are used.
5.1.1 Direct-expansion Liquid Cooler
In a direct-expansion liquid cooler (shown in Figure 5.1), liquid refrigerant evaporates

inside the copper tubes while chilled water fills the shell. An expansion valve and sometimes a
distributor are used for each group of refrigerant circuits connected to the same suction header
and compressor. In a direct-expansion liquid cooler, various inner surface configurations and
enhancements are used to increase the boiling heat transfer. To provide optimum velocity and a
higher rate of heat transfer on the water side of the liquid cooler, baffle plates are used to guide
the water flow in the shell in multipass arrangements.
Direct-expansion liquid coolers are usually used for refrigerating systems equipped with
multiple compressors. In a direct-expansion liquid cooler, refrigerant circuits may be connected to
a single header and compressor or to two separate headers and multiple compressors
Figure 5.1 Cut-way View of a Typical DX Liquid Cooler
5.1.2 Liquid Overfeed Cooler

A liquid overfeed cooler can be an air cooler or a liquid cooler. Liquid refrigerant is fed
to multiple evaporators by a mechanical pump or by a gas pump using the high-pressure gas
discharged from the compressor. Liquid refrigerant is fed at a mass flow rate 2 to 6 times greater
than the actual evaporating rate, which causes liquid recirculation, as shown in Figure5.1b. Liquid
recirculation pro vides a sufficient volume of liquid in the tubes and ensures that the inner surface
of the tubes is fully wetted throughout its length.
Compared with DX coils, liquid overfeed air coolers have the following advantages:
5.2
• They have higher heat-transfer coefficient on the refrigerant side, eliminating the decline of the
heat-transfer coefficient at the dry out area when the quality of the refrigerant is raised to 0.85 to
0.90 in a DX coil.
• They allow nonuniform loading between refrigerant circuits or between evaporators, so that
none are starved, with insufficient refrigerant supply.
• Air-refrigerant temperature difference is lower, which is especially beneficial for low-
temperature systems.
• Evaporators can be conveniently defrosted. Their main disadvantage is their higher initial cost.
Figure 5.2 Liquid Overfeed Cooler Using A Mechanical Pump.
5.1.3 Flooded Liquid Cooler

Most medium-size and large liquid coolers are shell-and-tube flooded liquid coolers. In a
flooded liquid cooler, several straight tubes are aligned in a parallel staggered arrangement,
usually held in place at both ends by tube sheets, as shown in Figure5.3a. Chilled water circulates
inside the tubes, which are submerged in a refrigerant-filled shell.
Liquid-vapor refrigerant, usually at a quality x around 0.15 in air conditioning
applications, is fed into the bottom of the shell. It is evenly distributed over the entire length of
the tubes. As the refrigerant boils and bubbles rise, the upper part becomes increasingly bubbly.
Vapor refrigerant is discharged from the opening at the top of the cooler. A dropout area, or
eliminator, is sometimes installed to separate the liquid refrigerant from the vapor. The amount of
refrigerant fed to the flooded liquid cooler is controlled by a low-pressure-side float valve, or a
multiple-orifice throttling device.
When halocarbons are used as the refrigerants, copper tubes are always used because they
provide higher thermal conductivity and do not react with halocarbons. Tube diameters of 3/4 and
1 in. (19 and 25 mm) are often used, such as either internally enhanced copper tubing of 1-in.-
(25-mm-) diameter or smooth bore of 3/4-in. (19-mm) diameter, and the number of tubes inside
the shell varies from 50 to several thousand. Integral fins are extruded on the outer surface of the
tubes to increase the outer surface area. Other tube geometry on the outside surface is also used to
Enhance the boiling heat-transfer coefficient, especially to coupling of a high-voltage and low
current electric field with the fluid field called electro-hydrodynamics, and the boiling and
condensing heat-transfer coefficient may be increased in excess of tenfold.
Possible water flow arrangements in flooded shell-and-tube liquid coolers are shown in
Figure5.3b. A one-pass arrangement has the highest chilled water flow rate, two-pass has a lower
rate, and three-pass has the lowest chilled water flow rate. The two-pass water flow arrangement,
with the water inlet and outlet on the same side, is the standard arrangement. Performance
analyses showed that there is no significant difference between a two-pass arrangement with the
water inlet and outlet located side by side and one with the inlet at the bottom and outlet at the
5.3
top. Water velocity inside the copper tubes is usually between 4 and 12 ft/s (1.2 and 3.6 m/s);
water velocity exceeding 12 ft/s (3.6 m/s) may cause erosion. Water-side pressure drop is usually
maintained at or below 10 psi (70 kPa) to optimize pump energy consumption. Because of the
greater flow passage for refrigerant within the Shell, the pressure loss on the refrigerant side is far
lower than the pressure loss in DX coils.
(a)
(b)
Figure 5.3 (A) Schematic Diagram of Flooded Liquid Cooler. (B) Passages of Water Flow
5.2 Flooded-liquid Chiller of PAC-105

Previously we have discussed various types of water chillers. For PAC-105 a flooded
liquid chiller will be used. Actually it is a shell and tube chiller with bundle of tubes enclosed
in a cylindrical shell. Total 50 no. of copper tubes will be used. After a while refrigerant side
of tubing gets scaled, reducing heat transfer coefficient, hence reducing the heat transfer area
of chiller therefore no fins on inner or outer side of tubes will be used. The flow arrangement
of water will be two pass, as shown in figure 5.3b, which means that there will be 25 tubes in
each pass. The shell of chiller can be made of any material which do not reacts with
refrigerant R-134a.chiller can be made in single piece or can be constructed with removable
ends, called heads. For PAC-105 bolted ends configuration will be used. The reason of
choosing bolted configuration is that, it is easy to clean and allows the replacement of
individual tube.
As mentioned earlier R-134a will be used as refrigerant in PAC-105 water chiller. The duty
of chiller will be to generate a continuous supply of chilled water at the rate of 0.91
kg/sec.The temperature of water leaving the chiller will be 4 o C .After leaving chiller tubing,
5.4
chilled water will travel in a 70m long PVC pipe, well insulated and placed in a small
underground channel. After this, chilled water will circulate through cooling coil of air
handling unit with temperature rise of 8 o C then again traveling in a 70m long PVC pipe,
water will enter in chiller tubing at 16 o C .Again chilling will be performed by chiller and
water will leave chiller at 4 o C , thus completing a cycle. Hence chiller will drop the
temperature of water by 12 o C . The arrangement of tubing for PAC-105 will be reverse as
that shown in figure 5.3a
That is, warm water coming from air handling unit coil will first enter in the bundle of copper
tubing placed in the upper compartment of shell and then after passing through lower bundle
of tubes (Dipped in saturated liquid refrigerant) leaves the chiller shell, thus making a
counterflow arrangement. The advantage of using such an arrangement is that, warm water
first comes in contact with superheated vapors of refrigerant, as water moves forward it loses
heat and gets cooler and cooler, thus providing a more efficient arrangement and better heat
transfer area.
5.3 Design of PAC-105 Flooded Liquid Chiller
Known Parameters
Refrigerant used R-134a

Evaporating temperature of the refrigerant = -10 o C (From unit 5)
Temperatures of water entering in chiller = 16 o C (From unit 4)
Temperatures of water leaving the chiller = 4 o C (From unit 4)
Required mass flow rate of chilled water = 0.91 kg/sec (14.5 GPM approx.) as discussed
in unit 4.
Properties
All properties of refrigerant are evaluated at evaporating temperature (-10 o C ) from table
B-3.
All properties of water are evaluated from TableB-2 at mean temperature of water
Tw,i +Tw,o 16 + 4
T
w,m
= = = 10 o C
2 2
Design Calculations
The steps in design procedure are as under.
5.3.1-Determinition of Amount of Heat Rejected by Chiller
To determine the amount of heat rejected from water by chiller to provide desired
mass flow rate and temperature conditions, using thermal balance analogy
Q = mw. C pwΔTw
mw. = Mass flow rate of water = 0.91kg/s

Q=Total amont of heat rejected by chiller in kw
5.5
C pw = Specific heat of water = 4.18 kJ/kg.k
ΔTw = change in temp of water= (16-4 ) =12 o C

Putting values in above relation
Q=0.91× 4.18 × 103 × 12 = 45.65kw
Also well known relation for heat transfer for any type of heat exchanger is
Q = U × A × ΔTlm
Where,
U =Over all heat transfer coefficient w/m2.k
A=Total heat tansfer area required m2
ΔTlm = Log-mean temperature difference K
To find the required surface area of chiller, we need U and ΔTlm , now we proceed to find the
value of overall heat transfer coefficient U, ass under,
5.3.2-Determinition of Over All Heat Transfer Coefficient U0
The expression for over all heat transfer coefficient is of the form, [a]
ln ⎛⎜ ⎞⎟ R
D
1 1 1 d f ,i R f ,o
= + + ⎝ ⎠+ +
Ui Ai hi Ai ho Ao 2π kL Ai Ao
Whereas, L is total required length of tubing, k is conductivity of copper = 400 W / m.k ,

d=10mm and D=12.7mm are inner and outer diameters of tubing. R f ,i , R f ,o are the fouling
factors of inner and outer sides of tubing.
In 1982, ASHRAE Journal published research results on the fouling of heat-transfer
surfaces such as evaporators and condensers in air conditioning. The study showed that with a
certain water treatment and in the absence of biological growth and suspended particulates, long-
term fouling did not exceed (0.000035 m2 K/W) and short-term fouling did not exceed (0.000018
m2 K/W).
The Air-Conditioning and Refrigeration Institute (ARI) Standard 550-88 specifies the
following:
Field fouling allowance (0.000044 m2 K/W) ARI Rating Standard (new evaporators and
condensers) thus,
R =0.000044 m 2 . k/W (for refrigerant side)
f ,o
R =0.0001 m .k/W
2 (for water side[a])
f ,i
And U i is the over all heat transfer co-efficient based on inner side of tubing, because inner side
is exposed to higher temperature.
Now modified form of above expression is as under,
ln ⎛⎜ ⎞⎟
D
1 1 1 d ⎝ d⎠ d
= + × + ×d + R f ,i + ×R f ,o
Ui hi ho D 2k D
5.6
Now we have all of the values in above relation for overall heat transfer coefficient except hi and
ho which are heat transfer coefficients for inner (water side) and outer (refrigerant side) sides of
tubes. Therefore to find U first these values must be known. Now we shall find these values one
by one.
5.3.2.1 -Determination of Water-side Heat Transfer Coefficient
As 25 tubes are used in each pass, therefore mass flow rate of water entering in chiller will be
divided into 25 parts, therefore mass flow rate of water through each tube of chiller is
m.w 0.91
pipe
m.w = = = 0.0364kg/sec
per tube 25 25
Where,
m.w = total mass flow rate of water entering in chiller kg/sec
pipe
m.w = mass flow rate of water in each tube of chiller kg/sec
per tube
.
4 mw
Now Reynolds’s no of water flowing in each tube of chiller is Re w =
π d μw
Where μ w is viscosity of water, and is
−3 Pa.sec
μ w = 1.31 × 10
Putting values we get,
4×0.040
Re w =
π ×0.0102×1.31×10−3
Re =3468.48
w
As
Re w ? Rec (critical Rynolds no)
Rec = 2000 for fluids flowing inside a pipe
Therefore flow is turbulent, thus using Dittus-Boelter relation [g] for Nusselt no. for turbulent
flow inside the circular pipes.
4 1
Nu = 0.023 ( Re ) 5 Pr 3
(Water flowing inside the chiller tubes is being cooled; therefore exponent of Pr is taken as 1/3.)
Now
1
4 ⎛ C pw μw ⎞ 3
Nu = 0.023 ( Rew ) 5 ⎜⎜ ⎟
⎝ kw ⎟⎠
All values are taken from table B-2
k w = 0.586W / m.K
C pw =4.18×103 J / kg .K
μ w = 1.31× 10−3 Pa.sec
5.7
Note: The properties not directly available from table are found by using interpolation technique.
Putting all values in above relation we get,
hd
Nu = i = 30.59
kw
30.59×0.586
hi = = 1754.43 W/m2 .K
0.0102
5.3.2.2 Determination of Refrigerant-side Heat Transfer Coefficient
For finding refrigerant side heat transfer coefficient, first we will predict that which type
of boiling is involved. For this we check the temperature difference between tubing surface and
saturated liquid refrigerant (also called excess temperature ΔTe )
ΔTe = Ts − TSAT =10 o C -(-10 o C ) =20 o C
As ΔTe =20 oC Therefore, condition of nucleate pool boiling [h]prevails
Hence using Rohsenow correlation [h] for nucleate pool boiling in shell (outside the tubes),
3
⎡ g ( ρl − ρv ) ⎤
1/ 2 ⎛ C ΔT ⎞
⎜ p ,l ⎟
qs′′ = μl h fg ⎢ ⎥ ⎜ ⎟
⎣ σ ⎦ ⎜ Cs , f h fg Pr nl ⎟
⎝ ⎠
All properties are evaluated at evaporating temperature (-10 o C ) of refrigerant. From index B-3
and are as under,
ρl = density of liquid refrigrant =1325.6kg / m3
ρv =density of vapor refrigrant =10.04kg / m3

kl =conductivity of liquid refrigerant = 98×10−3 W / m.k
μl = viscosity of liquid refrigerant =326.3×10−6 Pa.sec
C p,l =specific heat of liquid refrigerant =1.306 KJ / Kg.K
σ v =surface tension of vapor refrigerant =13.16×10−3 Pa.sec

h fg =specific enthalpy of vaporization of refrigerant =206 kJ / kg
g =gravitational acceleration=9.81m/sec2
The coefficient C s , f and the exponent n depend on the surface—liquid combination.Piret and
Isbin [i] have found the value of C s , f for the CC14-copper combination as 0.013. The same
value can also be used for copper and R 22 and other fluorocarbons. And the value of n
corresponding to 0.013 is given as 1[h].Same values will be used for copper and R-134a
combination in calculation procedure. So putting values in above relation, and solving for heat
flux, we get
q ′′ =739.562 KW / m 2
Now using relation for Newton’s law of cooling [h]
(
qs′′ = h Ts − TSAT )
qs′′ 739.562×103
ho = = = 36978 W / m 2 .K
(Ts −TSAT ) 20
5.8
So 2
ho = 36978 W / m .K
Putting all values in above relation for overall heat transfer coefficient and Solving we get,
U i = 1360.40W / m 2 .K
5.3.2.3 Finding Logarithmic Mean Temperature Difference (LMTD)
Using relation for log-mean temperature difference of a counterflow chiller/heat exchanger, [e]
ΔT =
(Tr −Tw,i )−(Tr −Tw,o )
lm ⎛ T −T ⎞
ln⎜ r w,i ⎟
⎜ Tr −Tw,o ⎟
⎝ ⎠
Where,
Tr = Evaporation (saturation) temperature of refrigerant = -10 o C
o
T = temperature of water entering the chiller = 16 C
w,i
Tw,o = temperature of water leaving the chiller = 4 o C
Putting values in relation for Logarithmic Mean Temperature Difference
ΔTlm =
⎛ T −T ⎞
ln⎜ r w,i ⎟
⎜ Tr −Tw,o ⎟
⎝ ⎠
( (−10)−16 )−( (−10)−4 )

ΔT =
lm ⎛ ( −10)−16 ⎞
ln ⎜ ⎟
⎝ ( −10)−4 ⎠
−26+14 −12
ΔTlm = = =−19.38 o C
⎛ -26 ⎞ 0.619
ln ⎜ ⎟
⎝ -14 ⎠
(Negative sign shows the direction of heat flow towards the inner side of piping, we will use the
magnitude of temp. difference only).
5.3.2.4 Determination of Required Surface Area and Length of Tubing
Using appropriate form of relation for heat transfer as discussed above,

Q = U i A(ΔT )
lm
Thus, the required area is,
Q 45.65×103
A= = = 1.7315m 2
Ui ×( ΔTlm ) 1360.40×19.38
This is the total surface area of tubes array. It can also be written in other form as follows,
Total Surface area=A = Surface area of 1 tube × total no. of tubes

Thus,
Total Surface area =A = π dl × (no. of passes × tubes/pass)
Total Surface area =A = π dl × (2 × 25)
5.9
Where, l = length of each tube in m
Hence, now the corresponding length of tubing is,
A
l=
π ×d ×50
Here, the reason of using d (inner diameter of tubing) and not D, in area calculations is that, the
value of heat transfer coefficient is based on the inner area of the chiller tubing.
Now putting values,
1.7315
l= = 1.08 m
π ×0.0102×50
To account for load variations and design safety, we select
l = 1.20 m
Table 5.1: The PAC-105 Water Chiller Capacity Chart.
Chilled Effective
Water Tube Designed Number
Capacity Temperature Area No. of Of
Model Kw GPM In Out Refrigerant m2 Pass Tubes Type†
0 0
C C /pass
PAC- Reci-
FC-1.2 procating
45.65 14.5 14 4 R134a 1.7315* 2 25 Flooded-
type
† The chiller is horizontally placed, with drain or purge out system placed beneath the cooler body. The chiller is
insulated with standard insulation i.e. nitrile foam. For the power input to the compressor see the capacity table in the
unit 4.
* The effective tube area here is the total outside surface area excluding fins area, so finned surface may used to
enhance the boiling heat transfer coefficients and effectiveness of the chiller.
5.4 Comments on PAC-105 Flooded Liquid Cooler Design
1. Tubing is available in variety of materials like steel, copper, brass, etc but for PAC-105
chiller we selected copper tubing. Although it will increase the initial cost of system, but
copper has relatively high value of thermal conductivity, thus overall size of chiller will
be small and compact.
2. Copper tubing offers less resistance to flow of fluids. Therefore it causes low pressure
drop of water. Also copper tubing is less subjected to oxidation and scaling, hence
imparting more durability to system.
3. The overall arrangement of chiller is such that warm water coming from coil will first
enter in the top half of tubes grid and then progressively moves to the lower half. In such
an arrangement warm water will come in contact with refrigerant vapors first and then
gradually with saturated liquid, making a counter flow arrangement. Hence better heat
transfer between fluids.
4. Bolted heads will be used on the ends of chiller, which facilitate the easy cleaning of
tubes.
5.5 Suggestion for PAC-105 Flooded Liquid Cooler
1. For getting desired out put from the chiller, before operation it must be carefully assured
that the refrigerant charge is enough to dip the entire tubes grid completely.
5.10
2. Because the chiller tank will contain cryogenic fluid, therefore it must be thermally well
insulated and then covered with a vapor barrier.
3. Provision should be made to protect the machine from weather effects.
4. Liquid line providing saturated refrigerant in the shell must be well insulated and kept
short in length (see for further detail unit 5), to reduce the heat transfer and excessive
pressure drop. And similarly the suction line leading refrigerant vapors to compressor
5. Refrigerant vapors entering in the compressor may lead it to malfunctioning; therefore
eliminators must be installed along length on the top inner side of chiller before suction
line.
6. Supply and delivery lines carrying warm and chilled water respectively must be well
insulated
Note: Constructional details of PAC-105 chiller are shown in figure 5.4 and the schematic of
PAC-105 refrigeration system is shown in figure 5.5
5.11
Eliminator
Compressor Suction line Conection
Chilled water inlet
Dropout Area
Rear-end
Dome
Chiller Shall
Pump-end Dome Bolted
Bolted
Water Tubes
Bundle
Chilled water outlet
3Way Valve Return Refrigerant inlet Purging

Conecction Valve
Connection
Detail of Rear-end Dome
5.12
Dropout Area
Detail of Rear-end Plate
2 Baffles
18.7
Detail of Section A-A
5.13
Chilled-water Inlet
Partition
Thick
Chilled-water
Ø16 No. 8 Outlet
Return Chilled-water
From 3-Valve, A/A
Details of Pump-end Dome
Dropout Area Eliminator
Partition b/w
Chilled-water at Inlet
& Outlet
Refrigerant
Distributor
Detail of Pump-end Plate
Figure 5.4 Details Drawings of PAC-105 Water Chiller (All the Dimensions are in Millimeters)
5.14
PAC-105
Reciprocating Water
Chiller Cap. 13TR
Figure 5.5 the PAC-105 Reciprocating water chiller (2-D elevation and side view)
In the above illustration of the figure 4.6, the compressor is HG4-465-4 of the Bock compressor® so it is important to realize at this stage, don’t get confuse from the illustration.
Because the actual model of the compressor is HA6-1240-4 of the same manufacturer’s company (See Table 4.2).
5.15
PAC-105
Unit 6
Design of Water-
cooled Open-
type® Condenser
Introduction
C
ondenser is the main component of refrigeration or air
conditioning system. Its function is to reject heat to any cooling
medium that might be air or water, resulting in the condensation
of working fluid used in the system, called refrigerant.
This unit presents commonly used types of condensers. Then we
shall design an open-type water cooled condenser for PAC-105. Design
of a condenser means, “The determination of required surface area for
rejection of desired amount of heat to cooling medium”. During design
procedure, number of parameters will be considered. Two of them are
the most important for designing, namely cooling fluid (canal water)
side, and refrigerant side heat transfer coefficients. The refrigerant side
coefficient will be calculated by using correlation developed by
Rohsenow and the water side convection coefficient will be determined
using Zhukauskas correlation. Using these coefficients and appropriate
fouling factors; finally required heat transfer area will be calculated.
After finding the required heat transfer area, we shall arrange
this area in proper shape (coil or helical shape etc). At the end of this unit
we shall present the detailed drawing of PAC-105 water cooled open-
type condenser.
6.1
Unit 6: Design of Water-cooled Open-type® Condenser
6.1 Condensers
C ondenser is a device which condenses the superheated vapors coming out from the
compressor. The heat removed by condenser is actually the latent heat of
vaporization of refrigerant. As in most cases refrigerant vapors are superheated therefore the
amount of heat to be removed also incorporates the amount of heat causing superheating of
refrigerant. So condenser removes the heat from refrigerant vapors and its duty is in reverse as
that of evaporator / liquid chiller or cooler, in which heat is added to liquid refrigerant, changing
them into vapors. Thus both causing heat exchange between refrigerant and other fluid. Therefore
in broad sense condenser and evaporator can be called as heat exchangers. Since both the
condenser and evaporator are heat exchangers; they have certain features in common.
6.2 Classification of Condensers

One classification of condensers and evaporators is according to whether the refrigerant is
on the inside or outside of the tubes and whether the fluid cooling the condenser or being
refrigerated is a gas or a liquid. The gas referred to in Table 6.1 is usually air, and the liquid is
usually water, but other substances are used as well.
Table 6.1: Some Types of Evaporators and Condensers
Component Refrigerant Fluid
Condenser Inside tubes Gas outside†

Liquid outside
Outside tubes Gas inside†
Liquid inside
Evaporator Inside tubes Gas outside
Liquid outside
Outside tubes Gas inside†
Liquid inside
† Seldom used.
Table 6.1 indicates that certain combinations are not frequently used, particularly the
configuration where the gas is passed through tubes. The reason is that volume flow rates of gases
are high relative to those of liquids and would result in high pressure drops if forced through the
tubes.
Another classification of condensers is generally characterized by the cooling
medium used. Thus there are three types of condensers:
(i) Air-cooled condensers.
(ii) Water-cooled condensers.
(iii) Evaporative condensers.
There is also a fourth type dependent on ground-cooling which is not commonly used.
6.2.1 Air-Cooled Condensers
In air-cooled condensers, heat is removed by air using either natural or forced

circulation. The condensers are made of steel, copper or aluminum tubing provided with
fins to improve air-side heat transfer. The refrigerant flows inside the tubes and the air
6.2
outside.
Air-cooled condensers are used only in small capacity machines, such as
refrigerators and small water coolers which use vertical wire and tube or plate and tube
construction with natural circulation, and window-type and package air conditioners which
have tubes with 5–7 fins per cm and use forced circulation of air. The current practice in the
forced-convection type is to use 10-15 m2 of the total surface area per ton of refrigeration
based on 2–5 m/s face velocity of air over the coil.
Air-cooled condensers are seldom made in sizes over 5 TR because of high head pressure,
excessive power consumption and objectionable fan noise.
6.2.2 Water-Cooled Condensers
The most widely used types of condensers and evaporators are shell and tube heat
exchangers. Water-cooled condensers can be of three types, viz., shell and tube, shell and
coil and double tube. The shell-and-tube type, with water flowing through passes inside
tubes and the refrigerant condensing in the shell is the most commonly used condenser.
Figure 6.1 Water Cooled Condenser With Cleanable Tubes.
A shell-and-tube condenser also serves the purpose of a receiver, especially for

pumping down the refrigerant, because there is sufficient space in the shell. The bottom
portion of the condenser also serves the purpose of a sub cooler as the condensed liquid
comes in contact with the entering water at a lower temperature. Thus, we see that shell and
tube condensers, and, for that matter, all types of condensers are usually over designed. This
also keeps the head pressure low, and saves power. Further, the outside surface of the shell is
available for heat transfer. The shell is made of steel. Copper tubes are used for fluorocarbons
and steel tubes for ammonia.
The shell-and-coil condenser consists of an electrically-welded closed shell containing a
water coil sometimes of finned tubing.
In the double-tube arrangement, the refrigerant condenses in the outer tube and water flows
through the inner tube in the opposite direction.
Water-cooled condensers are invariably used in conjunction with cooling towers, spray
ponds, or natural sources of cooling water etc. Heated water from the condenser is led to
the cooling tower where it is cooled by self-evaporation into a stream of air. After cooling
the water is pumped back to the condenser.Figure6.1 shows a water cooled condenser.
6.3
6.2.3 Evaporative Condensers
The schematic diagram of an evaporative condenser is shown in Figure 6.2. The

refrigerant first rejects its heat to water and then water rejects its heat to air, mainly in the
form of evaporated water. Air leaves with high humidity as in a cooling tower. Thus an
evaporative condenser combines the functions of a condenser and cooling tower. Evaporative
condensers are commonly used on large ammonia plants as they are found to be cheaper. Such
Condensers require a larger amount of the refrigerant charge due to the longer length of the
refrigerant piping. But in the case of ammonia systems this is immaterial since the refrigerant is
quite cheap.
Figure 6.2 Evaporative-condenser.
6.3 Water-Cooled Open-type Condenser® of PAC-105

In previous sections we have presented the brief introduction of various types of
condensers used for refrigeration systems. The next step is to choose an appropriate type of
condenser for PAC-105.Obviously we shall use water cooled condenser, because our main
objective is to use the canal water as cooling water for condenser. After selection of cooling
medium for condenser, now we have to decide the configuration of PAC-105 condenser.
For PAC-105 a new type of condenser is introduced. That is “open-type water cooled
condenser “. The open-type condenser of PAC-105 will consist of a staggered tubes array with
refrigerant flowing inside the tubes and cooling water outside the condenser tubing. The
condenser will be completely dipped in the canal water by placing it on a specific plate form
constructed inside the canal. Thus requiring no pump for water circulation between the condenser
and cooling tower, as done usually in the refrigeration systems using water cooled condensers.
The availability of water source also eliminates the cooling tower fan motor .Because cooling
water is available at continuous rate. Thus saving energy as compared with other refrigeration
systems using water cooled condensers. A comprehensive mathematical discussion on energy
saving technique employed in PAC-105 is presented in unit 4.
6.4 Design of PAC-105 Water-Cooled Open-type Condenser®
Known parameters
Refrigerant used R-134a

Heat to be rejected = 54.155 kW (as found in unit 5)
Evaporating temperature of refrigerant = -100C
Condensing temperature of refrigerant = 340C
Temperature of condensing water =16 0C
Velocity of canal water
6.4
Assumptions
1. For water cooled condensers various configurations are used. But for PAC-105 condenser
we assumed two successive rows of tubes arranged in staggered configuration with 30
tubes in each row, which means that 60 Number of tubes in total. Other parameters of
tubes like transversal pitch, longitudinal pitch etc, are same as used for cooling coil of
PAC-105 AHU in unit 3.
2. Although the temperature of cooling water was found to be 16 o C , but to account for
seasonal variation in temperature, we shall use 20 o C in calculation procedure.
3. As the condenser will be placed in bulk of continuously flowing water therefore the entire
surface can be considered as having same temperature as that of cooling water (condition
of constant surface temperature), Therefore change in temperature (ΔT) of condensing
water will be 0. But we assume (ΔT) as 1 o C
4. We shall use K type copper tubing with outer diameter as 12.7 mm and inner diameter as
10.2mm.
Properties
1. All properties of refrigerant will be taken at saturation temperature of 34 o C from

Appendix B-3.
2. All properties of water will be taken at 20 o C from Table B-2 in Appendix B.
Design Calculations
The relation for heat transfer across condenser (or any type of heat exchanger) is given by
Q = UAΔTlm
Where,
Q = amount of heat rejected W
U =overall heat transfer coefficient W/m2 .k
A=required heat transfer area m2
ΔTlm =Log-mean temperature difference o C
After finding the values of U and log mean temperature difference, we can easily find the
required heat transfer area.
Finding Over-All Heat Transfer Coefficient U0
The relation for overall heat transfer co-efficient is [a]
ln⎛⎜
D⎞
1 1 1 d ⎟ R f ,i R f ,o
= + + ⎝ ⎠+ +
Ui Ai hi Ai ho Ao 2π kl Ai Ao
Where,
6.5
l is required length of tubing, k is conductivity of copper =400 W / m.k , d and D are inner and
outer diameters of tubing. R f ,i , R f ,o are the fouling factors of inner and outer sides of tubing, and
there values are taken as,
R f ,i =0.000044 m2.K/W (For refrigerant side, see unit6)
R f ,o =0.0005 m2.K/W (For water side, [a])
⎛D⎞
ln⎜ ⎟
The term ⎝d ⎠ , accounts for conductive resistance of the copper tubing.
2π kL
And U i , is the over all heat transfer co-efficient based on inner side of tubing, because inner side
is exposed to higher temperature.
Now modified form of above expression is as under,
ln ⎛⎜ ⎞⎟
D
1 1 1 d ⎝ d⎠ d
= + × + ×d + R f ,i + ×R f ,o
Ui hi ho D 2k D
All parameters in above equation have been defined except,

hi = Refrigerant side heat transfer coefficient W/m 2 .K
ho = Water side heat transfer coefficient W/m 2 .K

Now we shall find these two parameters one by one.
Determination of Refrigerant-side Heat Transfer Coefficient
The vapor compression cycle analysis performed in unit 5 shows that the mass flow rate
of refrigerant vapors entering in the condenser tubing is 0.2763 kg/sec.First of all we shall check
the condition of vapors velocity. I.e. Reynolds no of refrigerant vapors entering in condenser is
given by
.
4 mv
Rev =
π d μv
Where,
.
mv = Mass flow rate of ref. vapors kg/sec
μv = Viscosity of ref. vapors Pa.sec
Putting values in above Equation,
4×0.2763
Rev = = 2684966
π ×0.0102×12.72×10−6
As Rev = 2684966 > 35000
Therefore, refrigerant vapors velocity lies in high velocity region[b]. Thus the corresponding
Equation for convection coefficient will be of form, [c]
⎡ 1/ 2 ⎤
0.8
hi d 1/ 3 ⎢ d ⎛ ρl ⎞ ⎥
= 0.026 Pr G
⎢ μl ⎜⎝ v ρv ⎟⎠
+Gl ⎥
kl l
⎣ ⎦
All parameters in above Equation stand for usual notations except Gv and Gl , which are
6.6
Gv = ρv Vv = Mass velocity of refrigerant vapors Kg/m 2 .sec
Gl = ρl Vl =Mass velocity of liquid refrigerant Kg/m2 .sec

All properties of refrigerant are evaluated at condensation (saturation) temperature of refrigerant
at 34 oC , from table provided in appendix B for refrigerant R-134a and are as under,
k = 77.7 × 10−3 W/m,k
l
k v =12.72×10−3 W/m,k
ρl = 1171.3 kg/m3
ρv =42.12 kg/m3
C p,l =1.467 KJ/kg.K
μ l =191.4×10−6 Pa.sec
To proceed further for finding convection coefficient, we need Pr l and mass velocities of liquid
and vapor refrigerant. So first we calculate these,
Cp ×μ 1.467×103×191.4×10−6
Pr = l l = = 3.61
l kl 77.7×10−3
Now for vapors velocity, using continuity equation, we have
m.r ,v
m.r ,v = ρv AVv ⇒ Vv =
ρv A
4×m.r ,v 4×0.2763
Vv = = = 80.27 m / sec
ρv ×π d 2 42.12×π ×( 0.0102 )2
So,
Gv = ρ v Vv =42.12 × 80.27=3080.97 Kg/m 2 .sec
Similarly using continuity equation for liquid refrigerant, we get
.
4×m r ,l 4×0.2763
V = = = 2.886m/sec
l ρ ×π d 2 1171.3×π × 0.0102 2
l ( )
And the corresponding mass velocity of liquid refrigerant will be
G = ρ V =1171.3 × 2.886=3080.37 Kg/m2 .sec
l l l
Both of the liquid and vapor refrigerant mass velocities are same and the reason is constant mass
flow rate of refrigerant via condenser tubing. It means that rate at which vapors are entering is
equal to the rate at which it is being condensed by condenser.
Putting values in above Equation, for convection coefficient,
⎡ 1 ⎤
0.8
⎢ 0.0102 ⎛ 1171.3 ⎞ 2 ⎥
= 0.026 ( 3.61)1/3 ⎢
hi d
−6 ⎜ 3380.97× ⎟ +3380.37 ⎥
kl ⎢191.4×10 ⎝ 42.12 ⎠ ⎥
⎣⎢ ⎦⎥
6.7
hi d
= 5571979.45
kl
k
hi =5571979.45× l
d
77.7×10−3
hi =5571979.45× =42445372.85
0.0102
Thus,
hi = 42445372.85 W/m 2 .K
Determination of Water-side Heat Transfer Coefficient
Now for finding the value of outside heat transfer coefficient ho , similarly first we find
the value of Reynold, s no to predict the type of flow. Surely the flow will be laminar because it is
an open channel flow, however the value of Re is necessary because it will be used in calculating
ho ,later on.
ρ v D
Thus, Re w = w w
μw
All properties of water are taken from table B-2 at 20 oC .
ρ w = 998.21 Kg / m3
μw = 1.08 ×10 −3 Pa.s
D= 12.7mm =0.0127m
The velocity of water was measured to be 0.37 m/sec near canal bank, where the velocity of water
will be low due to stagnation condition and friction between walls and layers, actually the
variation in the velocity due to the change in the water low rate, and was estimated as 0.5 m/sec.
So,
vw = 0.5 m/sec
Putting all values in above Equation, we get,
Re w = 5868.45
(As already predicted, the value of Re is less than the critical value ( Rec = 5 × 105 for outer flow)
therefore, the flow is Laminar.)
It is already mentioned that we are using the same configuration for condenser as for cooling coil
(in unit 3), thus
ST = Transversal pitch=distance b/w two successive tubes centers in vertical direction=33.7mm
SL = Longitudinal pitch=distance b/w two successive tubes centers in horizontal direction=25.4mm
SD = Diagonal pitch= Diagonal distance b/w two tubes centers in successive rows=30mm
A1= Gap b/w two tubes in a row=21mm
d= inner diameter of tubes=10.2mm
D= Outer diameter of tubes =12.7mm
Thus using Zhukauskas relation[d] for calculation of water-side convection coefficient:

⎛ ⎞
1/ 4
Nu D = C Rem D,max Pr 0.36 ⎜⎜ Pr ⎟⎟
⎝ Prs ⎠
6.8
Where,
C and m are constants. Their values are available in. Re D ,max is Reynolds no based on maximum
velocity of water flowing across tubes array. All the properties of water will be taken at free
stream temperature of water. (I.e. Tw = 20 o C ) except Prs , which will be calculated at mean
T +T 20+34 54
temperature of water and refrigerant in tubing. ( Tm = w r = = = 27 oC )
2 2 2
Now first we shall find the max. Velocity of water passing through tubes array. As discussed in
unit 3, for assumed configuration of staggered tubes array, the max. Velocity of water flowing
through tubes array which is placed in mid across the flowing water of canal, will occur at A1 ,
and is given by relation,
S 33.7
Vmax = T ×V = 0.5=0.8m /sec
ST − D 33.7−12.7
And corresponding Re D ,max will be,
ρ V D 998.21×0.8×0.0127
Re D,max = w max = = 9390.57
μw 1.08×10−3
Now from appendix B-2, the values of Pr & Prs are
Pr =6.98
Prs =5.83
From [d] the values of constants C and m are C= 0.37 & m=0.6
Putting values in above relation for average Nusselt no we have,
1
0.6 0.36 ⎛ 6.98 ⎞ 4
Nu = 0.37 ( 9390.57 ) ( 6.98 ) ⎜ ⎟
⎝ 5.83 ⎠
Nu = 188.43
hwD
⇒ = 188.43
kl
k 0.603
ho = hw =188.43× l =188.43× =8946.72
D 0.0127
So,
ho = hw = 8946.72 W/m 2 .K
Now putting all values in above relation for over-all heat transfer coefficient, that is
⎛D⎞
ln ⎜ ⎟
× + ⎝ ⎠×d + R + ×R
1 1 1 d d d
= +
U i hi ho D 2k f ,i D f ,o
⎛ 0.0127 ⎞
ln ⎜
1 1 1 0.0102 0.0102 ⎟⎠ 0.0102
= + × + ⎝ × 0.0102 + 0.000044 + × 0.0005
Ui 42445372.83 8946.72 0.0127 2×400 0.0127
= 5.38 × 10−4
1
Ui
Ui =1858.18W/m2.K
Finding Logarithmic Mean Temperature Difference (LMTD)
6.9
Using relation for Log mean temperature difference of counter flow heat exchanger [e]
ΔT =
lm ⎛ T −T ⎞
ln⎜ r w,i ⎟
⎜ Tr −Tw,o ⎟
⎝ ⎠
Where,
Tr = temperature of refrigerant = 34 o C
Tw,i = temperature of water entering the condenser = 20 o C
Tw ,o = temperature of water leaving the condenser = 21 o C
Putting values in above relation for temperature difference, we have
( 34−20 )−( 34−21)

ΔTlm = = 13.5°C
⎛ 34− 20 ⎞
ln⎜ ⎟
⎝ 34− 21 ⎠
Determination of Required Surface Area
Now using relation,

Q = U i A(ΔT )
lm
Thus, the required area is,
Q
A=
Ui ×( ΔTlm )
54.155×103
A= = 2.157 m 2
1858.18×(13.5 )
This is inside surface area of tubing, because the value of over all heat transfer co-efficient was
calculated for inner side of tubing.
Now the corresponding length of condenser tubing is,
Ai
l=
π ×d ×NT ×N L
NT = Total no of tubes in each row = 30
N L = no of rows of tubing = 2
2.157
l= = 1.12m
π ×0.0102×30×2
So length of condenser = 1.12m
For finding the height of single row of tubes, we have relation (as used in unit 3)
Height of a row of tubes =( NT ×D )+( NT −1)× A1 (∴A1= ST -D )
Putting values in above equation we get,
Height of a row =990mm
Height of tubes array = H =990 + 1/2(ST ) =1006.85mm
Note: The PAC-105 condenser will be submersed in the channel water. The condenser can be configured in such a way
that the face of the condenser is parallel to the channel flow rate. The condenser can be a round annulus form for best
results and performance year round i.e. when condenser face would be parallel to the flow direction of the water there
6.10
will be less chance of sediments stuck-on on the surface and there will large temperature gradient between the water
and the refrigerant, so high transfer of the heat.
6.5 Suggestions for Construction and Installation of PAC-105 Condenser
1. In order to make the tubes array rigid and non-deformable in open channel flow, it is
suggested that, tubes should be arranged in a metallic rectangular frame with two
supports in between, so that the whole structure may not get buckled with water velocity.
2. The condenser array must be placed at the center of canal (point of max. water velocity)
in vertical position, on a rigid plate form. So that each tube in array may interact with
maximum velocity of water, hence getting largest possible value of convection
coefficient.
3. Canal water carries large amount of contamination such as sand, mud, minerals or any
other waste materials like grass, leaves, animals dung etc. Therefore, instead of placing in
the centers the optimum place is near the bank in order to make the design safe and
secure.
4. Condenser across the flowing water. It is suggested that condenser assembly must be
placed with its length along the flowing water. In such an arrangement the particulates
are less susceptible to settle on the tubing. Thus giving better heat transfer and less
cleaning required.
5. The upper layers of canal water will be at higher temperature. ( due to many reasons like
,direct sun radiation, evaporation effect , wind velocity etc ) The water temperature will
drop progressively in lower layers, and minimum temperature near canal bed.
Therefore, it is suggested that the refrigerant discharge line from compressor must be
connected to the tubes on top most position first. After gradually moving in lowers tubes,
the saturated or sub-cooled liquid refrigerant will leave from lower end of condenser at a
temperature of 25.550C, as shown in Figure 6.3. Such suggested circuiting arrangement
of refrigerant makes a counter flow arrangement of refrigerant and canal water. Thus
providing an efficient heat transfer b/w both fluids.
6. During operation tubes may get scaled due to sediments in water, making the condenser
surface less effective. Therefore Condenser tubing must be periodically cleaned to get an
efficient heat transfer area.
7. Usually the problem of sediments and fouling is very common in water cooled
condensers. Although during design we considered the rectangular configuration, But in
order to facilitate the easy cleaning and installation another optimum design of the
condenser might be as shown in the figure 6.3, which have many advantages over the
former configuration discussed. This design is entirely proposed by the authors in
accordance with the situation and local conditions. These construction and design
features (formulas) will never be directly available in any text; therefore we are
presenting here the design and manufacturing sizes of this particular configuration of the
condenser. It is actually a parallel flow circular-open horizontally positioned suspended-
type condenser of the PAC-105, which has only one inlet and one outlet for hot gas
refrigerant and liquid refrigerant respectively. Let
Rc = Radius of the Condenser = 18 in.
rb = Mean Radius of Bend, d b =2 rb
N t = Total Number of Tubes
N b = Total Number of Bends
Lc = Length of Condenser
6.11
Lt =Total Length of Copper Tube
Lt ,b
= Total Length of Bends
S = Peripheral Distance b/w Two Consecutive Tubes
θ = Subtended Angle b/w Two Tubes
dt =Diameter of Copper Tube
lb = Length of One Bend = π rb
P = Perimetric Correction Factor
Now by using relations given above for total length of tube, Lt is calculated as
Lt = 67.313m
Let us assume that, Rc =9 in. and N t =67, so now by using given relations from 6.1 to 6.9 we
can find all necessary dimensions of the condenser
Rcθ π Rc
rb = = ……....6.1
2 Nt
Where
360 2π
θ= in degrees and in radians =
Nt Nt
Lt ,b = π rb ⎡⎣( N t − 1) ⎤⎦ …….…6.2
⎡ L − Lt ,b ⎤
Lc = ⎢ t ⎥ …………...6.3
⎣ Nt ⎦
1 ⎛ 1⎞
N b = ( 2 N t − 1) or ⎜ N t − ⎟ ……………6.4
2 ⎝ 2⎠
⎡ ⎛ ( 2π Rc − N t dt ) ⎞ ⎤
N b = ⎢ 2 ⎜⎜ ⎟⎟ − 1⎥ ……………..6.5
⎢⎣ ⎝ 2 ( db − dt ) P ⎠ ⎥⎦
N b / side =
( 2π rb − Nt dt ) ………6.6
2 ( db − dt )
and also
Nt
N b / side = …….6.7
2
So here P in Equ.6.5 is ratio of the Equ.6.6 to Equ.6.7
Number of tubes in the condenser can be found by using given relation as
Lt
Nt = …………6.8
Lc
Or also if including the total bends length we can then use the following relation as
⎡ L − 2π Rc ⎤
Nt = ⎢ t ⎥ ……..6.9
⎣ L c ⎦
Total length of the bends can be found by using relation 6.2 as
Since we know that
6.12
360
θ= = 5.3730 or 0.02985 rad.
67
From Equ.6.1 mean radius of the bend can be calculated as
3.1416 × 9
rb = = 0.422in.
67
Hence also d b = 2rb = 2 × 0.422 = 0.844in.
So the total length of the bends can be found as
Lt ,b = π × 0.422 ( 67 − 1) = 87.5in. or 2.2231m.
Now we can found the length of the condenser by using relation 6.3 by taking 67 tubes as
mentioned above, but for both hot gas line and liquid line at one side we must take the number of
the tube as 66, so we have
67.313 − 2.2231
Lc = = 0.97149m with 67 tubes
67
Lc = 0.9862m with 66 tubes
Now let us check the total length of the tubes by using relation 6.3 as
Lt = 0.9862 × 66 + 2.2231 = 67.313m
It is correct value as found from the above relation of heat transfer. Other all the parameters and
dimensions can be found from the relations 6.1 through 6.9, the illustration of this condenser is
shown in the figure 6.3 with all necessary dimensions in inches and is according to scale.
6.6 Comments and Results
1. In commercial systems usually brass or steel, tubing is used for condensers. But for PAC-
105 condenser we selected copper tubing. Although it will increase the initial cost of
system, but copper has relatively high value of thermal conductivity, thus overall size of
condenser will be small than other system of same capacity using steel or copper tubing.
2. The K type copper tubing is selected, which has maximum wall thickness, therefore
condenser tubing will withstand maximum pressure of refrigerant vapors coming out
from compressor.
3. Copper tubing has very low coefficient of friction. Therefore minimum pressure loss of
refrigerant will take place in condenser, making the whole system more efficient.
4. Although the recommended value of fouling factor for water cooled condenser is
0.000176 m2.K/W [f] but we used higher value of 0.0005 m2.K/W for dirty water of
canal. It shows that we are using approx. 3 times larger value of fouling than normally
used.
5. The average temperature of canal cooling water was measured to be 16 oC . But in
calculation process we used the higher value of temperature (20 o C ), making our design
more safe and reliable.
6. According to Prof. Dr. Riaz Ahmed mirza (Chairman, Department of Mechanical
Engineering, and UET Lahore), “Practically the ratio of condenser to chiller/evaporator
surface areas is 1.20-1.30, or we can say that the condenser must be 20-30% larger than
evaporator/chiller of the refrigeration system”. Now we check this condition for PAC-105
Surface area of PAC-105 condenser 2.157

= = 1.2457
Surface area of PAC-105 chiller 1.7315
6.13
Hence the PAC-105 fulfills this criterion nicely.
The staggered arrangement is selected for tubes array of condenser. It provides the better heat
transfer configuration than in-line arrangement. Also only 2 no of rows are selected; such
configuration facilitates the easy excess to each tube of array during cleaning of condenser.
The specifications of PAC-105 circular-type open water-cooled condenser® are shown in Table
6.3
Flare Fittings 12 in. Canal water flow direction

Female part
18in
28.817in 0.422 in
0.422 in 38.817in
(0.7321m)
(0.9862m)
(a)
Refrigerant
Refrigerant vapors in
liquid out
2 Tubes 3 Anular
fastening Rings 18in
screws 12 in. 18-14-112 in
Ring 66 Tubes each of 12

fastening in. dia. and at angle
screws 5.37 deg
Condenser
fasteners
(b)
6.14
(c)
Figure 6.3 the PAC-105 Circular-Type Open Water-Cooled Condenser®

(a)Elevation (b) End View Showing Support Braces (c) Installation Position parallel to Water
Currents/Stream.
Table 6.3: Specification/Capacity Table for Condenser of the Figure 6.3
Condensing
Temp/Pressur Surface mr.
Mod Qcond e Tubes Area Weight
el* 0
C/Mpa Type Detail m3 Refrigerant Kg/sec Kg
KW
PAC 54.15 34/0.8652 Parallel K/1/2/ 2.157 R134a 0.2763 48
-OC- Flow/ Copper
54 Horizonta
l Water-
cooled
* Model name patent: PAC-OC-54
Note:
We introduced this configuration of water-cooled open-type condenser for PAC-105. This will give the best results for
designed conditions and can be used with full confidence because the problems of high proportion of sediments and
fouling in canal water leads to the use of circular configuration, therefore this configuration will be the best choice and
is recommended by the authors.
This particular condenser is intended for the satisfactory operation as accordance with the
circumstances that in the flooding season there may be a great risk of cleaning the tubes outer
surfaces on daily bases in order to make system performance at the peak. This particular
condenser type has the possibility to adjust at different height of the water in the whole season of
channel flowing so making our system running at almost every month of the channel flowing. As
seen from the figure 6.3a, both connections i.e. discharge and hot-gas is on the same side and they
can be easily checked for leakages, debris and damages.
6.15
PAC-105
Unit 7
Design of PAC-105
Hydronic System
Introduction
H ydronic system of the any central air-conditioning system should

have capability of supplying the designed volume flow rate for
year round smooth operation. All those components of hydronic
system i.e. pump-piping system, pipe sizing, and valve selection are a
major problem in any HVAC system. We have evaluated in this unit, the
actual pump head requirement for the system, pump power, and also
discussed total accessories that must be considered in the piping loop.
We have also analyzed the maximum pressure limits for the pipeline,
which must not cross in any conditions during the normal working
condition of the chiller or any other element of the PAC-105 system. The
pump piping system of PAC-105 is of PVC schedule 40, where fittings
and accessories will be mounted with steel fastening binding solution or
epoxy material.
7.1
Unit 7: Design of PAC-105 Hydronic System
7.1 Piping System of the PAC-105
T he most common heat-conveying media in air-conditioning and refrigeration systems

are air, water; and refrigerants. Airflow systems would be discussed in unit 9 and this
unit mainly concentrates on piping systems for water and chiller pump, which motivates the flow
of chilled and condenser water, called as hydronic systems.
The hydronic system of the PAC-105 carries chilled water from chiller to the AHU and sending
back to the chiller for again rejecting heat from the return chilled water to the refrigerant liquid.
The piping is not too complex that for which a special arrangement is needed. For corrosion
protection we are accommodating the polyvinyl chloride (PVC) pipes, which neither reducing
the cost but also giving the high resistive action against heat transfer. This unit also covers
guidelines for selecting the size of refrigerant pipes.
The requirements of a water-distribution system are that it provide the necessary flow rate to all
the heat exchangers, that it be safe, and that' its life cycle cost (including both initial and
operating costs) should be low. In selecting sizes of refrigerant pipes there are some standard
recommendations that are heavily influenced by the refrigerant pressure drop. Some pressure
drop is acceptable, but the pipe size should ensure that it must not be excessive, which will
result in high operating cost.
The piping system of the PAC-105 is installed under the ground 1-1/2 ft after carefully
insulated with insulation and proper gripers and hangers. During the design of the piping we
have been taken all those measures in the design to insure the longer operational and durable
performance of the system. The schematic piping layout of hydronic system of PAC-105 is
shown in the figure 7.1.
False Cielling
Rachna College of
Engineering & Technology
Gujranwala
M-2 Hall
www.rcet.edu.com
First Floor
Location
AHU Local Road of Chiller
Location College Circular
Road College
Boundary Wall
Canal
Ground level 112 ft
A 7ft
A
230 ft (70 m) Condenser
Figure 7.1 Layout of Hydronic System of PAC-105 Air Conditioning System.
The minimum thickness of the insulation for the hycronic system is given in the following
Table7.1; we are strictly following these instructions here in order to minimize the heat
conduction through pipe.
Table 7.1: Minimum Insulation for the PAC-105 Piping System
Fluid design Insulation Pipe Size Pipe Length insulation

Operating Conductivity in. Material ft in.
Temperature 0F Btu-in. / ft2.0F
7.2
40-60 0.22-0.28 1&1.25 UPVC 2×230 1
<40 0.22-0.28 1&1.25 UPVC 2×230 1
Note: 1) This insulation is based on the energy efficiency considerations only. Issues such as water vapor
permeability or surface sometimes require vapor retarders or additional insulation.
2) As pipes of PAC-105 hydronic systems are buried under the ground as shown in the figure 7.1, so this require
care for proper dismantling techniques and periodic repair clean-up schedule, so provision should be made for that.
3) Pipes can generate vibrations and noise during the higher velocity of the fluid; they should properly fasten with
devices i.e. hangers not shown in the figure 7.1.
Insulation
thickness:
1in.
Material:
Nitrile
Foam
Diameter
: 25.4
mm
M/t:
PVC
Figure 7.2 Cross-Section of the Pipe at Section A-A of the Figure 7.2
The cross section at section A-A in the figure 7.1 is shown in the figure 7.2 showing the
minimum thickness of the insulation.
7.2 Centrifugal Pump Selection Criteria of PAC-105
Since it has been already mentioned that, PAC-105 is the central air conditioning system
which is supplying the conditioned air to the M-2 hall after removing heat to the chilled water
coming from the chiller, installed at the bank of the canal. The pump piping system of the PAC-
105 is not very complex but just a long travel of the chilled water from chiller to AHU i.e. 2×70m
as shown in the Figure 7.3.
The centrifugal pump must have the capability to supply the desired volume flow rate at constant
rate, to overcome the piping friction and leakages in the pipes. The reasons for the selection of the
centrifugal pump rater than reciprocating or other types are only that they are smooth in operation
and reliability. The centrifugal pumps are the most widely used pumps for transporting chilled
water, hot water, and condenser water in the HVAC & R systems because of their high efficiency
and reliable operation.
Centrifugal pumps accelerate liquid and convert the velocity of the liquid to static head. A typical
centrifugal pump consists of an impeller rotating inside a spiral casing, a shaft, mechanical seals
and bearings on both ends of the shaft, suction inlets, and a discharge outlet. The impeller can be
single stage or a multistage. The vanes of the impeller are usually backward-curved. The factors
that must be account while designing a centrifugal pump are given below:
¾ Volume Flow Rate
¾ Total Head (Static, Velocity and Pressure Head)
¾ Net Positive Suction Head (NPSH)
¾ Pump Power
In the following pages we shall design and estimate the power consumption of the PAC-105
centrifugal pump also known as Mono-gold Pump® due to its manufacturer (Golden Pumps
Limited), see brochure of the centrifugal pump and illustration below.
7.3
Figure 7.3 Mono-gold PAC-105 Centrifugal Pump
7.3 Determination of the Pump Head of PAC-105

A common problem is to determine the pressure loss from friction in a closed system in
order to determine the required pump head. The system pressure drop is simply the sum of the
losses through each item is one of the paths or circuits from discharge to pump suction, including
piping, fittings, valves, and equipments. Information on pressure drops through equipment is
obtained from the manufacturer. Also the charts for the pressure drop due to friction in the PVC
pipes can be found from the handbooks i.e. Figure 7.4 from Handbook of Refrigeration by Shan
K. Wang, 2/e.
The PAC-105 hydronic system is shown in the figure 7.3
From above the total pressure loss is
Δpt = Δp + ΔpAHU + Δp
f chiller
Δpt =Δp f +Δpmachine ……………………7.1
Δp = ΔpAHU + Δp
machine chiller
Now find out the mass flow rate (MFR) of the water which is flowing through the pipes, for the
design purpose we have selected the polyvinyl chloride (PVC) pipes.
The design mass flow rate for the AHU of the PAC-105 is 0.91 kg/sec
So 0.91 kg / sec= 54.6 kg/min
kg 2.205lb 60min
= 54.6 × ×
min kg hr
7223.58lb
= since 500 lb/hr=1GPM
hr
MFR= 14.45lGPM ≈ 14.5GPM
The velocity of the water inside the pipe is given by the continuity equation as
MFR=ρ × Q
MFR=ρ × A×V
0.91 0.91 0.91×1000
V= = =
2 (25.4) 0.7854(25.4)2
2
ρ ×0.7854×⎛⎜ 25.4 ⎞⎟ 1000×0.7854×
⎝ 1000 ⎠ 10002
=1.796m/sec or V=5.89 ft/sec ≈ 5.89 ft/sec
Now for machine losses we know that
7.4
MFR of water through AHU is,
D= 0.5 in. (12.7mm)
Number of tubes per water circuit =10
MFR through each tube of the AHU is
1
= ×MFR pipe since MFR pipe =0.91kg/sec
10
1
= ×0.91 = 0.091 kg/sec or VFR =1.45GPM
10 tube
The velocity of the water in the AHU coil can be calculated by the relation,
MFR=ρ × Q since Q=1.45 GPM

0.91
or MFR = =0.091 kg/sec
10
= 1000 × 0.7854 × d 2V →
0.91
V=1.11 m/sec = 218.73 fpm
10
So in the table 7.2 all the accessories, fittings and pipes sections are considered for the design
purpose.
Table 7.2 Piping Pressure Drop and Pump Head Requirement for Pac-105 System
Friction
Total Loss Hf Total
D V E.L., No of Length, Ft. Head
Section Item In. GPM FPS Ft Items Ft w/100 ft Ft w.
AB Pipe 1 14.5 5.89 230 2 460 18
CD 16 1 16
Elbows, 1 14.5 2.6 9 23.5
90 std.
Unions 1.5 4 6
Gate 1 2 2
valves
Check 42 2 84
valves
Fittings
Subtotal 571.5 ×18/100 102.87
AHU 1/2 1.45 51.58 10* 515.8 18
Subtotal 571.5 ×18/100 92.8

Machines Chiller
1/2 0.58 7.87 25* 196.8 1
Subtotal 196.8 ×1/100 1.968

Total loss 197.63
* Numbers of the tubes in the AHU and chiller.
So clearly showing from the Table 7.2 that the minimum pump head requirement for PAC-105
hydronic system is equal to the total losses of the pipe and fittings, on the other hand the pump
required for the system must have head of 197.6 ft of water to overcome the friction and other
losses.
7.5
So from the brochure of the Golden Pump Limited the selected model is Mono-gold Pump® as
shown below:
Model Motors H.P.† Volts♦ Max. Max. Head‡ VFR L/Min
Suction*
1¼” × 1” 1 450 6M 10-24M 70-25
†
This is the experimental value of the power consumption i.e. factory tested rating at maximum volume flow rate and
designed head.
♦
Actually this model was coupled with a 1-phase motor so for matching with our requirements and energy supply
conditions, we have been selected the 3-phase motor.
* Maximum suction in case of the open piping system since every hydronic system (i.e. chilled water) is normally a
closed system so we shall use here the NPSH rather than suction head.
‡
This maximum head requirement is very mush smaller as compared with our head requirement so we have been
selected the larger or bigger capacity motor in order to overcome the friction and losses in the pipeline.
We shall now find the maximum pressure raised behind the valves (Hammer blow) during there
simultaneous closing action because as we know that PAC-105 is a microprocessor based DDC
control system, we must need to regulate the flow during the part load operation by automatic
closing of the valves (see for further detail unit 8).
As for as our PAC-105 system is concerned, we have been selected PVC pipes for chilled water
transport purpose with the characteristics as shown in the table 7.3.
.
Table 7.3 Maximum Allowable Pressures at Corresponding Temperatures
System
___________________
Maximum
Allowable
Pressure at
Temperature
Fittings Temperature psig
0
Application Pipe m/t Weight Joint type M/t F
Recirculating Steel Std. Thread Cast Iron 250 125
Water
2 in. and
Smaller copper, hard type L 95-5 solder Wrought Cu 250 150
PVC Sch. 80
Solvent PVC 75 350
CPVC Sch. 80 solvent CPVC 150 150
PB SDR-11 heat fusion PB 160 115
Insert crimp Metal 160 115
Note: Maximum allowable working pressures have been derated in the table higher system pressures can be used for
lower temperatures and smaller pipe sizes. Pipe, joints, and valves must be considered.
Note: A53 ASTM Standard A53
PVC Polyvinyl chloride.
CPVC chlorinated Polyvinyl chloride
PB Polybutylene
The operational and characteristics data concerning hydronic system is given below:
Length of the pipe………………………….70 m (1-sided)
Diameter of the pipe………………………..1 “(delivery end size)
Pipe m/t …………………………………….PVC schedule 80
Mass flow rate of the water in the pipe …….0.91 kg/sec
Velocity of the chilled water, V…………….1.796 m/sec
Sp. Weight of the chilled water, w…………..9.81 KN /m2
7.6
Bulk modulus of the water, K……………….2059.396 MPa or 2.059396 GPa
So we can now find the maximum pressure behind the AHU valve as shown in the figure 7.4 due
to slightly closing the valve manually in 10 seconds by the following relations as
p 1 wLV wLV
H= = × = …………………..7.2
w w gt gt
And when the valve is suddenly closed then we can find out the pressure behind the valves by
using following relation as
Kw w
p =V Q ρ=
g g
Or also
p = V Kρ …………7.3
Where H = pressure raised behind the valve or hammer blow (HB) in KPa
L = length of the pipe in meter
V = velocity of the chilled water in the pipe
g = acceleration due to gravity 9.81 m /sec2
t = closure time of the valve in seconds
K = bulk modulus of water in MPa
By using Equ.7.2, we know that
9.81× 70 × 1.796
HB = = 12.572Kpa
9.81× 10
The effect of the closure of the valve gradually and suddenly can be seen in the following figure
7.4.
tv = constant
HB
m 4.077
2.288
v = constant
1.525
1.144
0.9155
0 2 4 6 8 10
tv (V=constt.)
V ( tv = constt.)
Figure 7.4 Effect of Gradually or Suddenly Closure of PAC-105 Hydronic Valves
7.7
In the above figure 7.4 the velocity is assumed to be constant (V = 1 m/sec), but closure time of the valve, tv is changed.
In the graph (shown with dotted), the closure time of the valve is taken as constant i.e. 2 seconds but the velocity of the
chilled water is changed. Changing velocity or volume flow rate is important in any chilled water central system in the
summer to meet the space load requirement, so therefore it is important to keep this information in the mind.
The PAC-105 hydronic system layout is shown below in figure 7.5 showing all the components
7.4 Estimation of Centrifugal Pump Power of the PAC-105

From the table 7.2 the total head loss is estimated as 197.63 ft as accordance
with design conditions, so we know estimate the power input required for the PAC-105
centrifugal pump as
We know that the mass flow rate of water flowing through the pipes is
m.w = 0.91 kg/sec or 14.5 GPM
Total friction head loss in the pipe or total estimated head of the pump is
Ht =197.63 ft (see Table 7.2)
Sp. gr. of chilled water =1
Pump efficiency is assumed as 0.85
Now using Equ.7.4, we know that
Vw. ×H ×g
t s
Pp = ......................7.4
3960η pηmech
14.5 × 197.63 × 1
= = 0.877hp ≈ 1hp
3960 × 0.85 × 0.97
where, gs = Sp. gr. of water
The Mono-gold Pump® is coupled with a motor with the following specification as:
H.P KW Volts Amperes R.P.M.
1 0.746 440 1.75 *1425
2 1.49 440 3 *1425
* Since these speeds of the motor are the designed speed for the VFR of 70-25 liter/minute as per mentioned in the
brochure provided by the GOLDEN PUMPS PRIVATE LIMITED. In our system designed VFR is 0.91 kg/sec or 54.6
liter/minute, which is obvious that this the in between the brochure value so pump modulation via motor speed or
valves is required so we shall vary the speed of the motor till adjustment of the designed VFR.
The control system of the PAC-105 air conditioning is microprocessor based DDC (see for further detail unit 8), so
easily volume flow rate VFR of the water can be adjusted with the help of the stepper motor or through electronic
circuitry (see the references at end of this thesis report).
7.8
Supply duct
Temperature Guage
Temperature guage
Air Handling Unit Water Chiller

Chiller pump
AHU Motor
Temperature Direct Drive
guage
3-V, A/A
SV1
U1 Venturimeter
From PHE
Chilled water U2
inlet to AHU To AHU
SV2
From AHU To PHE
Figure 7.5 Hydronic System of PAC-105

This illustration of the PAC-105 hydronic system is showing all the necessary piping arrangement and accessories which are to be installed in the pipes for year round satisfactorily
functioning. Note also that PAC-105 is a DDC system, which requires special electronic measuring instruments in the piping circuit so therefore conventional gauges can be
replaced by the sensors of pressure, temperature, and volume flow rate measurement. One can also note all the components supplied to this equipment i.e. PAC-105 Air
Conditioning System in the Commissioning Check Lists in the unit 9 of this thesis report.
7.9
As PAC-105 system is a single zone, constant volume system, in which conditioned air is
supplying to the M-2 hall all round the summer season. So the hydronic system become very
important in any HVAC system, where we have to control the either air quantity incase of VAV
air system or regulating flow of water in the pipe to maintain the space temperature comfortable
to the occupants/inhabitants. These comments are based on the analysis not on the actual
conditions that the system is giving during the normal operating mode of the system during the
peak-load season in summer.
1. During the part load operation, energy input to the centrifugal pump of the chiller is directly
proportional to the total space load. This can be mathematically proved and it will be very helpful
in analyzing what pump speed is required in order to maintain the system capacity at full load or
part load operation of the system? Thus we can save the energy input to the pump and can be
modulate a DDC microprocessor-based control system for the part-load operation.
A little more complex analysis is needed to formulate relations of the space load and pump speed
etc. we know that The velocity triangles are shown in the figure 7.6, at inlet, the fluid moving
with an absolute velocity of v1 enters the impeller through a cylindrical surface of radius r1 and
may make an angle α1 with the tangent at that radius. At outlet, the fluid leaves the impeller
through a cylindrical surface of radius r2, absolute velocity v2 inclined to the tangent at outlet by
the angle α2.
The general expression for the energy transfer between the impeller and the fluid, based on the
one-dimensional theory and usually referred to as Euler’s turbine equation, may be now derived
as follows.
u2
Vw2
ί 2'
a2
Outlet Velocity V2 Vr2
Diagram
a1
Inlet Velocity V1 r2
ί2
Diagram Vf1
Vr1 Vw1
u1
r1
ί1
Figure 7.6 One-Dimensional Flow through a Centrifugal Impeller
From the Newton’s second law applied to an angular motion,

Torque = rate of change of angular momentum.
Now, angular momentum= (Mass) (tangential velocity) (radius).
Therefore,
7.10
Angular momentum entering the impeller per second = mw. vw1r1
Angular momentum leaving the impeller per second= mw. vw 2 r2
In which mw. is the mass of chilled water flowing per second. Therefore,
Rate of change of angular momentum = m.wvw2 r2 - m.wvw1r1
So that (
Torque transmitted = m.w vw2 r2 − vw1r1 )
Since work done in unit time is given by the product of torque and angular velocity,
(
Work done per second = (torque) ω = m.w vw2 r2 − vw1r1 × ω , )
But ω = u / r , so that ω r2 = u2 and ω r1 = u1 . Hence, on substitution
(
Work done per second, Wt = m.w vw2u2 − vw1u1 …..……….7.5 )
In SI unit the above expression are joules per second or watts.
Since the work done per second by the impeller on the fluid, such as in this case, is the rate of
energy transfer then:
Rate of energy transfer /unit mass the fluid flowing, Y= gE = Wt / mw. .
The product gE = Y known as specific energy is of significance in the case of pumps and fans.
From the specific energy, the Euler’s head E is given by:
E = (1/ g )( u2 vw 2 − u1vw1 ) . ..….7.6

The units of this equation are joules per kilograms divided by m/s2. this of course, simplifies to
meters and, therefore, is the same as all the terms of Bernoulli’ s equation and ; consequently, E
may be used in conjunction with it. Equation is known as Euler’s’ equation.
It is useful to express the Euler’s head in term of the absolute fluid velocities rather than their
components. From velocity triangles of Figure 7.6,
vw1 = v1 cos α1 , and vw 2 = v2 cos α 2 ,
So that E = (1/ g )( u2 v1 cos α1 − u1v2 cos α 2 ) . ………………7.7
But, using the cosine rule,
vr21 = u12 + v12 − 2u1v1 cos α1 ,
So that
1 2 2
u1v1 cos α1 =
2
( u1 − vr 2 + v12 ) .
Similarly,
1 2 2
u2 v2 cos α 2 =
2
( u2 − vr 2 + v22 ) .
Substituting into Equ.7.7,
⎛ 1 ⎞ 2
E =⎜ ⎟ ( u2 − u1 + v2 − v1 + vr1 + vr 2 )
2 2 2 2 2
⎝ 2g ⎠
And
⎛ v2 − v2 ⎞ ⎛ u 2 − u 2 ⎞ ⎛ v2 − v2 ⎞
E = ⎜ 2 1 ⎟ + ⎜ 2 1 ⎟ + ⎜ r1 r 2 ⎟ . ……………7.8
⎝ 2g ⎠ ⎝ 2g ⎠ ⎝ 2g ⎠
In this expression, the fist term denotes the increase of the kinetic energy of the fluid in the
impeller. The second term represents the energy used in setting the fluid into a circular motion
7.11
about the impeller axis (forced vortex). The third term is the static head due to reduction of
relative velocity in the fluid in the fluid passing through the impeller.
The velocity triangles of the PAC-105 centrifugal pump are shown in the figure 7.6. Since in
general, u = ωr, it follows that the tangential blade velocities at inlet and outlet are given by
u1 = ω r1
u2 = ω r2
and
2π N
ω= where N= number of revolution of the impeller in rpm.
60
Since the flow at inlet and outlet is through cylindrical surfaces and the velocity components
normal to them are v f 1 and v f 2 , the continuity equation applied to inlet and outlet for the mass
flow mw. and infinitely thin blades gives:
mw. = ρ1 2π r1b1v f 1 = ρ2 2π r2b2 v f 2 ……...7.9
Where b1 and b 2 are the impeller widths, as shown in the figure 7.7, and ρ1 and ρ 2 are the inlet
and outlet densities, respectively. For incompressible flow equation 7.9 simplifies to
r1b1v f 1 = r2b2 v f 2
b2
u2
w
b1
impeller blades
flow
inlet
r1
r2 inlet
outlet
outlet
Figure 7.7 A Centrifugal Pump impeller
We know that the total heat that can be carried by the water is given by the following relation as
( )
Qt = mw. c pw Tin ,chiller − Tout ,chiller = mw. c pw ( ΔTchiller ) ..7.10
Where
Qt = total load on the chiller or space load at the given conditions
Now from equation 7.10, the mass flow rate that is required to main constant temperature inside
the space should not be less than mw. so we have
7.12
Qt
mw. = .................................7.11
c pw ( ΔTchiller )
So we also know that the energy required for the pump to deliver the required mass flow rate of
chilled water can be estimated from Equ. 7.5, so therefore
Win = mw. ( u2vw2 − u1vw1 )
Substituting from Equ. 7.11 in Equ. 7.5
Qt
Win = × ( u2 vw 2 − u1vw1 ) .......7.12
c pw ( ΔTchiller )
So now let us assume that the absolute velocity of the fluid is radial at inlet then
We have v1 = v f 1 , and vw1 = 0 , from Equ. 7.12
Qt
Win = × ( u2 vw 2 ) ................7.13
c pw ( ΔTchiller )
π ND2
We also know that u2 = ω × r2 or u2 = , v w2 = v2 cos α 2 so now substitute them in
60
Equ.7.13, we have
Qt ⎛ π D2 N ⎞
Win = ×⎜ × v2 cos α 2 ⎟ .....7.14
c pw ( ΔTchiller ) ⎝ 60 ⎠
Where v 2 = abs. velocity of the fluid at the exit of impeller
Now rearranging equation 7.14, we have
π D2 cos α 2
Win = ( N × Qt × v2 ) ……..7.15
60c pw ( ΔTchiller )
So let us assume that if there is no heat transfer occurs between the water and the surrounding in
the PVC pipes of the PAC-105, so then we can take ΔTchiller as constant through out the system
normal operating season i.e. in summer cooling mode. On the way other for a given centrifugal
pump the dimension and conditions does not vary, also since there is no large change in
temperature so the specific heat of the water can be assumed as constant. So Equ.7.15 can be
written as
Win = Z ( N × Qt × v2 ) .......................................7.16
π D2 cos α 2
where Z = constant =
60c pw ( ΔTchiller )
So from the Equ.7.16, one can deduce the following results:
Energy input to the chilled-water centrifugal pump as shown in the figure 7.3, is directly
proportional to the space load, Qt, on the way other temperature difference
(Twe − Twl ) has a direct impact on Pump Power. At full load operation of the PAC-105
chiller, the volume flow rate of the chilled water is 1.61gpm/ton with a temperature
difference of 21.20 F which is a standard value from most chillers manufacturers.
In order to maintain the desired space load, we must have to increase the speed of the
pump, or on the way other volume flow rate of chilled water, it is obvious from the above
relation that increase in speed would definitely increase the volume flow rate of the
water, so then grater energy is consumed this is the main theme behind any constant
volume CV air conditioning system as of PAC-105.
7.13
So it is obvious that in this case we are not changing the speed of the compressor yet in
the above results. So it is cleared also here that in a VAV system we don’t change that
volume flow rate of the chilled water.
In the VAV system we change the supply air volume flow rate of air in the fan coil units
during a part-load condition which is more economical than changing VFR of the water
as in the CV system.
2. So during part load operation in the summer, let us say 60% of the total space load has to
maintained inside the M-2 hall then from the above relation i.e. Qpart-load = 0.6Qt , so then from
the above relation, it is evident that the total energy input to the pump reduces to 60%.
3. the total heat absorbed or temperature rise in the pipe by the chilled water can be estimated by the
using the convective heat transfer as given below:
Heat gain by the hydronic piping system for a constant volume flow rate can be calculated as
⎛ T −T ⎞
qd = U oπ D p L ⎜ Tamb − en l v ⎟ .................7.17
⎝ 2 ⎠
Where
U0= overall heat transfer coefficient of pipe wall, (w/m2. K)
L = length of the pipe from AHU to the chiller tank in m
Dp = diameter of the pipe in m2
Tamb= ambient temperature in 0C
Ten , Tlv = temperature entering and leaving the pipe exposed section to the air, these temperature
cab be recorded by the temperature gauges of the AHU and chiller as shown in the figure 7.5.
The temperature rise or drop of the water through the pipe section can be evaluated as
qd
Tlv − Ten = …...7.18
60 Ap v ρ wc pw
Where Ap = cross-sectional area of the pipe in m2, v = mean water velocity in the pipe can be
expressed as (m/s)
If substituting equation 7.17 into Equ.7.18, for the round pipe section we have
30 D p v ρ w c pw
y= ………….7.19
Uo L
Then the temperature of the water leaving the pipe section is
2Tamb + Ten ( y − 1)
Tlv = ..........2.42
y +1
This leaving temperature should not exceed to a higher value otherwise there may be an abrupt
loading on the chiller and thus on the pump, this may not be balanced easily within a short time,
so therefore consuming more electric energy to the pump for a longer time.
7.14
PAC-105
Unit 8
Design of
PAC-105 Control
System
Introduction
A
n air conditioning automatic controls system or simply control
system, primarily modulates the capacity of the air conditioning
equipments to maintain predetermined parameters within an
enclosure of fluid entering or leaving the equipments to meet the load
and climatic changes at optimum energy consumption and safe operation.
The predetermined parameter to be controlled is called the controlled
variable. In air conditioning the controlled parameter can be temperature,
relative humidity, pressure, enthalpy, fluid flow, contaminant
concentration etc.
Because of variation of the space load and outdoor climate, a
control system is one of the decisive factors for air conditioning
equipment or HVAC system to achieve its goal: to effectively control the
indoor environment parameters, provide an adequate amount of outdoor
air, be energy efficient, and provide the better security and safety. Today
nearly all HVAC systems are installed with a HI-TECH control system
to provide effective operation and energy conservation.
This unit presents the sequence of operations and precedence for
PAC-105 control. At the end of unit a tabular description is given which
provides the necessary information for design/selection of control system
i.e. set points, control modes etc of various elements of PAC-105
refrigeration and air-conditioning system.
8.1
Unit 8: Design of PAC-105 Control System
8.1 Control System of PAC-105
T he function of an air conditioning (or HVAC&R) control system is to modulate the

air conditioning system capacity to match the off-design condition, load variation,
and climate changes to maintain the indoor environment within desirable limits at optimum
energy use.
We have already discussed that PAC-105 will be a Constant Volume (CV) Single Zone system.
The part load operation of such a system is usually controlled by two types of control systems.
1. Water flow rate modulation
2. Two positions or cycle control
For PAC-105 we shall use the first method i.e. by controlling the mass flow rate of chilled water
through cooling coil of PAC-105 air handling unit (AHU). For all of the control system we shall
use direct digital controller unit (DDC unit).The schematic of control system is shown in figure
8.1. Although in order to control the cooling capacity of system we shall have to control the
hydronic system, air system, and the refrigeration system simultaneously, but for sake of
convenience first of all we shall discuss the hydronic system and refrigeration system control side
by side. Later on the air system control will be discussed. The proportional plus integral
control system has to be considered for controlling of the necessary inputs which are mentioned
above.
Proportional plus Integral (PI) Control. PI control improves on simple proportional control by
adding another component to the control action that eliminates the offset typical of proportional
control (Figure 8.1). Reset action may be described by
V p = K p e + K i ∫ edθ + Vo
Where
Ki = integral gain
θ = time
The second term in Equation (2) implies that the longer error e exists, the more the controller
output changes in attempting to eliminate the error. Proper selection of proportional and integral
gain constants increases stability, and eliminates offset, giving greater control accuracy. PI
control can also improve energy efficiency in applications such as VAV fan control, chiller
control, and hot and cold deck control of an air handler.
Fig. 8.1 Proportional plus Integral (PI) Control
8.2
Control System Terminology:
The set point is the desired value of the controlled variable. The controller seeks to maintain this
set point. The controlled device reacts to signals from the controller to vary the control agent.
The control agent is the medium manipulated by the controlled device. It may be air or gas
flowing through a damper; gas, steam, or water flowing through a valve; or an electric current.
The process is the air-conditioning apparatus being controlled. It reacts to the control agent’s
output and effects the change in the controlled variable. It may be a coil, fan, or humidifier.
The controlled variable is the temperature, humidity, pressure, or other condition being
controlled. The figure 8.2 shows a typical control system of the supply air temperature of the
PAC-105 air conditioning system’s AHU.
Figure 8.2 Feedback Control System: Discharge Air Temperature Control
8.2 Hydronic System and Refrigeration System Control

As we already have been discussed that cooling capacity of system will be controlled by
changing the mass flow rate of chilled water through cooling coils. Now the variable mass flow
rate of chilled water can be achieved either by varying the speed of pump or by using a flow
regulating valve. In the former case pump head will be changed at various speeds. But in order to
overcome the frictional losses our requirement is to have a constant head from pump. Therefore
first option will not work. Hence we shall control the mass flow rate of chilled water by using a
three way diverting valve, which will bypass the excess water towards pump suction at part loads.
Now at part loads, return water from air handling unit will be at varying rates and thus, it
will impart the proportional variation to the boiling rate of refrigerant inside the chiller shell. This
variation in boiling rate can be predicted from the superheating of refrigerant vapors coming out
of chiller shell and progressing to the compressor via suction line. Greater degree of vapors
superheat from predetermined value will show the lack of refrigerant supply and vice versa.
Hence the degree of superheat will be the representative of refrigerant mass flow rate and can be
use as an input to control it.
The control mode used for PAC-105 hydronic and refrigeration system control will be
proportional plus integral (PI). Figure 8.1 shows a temperature sensor T1 located at the suction
line. It will measure the temperature of refrigerant vapors and will send an input signal to DDC
unit. The DDC unit will compare it with set point temperature (0 Celsius) and will send an output
/ correction signal to compressor speed regulator to regulate the speed of compressor. Same
signal will be send to expansion valve to modulate the mass flow rate of liquid refrigerant coming
into the chiller shell. As PI control mode will be used for controlling, therefore in next turn
control system will set the compressor speed and refrigerant mass flow rate accordingly, hence
making the whole system stable.
8.3
O Ci Cl
m
Figure 8.1 Schematic Diagram of PAC-105 Control system
8.3 Supply Air System Control
8.4
Figure 8.1 shows the schematic of PAC-105 control system, with sensors and their
respective positions. The enthalpy sensors E1 and E2 will measure the enthalpies of indoor and
outdoor air respectively and then send an input signals to DDC unit. The DDC unit will compare
both the values. There might be two possibilities as follows,
1) E ≥ E
2 1
2) E2 < E1
Case 1
In first case if enthalpy of outdoor air is greater than or equal to that of indoor air.
Therefore it will be economical to use the indoor air again for treatment and then supply to
conditioned hall M-2.Thus under this condition the DDC unit will not send any signal to dampers.
Therefore the outdoor dampers (fresh air and return air dampers), which are normally close (NC)
will remain closed. And the recirculating air damper DM1 will remain fully open (normally open
NO).
The temperature sensor T1 will sense the temperature of indoor air and then send an input
signal to DDC unit. The DDC unit will compare it with set point (24 o C ) and then send an output
signal to the actuator of valve V1. The valve actuator will open or close the valve according to
input from DDC unit to control the mass flow rate of chilled water from pump.
The humidity sensor H1 will measure the humidity of indoor air and will send an input
signal to DDC unit. In the meantime any signal between sensor T1 and compressor speed
regulator & expansion valve will be overridden. The DDC will compare it with set point (50%)
and then according to offset, it will send an output signal to compressor speed regulator and
expansion valve. Due to change in mass flow rate of refrigerant, the temperature of chilled water
will change. Imparting a proportional change to mean surface temperature (or apparatus dew
point temperature) of coil for constant opening of control valve V1. It will cause a change in
humidity of supply air and hence that of room air. The schematic of control is shown in figure 8.2
Figure 8.2 Schematic Diagram of Control System for Case 1
8.5
Case 2
In second case it will be economical to use 100% outdoor air in air handling unit
therefore the return air from room must be exhausted and not recirculated. In this case the DDC
unit will send an output signal to actuators of dampers. The dampers DM2 and DM3 will be fully
open and DM1 will be closed completely. As the outdoor dampers will open the relief fan will
start running at full speed. Later on any variation in indoor temperature and/or humidity will be
controlled in same way as discussed above in case 1. The schematic of control is shown in figure
8.3.
Case 3
In case 2 there will be no problem of indoor air contaminants or smoke, because the
outdoor air will be used continuously and the indoor air will be completely exhausted. But in case
1 where the indoor air will be recirculated again and again. After some time smoke and
contamination level in the indoor air will tend to exceed some predetermined safe limit of indoor
air quality. This exceeding will be detected by a smoke detector SD. It will send signals to DDC
control panel that will compare it with set point (100ppm) and will send an output signal to
damper actuators. Responding to this corrective signal from DDC control panel, actuators will
open the dampers DM2 and DM3 by some permissible limit say 20% and will close the
8.6
recirculating damper DM1 by the same proportion. At the same time due to opening of outdoor
dampers relief fan will start running at same proportion as the dampers will be opened. Now
again the temperature and humidity of indoor air will be controlled in the same way as discussed
in case 1 and 2.the schematic of control is shown in Figure 8.4.
The following table 8.1 represents the description of control and operating conditions of various
control elements of PAC-105 control system.
8.7
Table 8.1: Description of the Control and Operating Conditions for Various Control Elements of
PAC-105 Air Conditioning System
Sr. Control Symbol Set Control Normal Actuator Control

No Variable Point Element Operating /Regulator Mode
(CV) (SP) (CE) Conditions Type
Of CE
1. Room Temp T2 24 Valve V1 Normally Modulating Proportional
Closed(NC) Mode With Plus
50%Open Supplementary Integral(PI)
At50% Load Power Supply
2. Room R.H E1 50% Compressor Running Electric PI
3. Indoor H1 Dampers Dm1(NO) Electric Motor PI
Enthalpy Dm1,Dm2 Dm2 And
Dm3 Dm3(NC)
4. Outdoor H2 H1 - - - -
Enthalpy
5. Room - Dampers Dm1(NO) Electric Motor PI
Smoke Level Dm1,Dm2 Dm2 And
Dm3 Dm3(NC)
6. Ref. Vapors T1 0 Compressor, Running Electric, PI
Temperature E.V Pneumatic
8.8
PAC-105
Unit 9
Commissioning and
Maintenance of PAC-
105 Air Conditioning
System
Introduction
H eating, ventilating, and air conditioning (HVAC) systems are

designed to provide controlling of space temperature, humidity,
air containments, differential pressurization, and air motion.
Usually an upper limit is placed on the noise level that is acceptable
within the occupied spaces. The above mentioned designed parameters in
the M-2 hall can only be achieved if the system (PAC-105) and air
distribution system/devices must satisfactorily perform the tasks
intended.
In the previous units we have been discussed and designed all the
components which are involved in the design intent of the system. It is
necessary now to discuss the commissioning and maintenance schedule
of the PAC-105 so that it must satisfy the intended means. In this unit we
have been discussed the basic strategy and methods to improve the
system performance in the peak loading hours i.e. in the peak season of
the summer. The information given in this unit is entirely related to our
system and provides optimum maintenance and repair techniques and
schedules which are adopted by the experts of the HVAC system in the
field.
9.1
Unit 9: Commissioning and Maintenance of PAC-105 Air Conditioning System
9.1 Fundamental of Commissioning
9.1.1 What is Commissioning?
C ommissioning is quite simply assuring that mechanical systems are installed and
functioning in accordance with the design intent. Achieving this assurance is
anything but simple. It involves rigorous efforts to exercise mechanical systems through their full
range of operations in attempts to verify that the systems will perform as intended by the designer
and as expected by the owner.
9.1.2 Objectives of Commissioning
The objectives of the commissioning are somewhat that assuring the performance of the
every mechanical system of the HVAC. Commissioning is the final stage in any quality assurance
program; and though it can be an add-on to an already completed project, commissioning
provides the best results when it has been integrated into the project from the earliest stages of the
design. Commissioning of the system is always performed by an independent commissioning
agent as accordance with the PAC-105 commissioning, so there will be a clarification between a
commissioning agent and a HVAC designer. On the way other that, if PAC-105 system really
started its work on the site or must be installed so then RACHNA college authority must have a
commission agent to insure that all the designed or intended HVAC equipments have been
purchased or installed correctly provided that if we are the designer. Commissioner is a person
not responsible for the design, installation, or operating and maintenance of the mechanical
systems.
Employing the services of a commissioner acting as an independent agent for the owner
provides the commissioner autonomy, allowing for objective and unbiased evaluations and
assessments in the commissioning process. The services of an independent agent, though
providing the optimum, are not absolutely required. Commissioning can be performed by the
design architect/engineer (A/E), by the installing contractor, by the owner, or by the owner’s
operating and maintenance personnel. Each of these entities brings the potential for the individual
bias (prejudice or inclination) and self-interest to skew the commissioning process.
The commissioner as early has been explained that he or she must be an independent body, if let
us say the system is being installed by installing contractor he would always insure that the
mechanical equipments are functioning up to that level provided in contract documents or
intended by the owner. The installing contractor may have a great potential for exercising the bias
in commissioning his installations as in Pakistan especially in Gujranwala, this being the
proverbial “fox guarding the chickens”.
Remember, the commissioning is an assurance of what has been purchased by the owner has in
fact been provided. The initial role of the commissioner as A/E is to provide the owner with
mechanical systems which will serve the owner’s needs.
Commissioning is not intended to provide a design review; it is assumed that the design of
mechanical systems will be competently provided by the design engineer. The role of the
commissioning agent through the design phase is primarily one of observer, to gain insight into
design intent (aim-meaning) and expectations and to be cognizant (having knowledge of) of the
design decisions and trade-offs which ultimately will effect the systems performance and
operations. The commissioning agent will also serves as an advisor, offering guidance in the
preparation of documents to assure that all necessary systems components and test procedures are
provided to facilitate the commissioning.
9.2
9.2 Commissioning Check Lists of PAC-105
As discussed shortly in the above that the commissioning is somewhat what a designer
specified and what receive to an owner. So the following entire check lists are concerned to the
PAC-105 system. These check lists are to be filled by the contractor and certified by the
commissioning agent. Be remember that we have been stated earlier above that commissioning
agent may not a member of the design team but may have a close contact with the designing
teams from early part of the design.
The PAC-105 Commissioning Check Lists
Table 9.1: Commissioning Check Lists of PAC-105.

Commissioning Check List 1
PUMP
Number: _01-105AC____________ serving: ____________________
GPM Head, H.P. v/ph/fr RPM Type Manufa- Model Comments

ft cturer No.
Specified 16 197.63 1 * 1425 A Golden -
Installed 14.5 205 1¼˜ * 1425 A Goldenº -
Comments:
1. * 440V-50Hz. ~3P
2. º alternative may be considered in case of imperfection
3. ˜ high H.P preferred incase of unusual performance based on PPS
Designed or Designed or
Specified Provided Specified Provided
Installation Installation
Yes No Yes No Yes No Yes No
Check Check
Pressure Gage Suction Diffuser
Suction Strainer
Discharge Drain
Isolation Valves Thermometers

Balancing Valves Inertial Base
Check Valves Vibration Pads
Unions
Comments:
1. º strainer preferred incase of high risk, but most pressure is dropped across them
2. In the above check list it is minimum equipments list requirement for system running normally
3. Note: This is only for a clarification of the idea of using CCLs
Contractor Commissioner
Comments
Recorded Date Observed Date
Operational Check
Pump Discharge
Pressure (PSIG)
9.3
Pump Suction Pressure

(PSIG)
Pump Rotation
Alignment
Motor Amps
Type:
A ≈ Centrifugal
B ≈ Reciprocating
HYDRONIC SYSTEM ACCESSORIES
Number: _________________ serving: ____________________
Air Expansion
Separator Tank Strainer
Specified
Installed
Comments:
1.
2.
Check Check
Air Separator Make-Up Water
With Strainer Pressure Regulating
Valve
Without Strainer Back-Flow Preventor
Pressure Gages Isolation Valve

Isolation Valves Strainer
Drain By-Pass
Expansion Tank
Tank Fittings Pressure Relief Valve
Site Glass
Drain Unions
9.4
Comments:
1.
Design is assumed to be leak-proof, assuring joints air tight and fulfill international standards
2. not yet considered into design but shall be prefer for continuous system working in the summer
3. There may be a little variation in the accessories mentioned above for making system performance more
economical, and energy savings.
Comments
Operational Check
Air Separator Pressure
Drop (PSIG)
System Fill Pressure
(PSIG)
Relief Valve Setting
(PSIG)
Comments:
1. We can evaluate this CCL above because of the misinformation and control. lack of information etc
2.
3.
AIR HANDLING UNIT
Number: _________________ serving: ____________________
Supply Fan
Unit
Style-Horiz, Mfg.
Min. E.S.P Drive Power Verl, Floor,
Total OA In. Belt/ V/Ph/ Draw/Blow- Hung ,
cfm cfm WG RPM Direct HP Freq Mfr. Thru AF/FC Roof
etc.
Specified 3790 2 1250 B.D 1.75 440/3 Local Vertical, draw Floor
/50
Installed 3795* 2 1255 B.D 1.75 440/3 Local Vertical, draw Floor
/50
Comments:
1. * this CFM is intentionally provided to full fill the losses i.e. leakages in the various joints etc
2.
9.5
Cooling Coil
E.A.T. L.A.T Air GPM Water Rows/ FV Total Sens E.W.T. L.W.T
0 0 0 0
F F P.D. P.D. Fans FPM Clg Clg F F
db/wb db/wb In.WG In.WG MBH MBH
Specified
Installed
Comments:
1.
2.
3.
AIR HANDLING UNIT

CONSTANT VOLUME, HEATING/COOLING
Number: _________________ serving: ____________________
Designed
Or
Designed Specified
Or
Specified Provided Provided
Installation Check Yes No Yes No Installation Check Yes No Yes No
Supply fan Prefilter Section

Isolation Type (Flat, Angle, Bag,
(external/internal) Etc.)
Access door Access
Discharge flex Frame
connection
Cooling coil Starter
Control valve Vibration Isolation

Face and by-pass Bass(Spring, Pad, etc)
damper
Condensate drain Hanger(Spring, Rubber,
etc)
Smoke detector Curb Isolators
Supply air Spare Belts
Return air Spare Filters

Casing
Double wall
Single wall
Comments:
1. HEPA filters of sq. cross-section are preferred for the system due to occupant safety, see unit 4
2. Since PAC-105 is DDC micro-processor control system, requires lot of strict control and
management.
9.6
Operational Check Recorded Date Observed Date Comments

Dampers Operation
NC-NO
Min. Damper Position

Safeties
Leakage
Filters
Clean
Differential Pressure
Clean
Differential Pressure
Load
Control Valves
NO-NC
Safeties
Face & By-Pass
Dampers
NO-NC
Safeties
Condensate Drain
Continued…
Operational Check Recorded Date Observed Date Comments

Clean Coils
Smoke Detectors
Operation
Temperature Control
Operation
Space Temperature
Discharge Air
Mixed Air
Return Air
Start/Stop Control
Cooling Sequence
Occupied
Cooling Sequence
Unoccupied
9.7
Comments:
1.
2.
3.
PAC-105 Water Chiller
Number: _________________ serving: ____________________
Qrc W.E.T. W.L.T. Model

GPM TR 0
F 0
F RPM Type Manufacturer No. Comments
Specified
Installed
Comments:
1.
2.
Check Check
Pressure Gages Sight glass
Entering Control switches
Leaving Drain
Isolation Valves Thermometers

Balancing Valves Ref. Purging system
Check Valves Vibration Pads
Unions Anti-corrosion Agent
Comments:
1.
2.
Comments
Operational Check
Chiller Pressure (PSIG)

Pump Suction Pressure
(PSIG)
Pump Rotation
TEV Differential
Pressure(PSIG)
Comp. Motor Amps
9.8
Comments:
1.
2.
9.3 Maintenance and Repair of PAC-105
Broadly the term “maintenance” can be explained as the practices performed on the
mechanical systems after their installation and functioning on the floor after a period to insure
their outcomes according to design intents, reliability, and perfection so that they could meet the
owner’s satisfaction and economics. Other factors are also very much important we are not yet
considering them here i.e. maintainability, calibration of system equipments, saving energy and
capital flow/cost of maintenance etc. there are various types of maintenance we shall discuss here
only concerning to PAC-105 refrigeration system.
Repair: that facility work required to restore a facility or component thereof, including collateral
equipment, to a condition substantially equivalent to its originally intended and designed
capacity, efficiency, or capability. It includes the substantially equivalent replacements of utility
systems and collateral equipment necessitated by incipient or actual breakdown. There are four
types of the maintenance commonly practices when they are concerned by maintenance engineers
(M/E).
9.4 PAC-105 Maintenance Practices and Repairing Schedule
The system maintenance becomes inevitable when it is not properly functioning or

exceeding the limits of the design intents. Here in the following pages we shall discuss the
reactive or shutdown maintenance for the illustrative purpose. The mechanical system equipments
of PAC-105 would have been mention in the previous sections so during the normal operation
mode of the system in the peak loading condition all the system equipments must satisfy the
design intent. So we shall discuss the repairing and maintenance schedule one by one.
9.4.1 PAC-105 System and Components
This has been thoroughly discussed in introduction unit of PAC-105, that it is a water-air
central, reciprocating chilled-water air conditioning system. Where we are transporting chilled
water from the chiller to the AHU coils, which is placed far away from the chiller (i.e. 70m), then
conditioned air is supplied to the M-2 hall through ducting. Since in the PAC-105 the water is a
secondary refrigerant main cooling agent carrying bulk of heat from the AHU to the chiller then
in the chiller it is absorbed by the an cooling agent known as primary refrigerant i.e. refrigerant
R134a. The refrigerant R134a partly absorbed this amount of heat and rejects it to the channel
water via condenser. The condensing unit is fully immersed in the channel. This must have some
provision for its life to be extending to years, because if the condenser does not properly function
then overall system effectiveness reduces to a minimum value which no doubt is a loss of capital
and energy.
The necessary Components of the PAC-105 air conditioning system are given below which need
to be maintained periodically for best system performance year round. They are:
¾ Hydronic system
¾ Cooling coils of AHU and Water Cooled Open-Type Condenser®
¾ Fans, Pump and Compressor Motors
9.9
¾ Golden® Centrifugal Pump

¾ M-2 hall air ducting system
¾ PAC-105 Water Chiller
¾ Control system
9.4.2 Hydronic System
The hydronic system of the PAC-105 is not so complex that it should required special provisions
to maintain its operation. We selected the PVC pipes in our design because of sufficient rigidness
and strength to sustain our system pressure and temperature. So a hydronic system in any aspect
should have capability to transport the design quantity of fluid to the terminal unit for which it is
designed.
Minor leaks at the joints of a hydronic system will not affect the system operations if the system
is equipped with an automatic make-up media. Systems without automatic make-up media will
have a loss of efficiency and equipment “lock out” when leaks occur; therefore repair should be
initiated promptly.
We have incorporated special “benchmarking” in the design to minimize the errors and defects
during the operation of the system in the normal working conditions. Because an improperly—or
poorly—installed piping system can later prove to a major service problem. In addition, it is
possible to have a piping configuration that is functionally correct, but it is configured in such a
manner that servicing the equipment is difficult, and in instance impossible. The piping of the
PAC-105 is buried in the land 1-1/2 ft to protect pipes from disturbances from humans and
vehicles. Chilling system is installed at the bank of the canal, it is very critical for us to maintain
its functionality year round. The both supply and return pipes for chilling water are double coated
i.e. one with insulation of nitril-foam and other with again a 2 in. pipe with small thickness to
protect pipe from moistures and mud (see figure 7.1, unit 7 for further detail).
PAC-105 Hydronic System Components
The hydronic of the PAC-105 consists of the following components
¾ Valves
1. Valves should be installed in a position that allows servicing of units.
2. Isolation valves should be installed in a position that will allow the removal of piping
system or equipment (see figure 7.5). Isolation valve should be rated at a pressure
differential high enough to accommodate full shut-off, with one side open to
atmospheric pressure. Or it must sustain the pressure or hammer blow (2.58 MPa)
when regulating valve is closed suddenly.
3. Drain valves should be installed at the bottom of the piping system risers in a
practical and serviceable area.
⇒ If the valve do not seat properly when first used, flush foreign matter off of
the seat by opening a valve slightly, when closing it, and repeating this
procedure as necessary.
⇒ Do not apply excessive force on the valve stem if you are feeling abnormal
seating of the valve because this might be due to debris and foreign matters
present below the seat of the valve. Because abnormal force applied on the
stem with cheater bars may distort or break the bonnet of the valve.
The following system Troubleshooting Table will show an idea of how we can repair a system
after defect has been observed: this Table is also showing the other components of the PAC-105
system and their maintenance procedures.
9.10
Table 9.2: Piping/Hydronic System of PAC-105 Troubleshooting Chart
Repair & Maintenance

Component Defect Cause
Procedure
Leak Dirt Remove, flush, or replace

AIR VENTS
Plugged Sediment (Depress stem to verify shut-off)
Gasket failure resulting

from expansion/ Clean joint – replace gasket.
contraction (Consider anchors and guides to control movement of
DIELECTRIC UNIONS Leak
Over tightening at time pipe.)
of installation damaged Replace fitting
component
Clean line and fittings

Dirt in gauge line Use snubber valve and shut-off
GAUGES False reading
Vibration or pulsation Valve. Open shut-off valve only
when reading.
Velocity Blow down, or adds scale cleaning agents or chemical to

PVC PIPES Algae/ scaling
fluctuation reduce the concentration of the Mg and Ca
Replace –Apply proper vapor

barrier
INSULATION Deterioration Condensation Metal jacket may be necessary for
protection
Saddles at Supports
PVC PIPE Leak at fittings Cracked ends of pipe Cut off defective ends before
makeup at joints.
PIPE CLAMPS Loose or

Vibration Tighten — use lock nuts
missing
Bleed system;
PVC PIPE Internal pitting Air (oxygen) in system Check air control systems;
Check compression tank air level
Table 9.2 continued…
Repair & Maintenance

Component Defect Cause
Procedure
PRESSURE Erratic flow Pilot line clogged Clean and flush line
REDUCING VALVES Fails to shut-off Contamination Replace or rebuild valve
Low mass flow rate Dirt Check pipe accessories and pipes, or
PVC PIPE
of chilled water Contamination, leakage replace a section or whole if damaged
9.11
Flush or clean seat

Weak diaphragm: Dirt
Leaks on seat valve spring
RELIEF VALVES
Fails to open tension
Replace valve, if necessary –
Corrosion
check pipe for cleanliness. Test
at system design.
Back flush
Remove screen – clean and
STRAINERS# Clogged Dirt in system replace
Verify mesh size of screen
system cleaning
Proper location of device

Excessive vibration or
Separation temperature
THERMOMETERS Use compound in well to transmit
False Reading Poor heat transfer
temperature
Wrong scale device
Replace with device with scale of
media range
Leak Dirt Clean joining surfaces
*
UNIONS Flow turbulence
Misaligning pipe ends Align pipe ends – tighten
Installation direction Install union in proper flow

direction
Will not turn Stem corroded Clean and lubricate stem (Do not
VALVES Will not shut-off paint stems)
Dirt in seats Clean seats, discs, gates;
Replace as required
Lack of flow Air in system Install manual air vents at high

WATER HAMMER Noise points to vent system
Condensate in steam Install drip leg and steam trap to
flow collect condensate
Leaking failure Pipe weight or Support pipe independently;

VIBRATION alignment Align pipe
ELIMINATORS
*--Unions installation near AHU and chiller for isolation purposes see Figure 7.3
#-- considered in the designed commissioning check lists of PAC-105, location not defined in the figure 7.5
⇒ If the valves do not function properly, system pressures could rise, fluid temperatures could go to extremes, hot or
cold, flow rates could differ from design, critical fluids could be lost, and personnel could be injured.
9.4.3 Water-cooled Open-type Condenser® & AHU Coils Care
The coils are generally heat exchanging devices from one fluid to an other both at
different temperatures without changing the chemical properties of the either fluid. So it is clear
that the coils are static devices which can not create pressure, pressure surges, energy,
temperature, plunging solids or scale. If the coils are properly designed for services and operated
within its original design parameters, it will provide many years of trouble free, high efficiency
services. In the PAC-105 system the coils of the AHU is cooling the return air coming from the
M-2 hall (see unit 3 for further detail), so if the coils are clogged before there normal operation
9.12
then effectives of the AHU coils will be significantly reduced. In case of the condenser coils the
purpose is same to reject the heat to the fluid either air, oil or water. So we are discussing about
the PAC-105 Water-cooled Open-type condenser® (see figure 6.3), which is fully immersed in the
channel water. There is a high risk of the sediment during the rainy or flooding season. So in this
situation heavy thick layer of the sediments and scale may be formed on the surface of the coils to
resist the heat convection transfer to the water. So we shall discuss them in the following pages.
AHU Coil Cleaning Methods
After consistent inspection and monitoring it is wise to take the cleaning or maintenance. In the
AHU since chilled water is flowing at a velocity of the 1.11m/sec (in each circuit of the coil). If
the face velocity of the air does not optimized then there may significant condensate on the coil
surface which is a resistance to heat flow. We have determined face velocity of the PAC-105 as
2.48 m/sec a standard value for most of the cases in designing of coils so that condensate drop
shall not stick on the surface.
Following are the standard methods for a coil cleaning:
On-Site Cleaning: depending upon the nature of the transfer of the fluids and the application,
performance of the heat exchanger may degrade over the time. This decline in performance is
typically due to the build-up of scale, sediment and/or biological mass on the plates. Fouling of
the coils manifests itself as a decrease in thermal performance, an increase in pressure drop across
the coils and/or a reduction in the flow through the coils. This method of cleaning is normally
done on the site where exchanger is functioning under a skilled field service engineer.
Nonmetallic brushes, high pressure washing and various cleaning agents can be used to clean the
coils, fins and braces support on-site. Common cleaning agents are given below:
Hot Water
Nitric, sulfuric, citric or phosphoric acid
Complexing agents such as EDTA or NTA
Sodium Polyphosphates
Off-Site Cleaning: a recommended cleaning alternative to on-site cleaning is to have the coils
and assembly off-site in a qualified PHE service center. Same chemical actions can be done on
coils as done on-site. The coils are inspected, disassembled, plates reconditioned and the
exchanger reassembled. The exchanger can also be hydrotested at the center prior to it being
shipped back to the site.
Cleaning In Place (CIP): cleaning in place (CIP) is a procedure used to clean the heat exchanger
while it is installed in the system without having to open the exchanger. During CIP cleaning,
specific chemicals at prescribed temperatures, typically 140 to 170 0F are circulated at low
velocities through the fouled side of the exchanger to chemically clean the unit of fouling
deposits. Sometimes CIP methods are used to clean the entire system.
Condensate Control in AHU Coils
Suitable condensate control is achieved and an acceptable HVAC maintenance

program can be implemented only when condensate is confined to (a) surfaces of the cooling
coil, (b) a small and properly sloped condensate drain pan, and (c) a well drained system
through which condensate flows freely and never stands nor stagnates.
9.13
Confining condensate to these three areas allows the system to operate virtually free of
excessive maintenance, property damage and health-threatening biological growth. When
condensate is confined in this manner, the required system maintenance consists of rather
simple periodic scheduled procedures: inspecting, cleaning, and flushing the drain system
(pan, seals and lines).
System deficiencies that allow the spread of condensate beyond the cooling coil and the drain
system include the following:
Condensate carryover from cooling coils
Condensate drips onto internal HVAC system components
Unsuitable drain pan designs
Very low supply air temperatures
Improper fan position inside the air handlers
Ineffective seals on condensate drain lines
Unsuitable installation of condensate drain lines
A suitable condensate control pan can be a good practice to control the condensate in the AHU
coil. So in the design, the total latent load is limited to 4.486 Kw (15293.18 Btu/ hr). This latent
load is largely consists of the occupants and the infiltration through the M-2 hall openings, one
important thing that should keep in mind we are not taking the concept of the mixing in the
design criteria of the PAC-105 system. So it is evident that because of this latent load there may
be significant problem of condensate control. The quantity of condensate calculated in section 2.8
(without air mixing), is
Mass of water vapor condense or condensate = 6.356 kg / hr
⇒ If Assuming condensate density same as water density i.e. 1000 kg/m3 also 1000 liter = 1 m3.
= 6.356 liter/ hr or 1.679 gal/hr or 0.02798 GPM
Total condensate per working hour day is = 1.679 × 8 = 13.432 gal/w.d
⇒ Since PAC-105 system operating hours per day are 8 in the design (2000 hrs/ O.S for SDC)
⇒ Condensate pan sizing can be found from the handbook of operation and maintenance of
HVAC.
Where w.d = working day, O.S = operating season, SDC = secure design criteria.
This is significant condensate quantity per working day (w.d), there should require a careful
design of condensate pan of the AHU of PAC-105 system. Poor condensate pan design can be a
problem for the coil performance and hygienic conditions. The condensate pan width, length,
depth and slop are a function of the condensate flow rate given above for efficient performance of
the coil (For Detail, see Unit 3).
Condenser unit which is dipped in the channel water should have a careful cleaning and
operational control. Since there is tremendous risk of sediments in the water in the flooding
season so daily cleaning and periodic check-up is needed to insure the satisfactory operation of
the Water-cooled Open-type condenser® of PAC-105 system. Nonmetallic brushes with hard
bristles should be use to clean sediments and biological elements from the surface of the
condenser. A special configuration of the condenser making it more feasible and reliable for the
situation. Long, annulus, hollow inside shape of the PAC-105 condenser is easy to clean and
check-up without disturbing the operation of the system in the operating season.
9.4.4 Maintenance of Blower, Pump, and Compressor Motor
Motors are the driving elements of any HVAC system, if they are not properly
functioning according to designing criteria; no one can guarantee you for the perfection of the
system. Care must be taken to daily evaluation of the performance of the motors performance.
9.14
All A-C motors induction motors will perform satisfactorily with a 10 % variation in voltage, a 5
% variation in frequency or a combination voltage-frequency variation of 10 %. For motors rated
208-220 V, the above limits apply only to 220V rating.
Motors are received with bearings lubricated and require no lubrication no lubrication for some
time depending upon the operating conditions.
Motor Lubrication and Maintenance
Since the selected motors for the blower, pump, and compressor use antifriction ball
bearings so there periodic maintenance scheduling is an important step in the design. Following
steps should be taken
Regrease or lubricate motor bearings according to the manufacture’s
recommendations. Motors manufacturer’s lubrication recommendations are printed
on tags attached to the motors.
DO NOT OVER-LUBRICATE the motors bearings.
Since the PAC-105 system will work under the ambient atmospheric conditions
ranges 40-48 0C, relubrication period should not be less than 3 year for the motors of
AHU and pump. For further detail see the following table
Table 9.3: Recommended Lubrication Intervals for Motors
Power Range Standard Severe duty 24 hr/day Extreme duty---very dirty

duty 8 dirty, dusty high ambients
hr/day
H.P* KW
11/2-71/2 2-10 5yr 3yr 9mo
10-40 13-54 3 yr 1yr 4mo
*1HP = 746 watts.
The blower is mounted on the two support antifriction ball bearings; they must be
covered with bearing houses tightly so that air containing moats, dust or particulate
matters should not penetrate into the bearings. Frequency of lubrication for such a
conditions can be taken periodically after checking maintenance check lists daily
filled by maintenance personnel on the site. For grease lubricated ball or roller
bearing pillow block, a good grade of grease free from chemically or mechanically
active material should be used. When grease is added, use caution to any dirt from
entering the bearing. So following table showing the frequency of lubrication for the
PAC-105 blower:
Operating speed (RPM)
Shaft size in. mm 500 1000 1500 *2000 *2500 *3000 3500 4000 4500
Lubricating frequency (months)

0.500-1.00 12-25 6 6 6 6 6 6 4 4 2
1.06-1.44 27-37 6 6 6 6 6 6 4 4 2
1.50-1.75 38-45 6 6 6 4 4 2 2 2 1
9.15
1.88-2.19 49-56 6 6 4 4 2 2 1 1 1
*figures with bold marks are the designed and optimum speeds for the PAC-105 system operating characteristics so
they must be strictly follow in order to minimize the lubrication cost or on the way other maximize the lubrication
period.
Normal operation of motors results in temperature rise. Permitted temperature rice

depends upon on type of motor installation. The total motor operating temperature is
the ambient temperature + motor temperature rise. The motor temperature rise
includes nameplate temperature rise, service factor allowance, and hot spot
allowance. The temperature rise due to friction between the moving elements of the
motor and the static body generates the heat this heat must be continuously removed
so that temperature remains constant. Motors are either air cooled or water cooled or
incase of severe duty like compressor motor the motor is usually cooled with the
refrigerant vapor passing through it.
9.4.5 M-2 Hall Ducting System
Ducting as so for has been explained in detail in unit 3 can be used in the air conditioning
system in order to distribute the conditioned air, and also return this air back to the AHU for
reconditioned. Clean ducts can assure the indoor air quality (IAQ) to the accepted level.
Generally as discussed above that in the M-2 ducting is not yet complex that needs to be complex
analysis for balancing of the system. Ducts should have the optimum thickness of insulation to
minimize the heat loss and risk of condensate on the surface; this can be a good sign for
biologically/hygienically clean indoor and outdoor environment. Following three methods may be
employed for cleaning of the inner surfaces of the M-2 hall ducts:
¾ Contact vacuum method (figure 9.1 a)

¾ Air washing method (figure 9.1 b)
¾ Power brushing method ( figure 9.1 c)
For an idea we shall discuss only one method here, and the other two methods can be seen in the
figure 9.1
Contact Vacuum Method
Conventional vacuum cleaning of interior duct surfaces through openings cut into the
ducts is satisfactory so long as reasonable care is exercised. The risk of damaging duct
surfaces is minimal. Only EPA (high efficiency particle arrestor) vacuuming equipment
should be used if vacuum equipment will be discharging into occupied space. Conventional
vacuuming equipment may discharge extremely fine particulate matter back into the building
air space, rather than collecting it. This process may leave particulate matter in the duct
which may later become airborne and contaminate the occupied space. This may occur
because the duct is not under negative pressure during the cleaning operation.
Direct vacuuming will usually require larger access openings in the ducts in order for
cleaning crews to reach into all parts of the duct. Spacing between openings will depend
on the type of vacuum equipment used and the distance from each opening it is able to
reach.
The vacuum cleaner head is introduced into the duct at the opening furthest upstream and
the machine turned on. Vacuuming proceeds downstream slowly enough to allow the
vacuum to pick up all dirt and dust particles. The larger the duct the longer this will take.
9.16
(a)
(b)
(c)
9.17
Figure 9.1 (a) Contact vacuum cleaning (b) Air washing method (c) Power brushing method.
Observation of the process is the best way to determine how long it takes before linings
are considered sufficiently clean.
When observation indicates the section of duct has been cleaned sufficiently, the vacuum
device is withdrawn from the duct and inserted through the next opening, where the
process is repeated.
9.4.6 Refrigerant Compressor
Since PAC-105 is a reciprocating chilling system in which we have selected the

refrigerant 134a which is environmental friendly refrigerant and it has zero ODP. It is obvious
that the purpose of the compressor is to move the refrigerant through the system by causing a
pressure difference between the high side and low side. The compressor failure is normally
observed in the system only because of the following reasons:
Heat: heat is the biggest enemy of the compressors, especially hermetic and semi-hermetic type.
It should keep in mind here that the designed type for the PAC-105 is semi-hermetic compressor
(see for further detail unit 4).
Heat can cause the motor windings to overheat and the compressor lubricating oil to break down,
causing a mechanical failure. Should there any be moisture inside the refrigerant circuit, heat will
increase its effects by each degree of temperature increase.
The heat will cause the moisture to change into acids that will attack every part in the system.
This is indicated by the motor windings breaking down and copper plating on all the steel
components. An overheated compressor can be caused by ht several circumstances, such as:
A dirty or scaled condenser
Shortage of refrigerant;
Overcharge of refrigerant;
To high superheat setting on the flow control devices;
Low or high voltage;
Dirty evaporator;
Low load; and
Dirty filters (in an air conditioning system)
Compressor and Condensing Unit Maintenance; Do’s And Don’ts
Keep coils clean of dirt and scale buildup.

Make sure the system has the correct refrigeration charge.
Make sure the flow-control device has the correct superheat setting.
Make sure that the unit is receiving the proper voltage.
Make sure that the filters are changed regularly.
Make sure the unit is correct size for the application; this point is being still
mentioned here only for the sake of knowledge.
Make sure the unit has proper lubrication.
Straighten bent fins.
Clean the contactor contact.
Don’ts:
File the contactor contacts; it’s a waste of your time and the customer’s money. Just
replace them.
Since the condenser unit is immersed in the channel water don’t try to make it clean
by pushing it up or down. This may cause a functional problem in the system.
9.18
Turn the nature direction of the condenser at which it is designed because this may
significantly reduce the capacity of the system.
9.4.7 Golden® Centrifugal Pump
Since we have been selected the centrifugal pump of Golden® Pumps manufacturers,
which matched our capacity requirement. The pump characteristics is given in the following table
MONO-GOLD PUMP® (1-¼”×1”)

Model Motor H.P. Volts Max. Suction Max. Head Qty, L/Min
1-¼”×1” 1 440 6M 10~24M 70~25
Motor
Model KW Volts AMPS. RPM Type
G.E motor 0.74 440 1.75 1425 Induction
Since maximum Head requirement is 197.63 ft (60.25 M), (See Unit 7 also) but in the table above
the maximum head produced by this particular pump is 24M; this problem can be coped by
increasing the size or capacity of the motor. The design mass flow rate of the water i.e. 0.91
kg/sec can be achieved by the selected pump of the Golden® manufactures given in above table.
Pump is a device that moves the heat transfer fluid in a system, and valves control the flow of the
fluid, a failure of either would cause the whole system to fail. The common problems during the
normal functioning of the pumps are:
¾ The part failure
¾ The “domino effect”
The part failure as name implies the disposition of any part from its location thus causing
disturbance in normal operation of the pump. Each component of the system is fitted with a
specific allowance as one component displaces it could cause the whole system to stop
functioning as designed.
The “domino effect” once a pipe or valves fail, the living space operating temperature starts to
differ from the control set point. This normally leads to discomfort for the occupants. If the relief
valve does not operate and the system pressure goes above design, a component in the system
could be damaged or rupture, causing property damage due to flooding. A valve that leaks all the
time causes new oxygen-laden water to enter the system, causing system components to corrode,
which could lead to a very expensive replacement.
If the chilled water pumps or valves fail, the chiller could freeze up and shut down, which
normally causes a long reset cycle, causing discomfort to the occupants.
The lesson is: maintain the equipment, repairs will be minimal, and damage loss will be
minimal.
Historical Failure Rate of the Pumps and Valves
Typically pumps and valves, if properly maintained, have a long, trouble-free life. Most
pumps don’t fail in a catastrophic way. The mechanical and electrical components of a pump tend
to give warning signs that parts are starting to fail. Periodic checking by the maintenance
personnel will pick up on these signs, and repairs can be scheduled accordingly.
The detectable parts of the pump are generally:
1. Bearings 5. Impeller wear
2. Water seals 6. Cracked or worn through casing
3. Coupling 7. Vibration
4. motor temperature
9.19
The nondetectable components would be:

1. Pump shaft failure 5. Spring fatigue and failure
2. Impeller hub fracture 6. Material fatigue and failure
3. Elastomer failure of sealing components
4. Motor winding insulation breakdown and shorting
When the system is first started and has settled out, performance tests should be rum on the
pumps. The performance tests should be run at 6 flow rates from 0 to full flow. The data should
be recorded on the yearly pump performance sheet (PPS), seen in the figure 9.2. This will be the
base line from which future performance curves can be compared.
Pump#__________________ Impeller Dia.___________________ Date _____________________

Mfg. ________________________ Suction size____________________ Discharge size ____________
Location_____________________ Bld. ___________Floor______________ System __________________
System fluid__________________ Concentration__________________ System Vol. __________________
Motor H.P. _________RPM ____________ F.L.A. _________________ Model # _____________________
RUN
Description 1 2 3 4 5 6
Disch. Press
Suc. Press.
Diff. press.
×2.31=Ft.
/Sp. Gr.
Head-Ft.
Velocity Head-Ft
Diff. press flow
GPM
RPM
AMPS.
VOLTS
Flow
reference
used
Figure 11.2 Pump Performance Sheet (PPS).
Grease Lubrication of the Pump
Since the pump (Mono-gold Pump®) of the PAC-105 grease lubrication should have to
periodic check up because of element of imperfection in design by the manufacturer. Most pumps
and motors these days use grease to lubricate their ball bearings. Some of the fractional and low
horsepower motors and some of inline pumps use permanently lubricated bearings. The re-
greasing intervals depend upon on running speed of the unit and operating temperature:
Pump RPM Regrease Interval

1450 *5000 hr
1750 4250 hr
3450 2000 hr
* Authors suggested regrease interval for PAC-105 Mono-gold Pump®

Most pump manufacturers recommend #2 lithium base petroleum greases some recommended
greases are:
9.20
Manufacturer Trade name

Exxon Unisex U2
Mobil Mobility Aw2
Valvoline Valplex EP
ESL Tempered W2
Texaco Premium RBI
9.4.8 PAC-105 Water Chiller (Shell and Tube, S&T Type)
In many way the operation and maintenance procedure of the shall and tube (S&T) chiller
is similar to those of a cooling coil thoroughly discussed above (coil care and maintenance),
except the physical outlook and operation mode. Water chilling system is a complex
configuration of tube bundles, baffles, separators and expansion devices enclosed in a shell.
Operation
During start up, the flow of the coldest fluid should be established first. After which the
hot fluid should be gradually introduced to prevent thermal shock. All vents should remain open
until air has been purged from both sides. In the shutting the chiller down, the flow of the hot
fluid should first be reduced gradually, followed by the systematic shutdown of the cold side. the
speed with which each side is started-up or shutdown is depend upon the nature of the fluids
involved, operating conditions and the differential temperatures and pressures.
Prior to start up and during operation, the external bolts should be checked to assure they are
tightened to the proper specification see figure 7.3. Bolted joints should be joints should be
tightened uniformly in a diametrically staggered pattern to the torque values specified by the
original equipment manufacturer. Overtightening may damage the gaskets resulting in leaks.
Maintenance of the Chiller
The interior and exterior surfaces of the shell and tube should be inspected on regular
basis. The exterior shell, flanges, bonnets and hub should be inspected for signs of damage such
as, dents, bulges, stress marks and corrosion. Gaskets should be checked for leaks and
displacement. Instrumentation should be checked and operating conditions noted for comparison
with previous readings. All variations and problems should be noted corrected. PAC-105 chiller
is open to the ambient then a special hood of metallic case should be on it all the year for
prevention from sunlight and rain effects. Interior inspection should be attempted only after the
unit has been fully drained and allowed to cool. A visual inspection of the tubes should be done
during the interior inspection. Where removable bundles are used, removal and replacement of
the damaged bundle should be done by a qualified service organization. Cleaning, leaks, and
splits tubes should be repair or removed after an expert decision. Mechanical cleaning of the
tubes may be required to restore the operating efficiency of the chiller. Rotary, nonmetallic,
electric or pneumatically driven brushes should be used to mechanically loosen tubes deposits
and scale. Use metallic brushes may damage the interior surface of the tubes, which could
accelerate the tube corrosion and failure. Since in the chiller, the tubes are of diameter of 12.5
mm, it is best practice to use the cleaning by pressure fluid forcing through he tubes one after
each if cleaning through power brushes is not possible.
During the reassembly of the chiller, all the gaskets should be replaced and all bolts tightened per
the manufacturer’s recommendations. Care should be taken to insure that all gaskets and seals are
properly positioned and that the bolts are not overtightened to prevent gaskets crushing and leaks.
9.21
Appendix A PAC-105
APPENDIX A
Symbols &
Abbreviations
Introduction
I n this appendix, all the symbols and

abbreviations concerning PAC-105 are
given. We have also incorporated the
conversion tables necessary for converting one
form of units to the other, because some of the
designing work e.g. chiller pump head, duct
sizes and analysis is given in the FPS system
due to the availability of charts and tables in the
FPS units.
A.1
Appendix A PAC-105
Abbreviations
*KWPT kilowatt per ton
A/E architecture engineer LiBr lithium bromide
ADC Air Diffusion Council LiCl lithium chloride
AHU air handling unit LPG liquefied petroleum gas
AMCA Air Movement and Control NBC National Broadcasting Corporation
Association NC noise criteria, normally-closed
ANSI American National Standard Institute NCDC national climate data center
ARI Air Conditioning and Refrigeration NFPA National Fire Protection Association
Institute NIOSH National Institute of Occupational
ASHRAE American Society of Heating, Safety and Health
Refrigeration and Air Conditioning NO normally-closed
Engineers NPSH net positive suction head
ASME American Society of Mechanical NWWA National Water Well Association
Engineers ODP ozone depletion potential
ASTM American Society of Testing and PI proportional plus integral
Materials PR pressure ratio
BAS building automation system PU packaged unit
BHP brake horsepower PVC polyvinyl chloride
BI binary or digital input, backward-inclined RH relative humidity
blade SBS sick building syndrome
BMS building management system *SDC secure design criterion
BOCA Building Officials and Code SEER seasonal energy efficiency ratio
Administrations SMACNA Sheet Metal and Air
CADD computer-aided design and drafting Conditioning Contractors’ National
CFC chlorofluorocarbons Association
COP coefficient of performance SI international system of units
DDC direct digital control SWSI single-width single inlet
DOE department of energy TIMA Thermal Insulation Manufacturers
DOP di-octyle phthalate Association
DWDI double width double inlet TR tonnage of refrigeration
DX direct expansion UL underwriters’ laboratories
EER energy efficiency ratio ULPA ultra low-penetration air filters
EMS energy management system VAV variable air volume
EIA Energy Information Administration of VVVT variable volume variable-
the Department Of Energy temperature
EPA Environmental Protection Agency WHO World Health Organization
FC fan coil, forward-curved blade WWR window-to-wall ratio
FDA food and drug administration * This is not a standard term which has been broadly
GWP global warming potential used in the HVAC. Actually this term has been taken
by the authors of this thesis and is equivalent to the
HEPA high efficiency particulate air F.O.S in the material science subject with the same
HFC Hydrofluorocarbons logics and idea.
HSPF heating season performance factor
HVAC&R Heating, Ventilation, Air
Conditioning, and Refrigeration
IAQ indoor air quality
I/O input/output
I-P inch-pound
IPLV integrated part load value
A.2
Appendix A PAC-105
Table A2: Conversions of Units From I.P. to SI.
A.3
Appendix A PAC-105
A.4
APPENDIX B
Tables & Charts
Introduction
T he Tables and Charts, which are

necessary for the design of the PAC-105,
have been incorporated in the Appendix
B, so that we can evaluate the necessary
parameters of the design.
Appendix B: Tables And Charts B.1

Table B1: Thermo physical Properties of Air at Atmospheric Pressure

TABLE B2: Thermophysical Properties of Saturated Water'
b
1 bar = 105 N/m2. `Critical temperature.

Figure B1: R134a Pressure-Enthalpy Chart (S.I. units)

Table B3: Properties of Refrigerant-134a

Table B3: Properties of Superheated Vapors of R134a. Continued…

Table B3: Continued…

Table B4: Local Loss Coefficients, Elbows

Table B4: continued...

Table B5: Loss Coefficients, converging junctions

Table B5: continued…
Table B6: Loss Coefficients, Transitions (Convergent Flow)

Table B7: Loss Coefficients, Diverging Junctions

Table B7: continued...

Table B7: continued…

Table B8: Circular Equivalents of Rectangular Ducts for Equal Friction and Capacity

Table B8: Continued…

________________________________________________________________________
References
A
ll of the references which are being used in the theses are grouped into four
categories given below. The first category i.e. key references are those from
where we have been used the information regarding mathematical equations,
graphs, charts and texts of each products in our PAC-105 air conditioning system. The second
category co-references as name implies are those references material which is thoroughly
consulted during and in the design but the nature of these references are same as that of key
references so there was no need of using their material in the design but in somehow we have
employed the mathematical equations. The third category manufacture’s brochures are very
important and indispensable in a way, that we are using all technical specs and data provided by
these manufacturers in the printed forms and software that is wholly or partially used to check the
validity of parameters during the design. The final one category is mentioned here, which is
straight a way is the dedication to the personnel and support organizations which took keen
interests and helped us in pursuing the HVAC products by their kind and sympathetic behavior
toward us. Some of the very important ones are being mentioned here in the following pages due
to shortage of space. The very important e-Source media is now a day keeps a lot of importance
because it provides us access easily to the latest information and products physical layouts
company “benchmarks”. So few numbers of the URLS are also added in this references list,
which we explored while designing the PAC-105 air conditioning equipments.
¾ Key Reference
•
[a,b,d,e,g,h,j,l ]
Frank P. Incropera, David P. Dewitt. Fundamentals Of Heat And Mass
Transfer, 5th ed. John Wiley & sons
• Edward G. Pita, Air Conditioning Principles and Systems,
•
[k,m]
Wang S. K. Handbook Of Air Conditioning And Refrigeration, 2nd Edition
McGraw Hill
• Roy J. Dossat. Principal Of Refrigeration, 2nd Edition John Wiley & Sons
• J. F. Douglas, J. M. Gasiorek, J. A. Swaffield. Fluid Mechanics, 2nd Edition Longman
International UK
• Robert C. Rosaler. HVAC Maintenance and Operational Handbook, McGraw Hill
• ASHRAE Handbook 2005 Fundamentals, ASHRAE Inc. USA
•
[f]
W.F stoecker J.W Jones. Refrigeration & Air Conditioning, 2nd edition. McGraw
Hill International
•
[c]
W.M Rohsenow, and J.P Hartnett, Handbook of Heat Transfer, “condensation
inside long tubes”. McGraw-hill, New York, 1973
•
[i]
C. P. Arora, “Refrigeration and Air Conditioning”, , 2nd edition , Tata-McGraw
Hill, New Delhi
¾ Co-references
• Holman J. P. Heat Transfer, 9th Edition, McGraw Hill International.

• Jones W. P. Air Conditioning Engineering, 3rd Edition, Edward Arnold.
• [n]
Gnielinski, V. “New Equations for Heat and Mass Transfer in Turbulent Pipe and
Channel Flow,” int. chem. Engg. vol. 16, pp. 359-368, 1976.
• Faber & Kell, “Heating & Air Conditioning of Buildings”, Oughton & Hodkison.
• R.K. Rajput, “Refrigeration & Air Conditioning”.
• Welty, Wicks, Wilson, Rorrer, “Fundamental Of Momentum, Heat & Mass
Transfer”, 4/e, John Wiley & Sons.
• Kaviary, “Principle of Convective Heat Transfer”, 2/e.
• William C. Whitman, William G. Johnson, “Refrigeration and Air Conditioning
Technology,” 3/e.
¾ Manufacturer’s Brochures, Softwares and Products Catalogues
• The TRANE® Company La Crosse, WI USA

• Golden® Pumps and Goldamatic™ uPVC Pipes (Pvt) Limited G. T. Gujranwala
• BOCK® Compressors, Germany
• SPORLAN™ Valves Company, USA
• ACSON® International Air Conditioning Systems, Malaysia
• Psychrometrics Analysis CD, Version 3.1.50, ASHRAE Inc. USA
• PIPE FLOW EXPERT™ Software For Engineering Professionals (Trial Version 1.12),
Flow Control Company United Kingdome
¾ Personnel/Support Organizations
• Asst. Chief Mechanical Engineer, Royal Palm Golf and Country Club, Lahore
• Siddique Sadiq Trust Memorial Hospital, Sheikhupura Road, Gujranwala
• Mian Corporation (Pvt) Limited, G T Road Gujranwala
• Engineer M. Qayyum, Execution Engineer HVAC, PITB Lahore
• Rupali Group of Industries, Lahore - Sheikhupura Road
• Pakistan Railways, Wagon Shop, Mughal Pura Lahore
¾ Web Sources
1. Http//: sporlan.com 11. Http//: alcocontrols.com

2. Http//: goldenpumps.com 12. Http//: emersonflowcontrols.com
3. Http//: dorin.com 13. Http//: trane.com
4. Http//: bock.de 14. Http//: allied-refrig.com
5. Http//: danfoss.com
6. Http//: flowcontrol.co.uk
7. Http//: oyl.com.my
8. Http//: directindustry.com
9. Http//: Copeland-corp.com
10. Http//: alcocontrols.com

PAC 105 Thesis-1

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Design of an Air Conditioning System

for M-2 Hall

PROF. DR. ARSHAD HUSSAIN QURESHI

MUHAMMED SHOAIB JAMIL SAJJAD AHMED

DEPARTMENT OF MECHANICAL ENGINEERING

This report is submitted to Department of Mechanical Engineering at

INTERNAL EXAMINER: SIGN: _______________

NAME: PROF. DR. ARSHAD HUSSAIN QURESHI

EXTERNAL EXAMINER: SIGN: _______________

DEPARTMENT OF MECHANICAL ENGINEERING

in recognition of the pivotal role played by

Unit 2 Cooling Load Calculation and Psychrometrics

Unit 3 Design of Air-Handling Unit and Ducting System

Unit 4 Design of PAC-105 Refrigeration System

Unit 5 Design of Water Chiller of PAC-105

--Introduction ………………………………………………...................................... 5.1

Unit 6 Design of Water Cooled Open-type® Condenser

-- Introduction ………………………………………………..................................... 6.1

Unit 7 Design of PAC-105 Hydronic System

-- Introduction ………………………………………………..................................... 7.1

Unit 8 Design of PAC-105 Control System

Unit 9 Commissioning and Maintenance of PAC-105 Air Conditioning System

--Introduction ……………………………………………………………………… 9.1

-- Appendix A ………………………………………………………………… A.1

I t is well known fact that energy is the soul of human

• Discovery of renewable energy resources

• An efficient use of every kind of resources (both renewable and Non-renewable)

I n this unit we are discussing two basic portions of HVAC system

GROUND FLOOR PLAN

4'-9" 4'-9" 4'-9" 4'-9" 4'-9" 4'-9"

STREET 8'-0" 8'-0"

OTHER BUILBING, CLASSROOMS

Table 2.1 Cooling Load Calculation

Area ft2 CLTD, F SCL

Solar Dir. Sh. SHGF Area SC SLF

Lights 600 W x 3.41x 1.25 BF x 1 CLF 2557.5

2.2 Psychrometrics Analysis of the PAC-105 Air Conditioning System

2.2.1 Coil Entering and Leaving Conditions

2.2.2 Determination of Supply Air Quantity

2.2.3 Condensate Formation during Air Conditioning Process

HUMIDITY RATIO - POUNDS MOISTURE PER POUND DRY AIR

DRY BULB TEMPERATURE - °F

A n air-handling unit (AHU) is the primary equipment in an air system of a central

• Horizontal or Vertical Unit

3.2 Design of PAC-105 AHU

Supply Air Duct

Coil Section Exchaust Air

Figure 3.1 the Schematic of PAC-105 Air Handling Unit

3.3 Design of PAC-105 AHU’s Cooling Coil

Amount of heat rejected by coil=Cooling load of hall M-2 = 30.65 Kw (neglecting

ho = Airside heat transfer coefficient W/m2.K

As convection heat transfer coefficient is very strong function of velocity of fluid,

And, from table B-2

Determination of Water-side Heat Transfer Coefficient

Determination of Overall Heat Transfer Coefficient

Determination of Log-Mean Temperature Difference and Surface Area of Coil

Determination of Efficiency of Single Fin

Determination of Overall Surface Efficiency of a Single Tube of Array

Determination of Overall Surface Area of Cooling Coil

ha = 4568.7 W/m2K (Using 6 no of water circuits)

And the face area will be AF = 0.695 × 1 = 0.653m2

Putting all values in Zhukauskas relation for Nusselt no,

3.4 Arrangement of Chilled Water Circuits for PAC-105 Cooling Coil

Supply Header Chilled Water Tubes