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PROPOSAL

________________________________________________________________

Propose Complete Set Of Air Cooled Chiller Package For


Educational Purpose
________________________________________________________________

PLACE :
AIR CONDITIONING & REFRIGERATION WORKSYOP
ORGANISED:
AIR CONDITIONING AND REFRIGERATION PROGRAM
MECHANICAL ENGINEERING DEPARTMENT
POLITEKNIK UNGKU OMAR

1.0

GOALS
Upgrading Air Conditioning workshop in order to increase the quality of DPU
students and also towards becoming the reference center of Air Conditioning and
Refrigeration sector. The students will have knowledge and skills that allow them to make
tangible contributions and meet new technical challenges.

2.0

BACKGRAOUND
Politeknik Ungku Omar (PUO) was established in 1969 by Ministry of Education
Malaysia with support from UNESCO. Strategic plan have been workout to upgrade PUO
becoming premier polytechnic. The main goal is to be the centre of students, staff,
programme, structure, industry, development and culture excellence. Apart from that,
Niche Area have been developed to be the identity and image of PUO. Thus, assigning
PUO as the premier polytechnic would give confidence to PUO member to be the
inflection point towards becoming Malaysias number one provider of an innovative
human capital through transformational education and training for the global workforce.
Diploma in Mechanical Engineering (Air Conditioning and Refrigeration) is the one
of the Polythecnic Programme in Malaysia. This programme was standing almost 22 years
in Polythecnic Ungku Omar, Ipoh. PUO should be produced the quality students that meet
industrial requirement. Because of that, PUO must be prepared all the equipment and
material for the teaching and learning purpose. However, PUO dont have enough
allocation to complete that requirement. PUO was been prepared a workshop to allocate
all the material / equipment teaching and learning such as split unit, cold room,
refrigerator, ice maker, water chiller system, training units and others. All the existing
facilities are too old especially water chilled water. Our department plan to upgrade the air
conditioning workshop especially chiller system because this system more related to Air
Conditioning and Workshop Practice 2 & 3. Between the topics that related to the practical
workshop are Air and Water Balancing, Chiller Maintenance Operation and Control,
Preventive Maintenance of Chiller System and others.
Chiller is the refrigeration unit that is applied for water cooling in conditioning and
cooling systems using the vapor compression cycle. It is mostly used when cooling is
needed for a quite large area of the building. Also it is able to maintain the temperature
required for continuous operation of the equipment for instance in data centers. Chiller
systems consist of refrigeration unit and another equipment serving for its operation. So,
chiller itself uses the principle of vapor compression cycle and contains condenser,

expansion device, evaporator, compressor and refrigerant circulated between them. For
proper operation of refrigeration unit it should be served by condenser cooling system. For
this purposes ambient air is usually used. This system, in turn, contains a number of
equipment like circulation pumps, pipes or ducts, cooler and other depending on
developed requirements. Through the various configuration and different types of its
components chillers system can be classified according to various criteria.
3.0

PROBLEMS/NEEDS
o

Practical or actual knowledge about air conditioning & refrigeration technical

among the lecturer and student seem to be crucial.


The existing facilities in the workshop are too old for student to learn about new
technologies. Although they can learn the basic concept of the system but the new

technology give them advantage and preparing for the future work.
The maintenance cost of the old facilities is slightly high. Besides that, the new

equipment can be resolving the high maintenance cost issue.


The lack of material for teaching and learning purpose. It can be seen during the
practical workshop period whereas the students have to be separated for the other

experiment for learning process.


The facilities in the workshop recently cannot be exposing to the student about the
variety of single system in HVAC. They can learn the fundamental of the system but
lack of the practical system whereas this is one of requirement in the industry
market.

4.0

OBJECTIVES
o
o

To improve the existing curriculum by adding in the aspect of air cooled chiller unit.
To make Air-Conditioning and Refrigeration workshop as a reference centre for

teaching and learning in the field of air-conditioning and refrigeration.


To accomplished with lecturers of highly qualified instructors using a variety of
materials and training aids in order to provide instruction to develop participants

skills.
To provide the students and participants of an Air Cooled Chiller equipment with the
training and information necessary to establish a high level of skill in operating,
servicing, maintenance and troubleshooting.

5.

EQUIPMENT JUSTIFICATION

Bill

METERIAL AND
EQUIPMENT

QUATITY

JUSTIFICATION

Chiller unit is a system that consists of four basic


components in the HVAC. It can cover the entire
core subject in the diploma of mechanical
engineering (air conditioning and refrigeration)
programme structure.

Chiller unit :

The theory core subject such as DJU2012,


DJU3012, and DJU5012 (Air Conditioning and
Refrigeration Technology 1, 2 and 3) can be
covered with this single equipment. Topic such
as basic cycle of refrigeration, basic four
components, mollier and refrigerant can be
covered for visual purpose and data
measurement.
Air cooled screw chiller c/w pipe
line.

Practical core subject such as DJU2022,


DJU3022 and DJU5022 (Air Conditioning and
Refrigeration Workshop Practice 1, 2 and 3) also
can be covered for all topic in the syllabus. The
practical task for component and accessories,
electrical wiring, and service and preventive
maintenance can be covered accordingly.
The 2 others core subject (Design) in the
programme also can be include such as for as
built drawing practical in the design stage.
The
common core
subject
such as
thermodynamics can also be including in the
demonstration of refrigeration system practical.

Air handling unit (AHU)


1
- Together
with
ducting
installation.
Air Side:
- Damper :

Oppose blade damper.

Butterfly damper.

Split damper.

Fire damper.

Diffuser :

Jet diffuser.

Round diffuser.

Air Handling Unit (AHU) is an air distribution


system. The system starts form the AHU to the
room to be supplied by the cool air. It consists of
a blower and motor, cooling coil, air filter,
ducting, damper and diffusers. All those
equipment can be used as the tools in the
practical and demonstration process in teaching
and learning process.
The main theory core subject such as DJU2012,
DJU3012, and DJU5012 (Air Conditioning and
Refrigeration Technology 1, 2 and 3) can be
covered with this single equipment. Topic such
as centralized air conditioning system,
psychometric
chart,
and
refrigeration
engineering can be covered for teaching and
learning purposes.

4 way diffuser.

Swirl diffuser.

Linear diffuser.

Practical core subject such as DJU2022,


DJU3022 and DJU5022 (Air Conditioning and
Refrigeration Workshop Practice 1, 2 and 3) also
can be covered for some topic in the syllabus.
The practical task for component and
accessories, air balancing, air properties and
psychometric, and service and preventive
maintenance can be covered.

Fan Coil Unit (FCU) :


1
1
1

Wall mounted.

Ceiling cassette.

Ceiling exposed.

Ceiling concealed.

Fan Coil Unit (FCU) is an air distribution


system. The function is same as the Air Handling
Unit (AHU) but the size is slightly small. This
FCU usually covered an intermediate size room
while AHU can cover several number of room or
a hall. It consists of a blower and motor, cooling
coil, air filter, damper and diffusers. All those
equipment can be used as the tools in the
practical and demonstration process in teaching
and learning process.
The core subject in the programme such as
DJU2012, DJU3012, and DJU5012 (Air
Conditioning and Refrigeration Technology 1, 2
and 3) can be covered with this single
equipment. Topic such as centralized air
conditioning system, psychometric chart, and
refrigeration engineering can be covered for
teaching and learning purposes.
Practical core subject such as DJU2022,
DJU3022 and DJU5022 (Air Conditioning and
Refrigeration Workshop Practice 1, 2 and 3) also
can be covered for some topic in the syllabus.
The practical task for component and
accessories, air balancing, air properties and
psychometric, and service and preventive
maintenance can be covered.

Pump :
- Chilled water pump
- Condenser water pump.
Valves :
- Controlled valve.

1
1

3 way valve.

Auto-balancing valve.

Gate valve.

#
#
#
#
#

2 way valve.

Many large buildings, campuses, and other


facilities have plants that make chilled water and
distribute it to air handling units and other
cooling equipment. The design operation and
maintenance of these chilled water plants has a
very large impact on building energy use and
energy operating cost.
This equipment can be suit with some core
subject in the programme. The design subject
such as DJU5043 and DJU6043 (Drawing and

Design) and practical subject such as DJU2022,


DJU3022 and DJU5022 (Workshop Practice) can
be used as the practical equipment with the
pump in the system provided. Service and
maintenance practical task also can be done to
full fill the syllabus requirement.
Variable Air Volume.

Electrical :
1

Complete chiller wiring.

Chiller control board.

For design subject, the pump and valve provided


can be as the guide to student in doing the pump
or valve selection in the design stage. The size of
the pump and valve will be as the reference to
student in the sizing process.
All electrical equipment and wiring in the chiller
system is one of the big elements in the HVAC
industries. The electrical control of the chillier is
one of the main aspects in the HVAC system.
The student must be familiar with that system in
order to supply competent personnel to the
industry. The student also has to expose to the
electrical standard use in the HVAC as the
reference in the design or operation stage.
The core subject that can be suite to this system
is DJU3032 control system. This subject is the
most relate to this electrical system. Student can
visualized the actual wiring or electrical control
in the chiller system and relate to the topic in the
syllabus. Topic such as motor control can be
easily demonstrate in the teaching and learning
process.
The practical subject such as DJU2022,
DJU3022 and DJU5022 (Workshop Practice)
also have several topic related to the chiller
electrical system such as motor control, domestic
and commercial refrigeration wiring.
DJU5043 AIR CONDITIONING SYSTEM
DESIGN 1

Building Automation System.


DJU6043 AIR CONDITIONING SYSTEM

Air

conditioning

CARRIER:

software

by

DESIGN 2
As part of the chiller system, software for system
design is need. Student will learn how to use the
program by completing several simple project
exercises. These exercises are intended to
confirm the student's ability to understand the

load estimating, system design, building energy


modelling, lifecycle cost analysis, and refrigerant
piping design.
6.0

IMPACT
o

Students will be expose to the actual system of Air Cooled Chiller that used in the
industrial field.

To make PUO as a center training in Air-conditioning and Refrigeration field.


o Lecturers will improve their skills and knowledge before expose to the students
especially in the workshop subject.

Industries does not have to give more intensive training for the PUO students when

they become as an employee in their company.

B
D

7.0

PROPOSE DESIGN

A
F
E

MAIN

FLOOR PLAN
G

LEGEND

E
Training
Unit
New AHU
A

Instrument

Staff Room

Practical

` Auto Tronic

Motor Control

Training Unit
Room

SECOND FLOOR PLAN

LAGEND
New AHU

A
B
D
C

Instrument
Motor
Practical
Training
Control
Unit

Training Unit

F
G

Staff Room
Auto Tronic

**New AHU (CARRIER)

**Refer Appendix

Side Elevation for Installation New AHU and Air-Cooled Chiller


*** New AHU will install in the new staging area above the existing base area of Water-Cooled
Chiller System.

HEAT LOAD CALCULATION

ft

ft

ft

21

21

8.33

Factor
75

B(i)

39

21

15

80

65520

B(ii)

70

21

15

80

117600

13

21

8.33

75

20475

35

21

8.33

75

55125

22

21

8.33

75

34650

12.71

10.21

8.33

75

9733

31

21

6.67

75

48825

Room

Total

Cooling Load
Btu/hr
33075

385003 Btu/hr
113 KW

6.0

CONCLUSION
We strongly hope that the Carrier be able to consider these recommendations for exposure

and effectiveness to the students and course participants in gaining knowledge in practice.

Appendix

New
AHU

Water

Figure 1 : Installation bay for new AHU.

Appendix

Area for installation Air Cooled Chiller outside the building

Figure 2 : Installation bay for Air Cooled Chiller.

Appendix

Figure 3 : View of the facility in air conditioning workshop