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THERMODYNAMICS
Thermodynamics is that branch of science dealing with the mechanical action of
heat. There are certain fundamental principles of nature, often called laws of
thermodynamics, which govern our existence here on Earth, several of which are
basic, in the study of refrigeration.
The first and most important of these laws is the fact energy can neither be
created or destroyed, but can be converted from one type to another.
HEAT
Heat is a form of energy, primarily created by the transformation of other types
of energy into heat energy. For examples, mechanical energy turning a wheel causes
friction which creates heat.
TEMPERATURE
Temperature is the scale used to measure the intensity of heat, the indicator
that determines which way the heat energy will move. In the United states,
temperature is normally measured in degrees Fahrenheit, but the Centigrade scale
(sometimes termed Celsius) is widely used in other parts of the world. Both scales use
two points as reference, the freezing point of water and the boiling point of water at
sea level. Water freezes at 32F or 0C., and water boils at sea level at 212F. or
100C.
On the Fahrenheit scale, the temperature difference between these two points is
divided into 180 equal increments or degrees F., while on the Centigrade scale the
temperature difference is divided into 100 equal increments or degrees C. The
relation between Fahrenheit and Centigrade scales can always be established by the
following formulas:
Fahrenheit 9/5 (Centigrade plus 32)
Fahrenheit 5/9 (Fahrenheit plus 32)
Reciprocating compressor
Rotary compressor
Scroll compressor
Screw compressor
Centrifugal compressor
Reciprocating compressor has one or more piston and cylinder combinations. In this
type of compressor, the pistons are designed in similar fashion to those used in a car
engine: they slide inside a cylinder, drawing in and compressing the gas refrigerant.
Each cylinder features a suction valve for the gas refrigerant and a delivery valve
through which the gas refrigerant is sent to the condenser after having been
compressed.
Rotary compressor uses a rotary impeller driving refrigerant through a curved
chamber to compress the refrigerant.
Scroll compressor features two involute scrolls: one stationary, and one orbiting
around the first. Due to which the gas contained between the two elements reaches a
very high pressure and discharged through a hole in the centre.
Screw compressor consists of two helically grooved rotors, housing with suction and
discharge ports and
compresses the refrigerant between the rotating groves.
Centrifugal compressor raises the pressure of the refrigerant by a centrifugal force
within a circular casing.
CONDENSER:
Condensers remove the cooling load, and the heat of compression and condense the
high pressure refrigerant gas into high pressure liquid refrigerant.
Condensers may be water cooled or air cooled. Water cooled condensers use cooling
towers. Various types of water-cooled condensers are shell and tube, shell and coil,
evaporative etc. Air-cooled condensers employ cooling coils and fans.
EXPANSION VALVE :
An expansion valve is used to regulate the flow of liquid refrigerant into an evaporator
depending on the load.
It reduces the pressure of the liquid refrigerant thus dividing the high and low side of
the system
EVAPORATOR:
Evaporator is a heat exchanger and transfers the heat from the substance to be
cooled to the liquid refrigerant and converts it to vapour.
ELECTRIC MOTORS
An electrical motor is such an electromechanical device which converts electrical
energy into a mechanical energy. Almost all the motors used in HVAC application is
Induction Motor. The name coming from the fact that the current in the moving part is
induced, the moving component having no connection to the source of current.
An AC motor has two basic electrical parts: a "stator" and a "rotor" as shown in
Figure . The stator is in the stationary electrical component. It consists of a group of
individual electro-magnets arranged in such a way that they form a hollow cylinder,
with one pole of each magnet facing toward the center of the group.
The term, "stator" is derived from the word stationary. The stator then is the
stationary part of the motor. The rotor is the rotating electrical component. It also
consists of a group of electro-magnets arranged around a cylinder, with the poles
facing toward the stator poles.
The rotor, obviously, is located inside the stator and is mounted on the motor's shaft.
The term "rotor" is derived from the word rotating. The rotor then is the rotating part
of the motor. The objective of these motor components is to make the rotor rotate
which in turn will rotate the motor shaft. This rotation will occur because of magnetic
phenomenon that unlike magnetic poles attract each other and like poles repel. If we
progressively change the polarity of the stator poles in such a way that their
combined magnetic field rotates, then the rotor will follow and rotate with the
magnetic field of the stator.
SINGLE PHASE MOTOR:
A single phase motor has only one running winding or phase. They cannot form a
rotating field hence they are not self starting. In order to provide starting torque a
second winding called a starting winding is provided. These two windings work
together to start the motor. A relay is used to remove the starting winding once the
motor reaches the rated seed. Single phase motors are limited to maximum 3 HP.
THREE PHASE MOTORS :
This type of motor does not require any starting device hence they are self starting
induction motor. Three phase motors are wound with 3 separate windings or phase.
Each of the winding is 120 Deg out of phase with other windings. This results in a
rotating magnetic field and the motor does not require separate starting mechanism.
Accessories include drain pan, dampers , VFD, Starters, Vibration isolators etc
The air is first passed through filters to remove dust particles and then over to the
cooling coils wherein the air is cooled and de-humidified. The blowers then convey the
pressurized air to the ducts which in turn distributes to the area to be air-conditioned
through grilles and diffusers..
CEILING SUSPENDED
COOLING TOWER
In a water cooled system the heat to be rejected is picked by water. Now to cool the
water a cooling tower is used. A cooling tower is an equipment used to reduce the
temperature of a water stream by extracting heat from water and emitting it to the
atmosphere.
Cooling towers are used to reject heat through the natural process of evaporation.
Warm recirculating water is sent to the cooling tower where it is sprayed through
nozzles into the air.
A portion of the water is evaporated into the air passing through the tower. As the
water evaporates, the air absorbs heat, which lowers the temperature of the
remaining water.
This process provides significant cooling to the remaining water stream that collects
in the tower basin where it can be pumped back into the system to extract more
process or building heat, thereby allowing much of the water to be used repeatedly to
meet the cooling demand.
The two types are :
Natural draft tower :
Natural draft towers are constructed of wooden louver held on wooden uprights.
Nowadays plastic louvers are also available. The space enclosed by the louvers has a
water spray system on the top. Warm water from the condenser is sprayed by nozzles
This finely atomized water flows by gravity into a small collecting basin.
Since its performance depends on existing air currents, ordinarily, a roof top is an
excellent location. Louvers must be placed on all sides of a natural draft tower to
reduce drift.
The drift loss ( loss of water due to wind movement ) and space requirements of a
natural draft tower are much greater than for other cooling tower designs.
Mechanical draft tower :
These towers use a motor and fan to pull ( induced draft ) or push ( forced draft ) a
constant volume of air through the tower. The water is sprayed through nozzles into
the draft thereby evaporating rapidly and cooling the rest of the water. The heat
transfer area is enhanced due to PVC fills. Water is collected at the base and again
sent to the condenser for cooling.
SPLIT AIR-CONDITIONERS:
The Split air-conditioner is split into two basic components, the Indoor unit and the
Outdoor unit. These two units are connected by refrigeration tubing. The indoor unit
( evaporator unit ) is kept inside the conditioned area whereas the outdoor unit
( condensing unit ) is kept outside. Thus noise level inside the conditioned area is
reduced.
The indoor unit comprises the evaporator or cooling coil, expansion valve and cooling
fan. Of late the expansion valve is shifted to the outdoor unit to avoid hissing noise.
For this unit you dont have to make any slot in the wall of the room. Further, present
day split units have aesthetic appeal and do not take up as much space as a window
unit. The outdoor unit, fitted outside the room, houses components like the
compressor, condenser and of late even the expansion valve.
There are many versions of the indoor units like High Wall, Floor mounted, Ceiling
mounted, Vertical, Concealed, Cassette etc.
The outdoor unit has the flexibility to be installed either on the roof or on a ledge or
on the floor.
EVAPORATIVE COOLERS :
In low-humidity areas, evaporating water into the air provides a natural and energyefficient means of cooling. Evaporative coolers rely on this principle, cooling outdoor
air by passing it over water-saturated cellulose pads, causing the water to evaporate
into it. The cooler and humidified air is then directed into the area to be used and
pushes warmer air out through windows.
When operating an evaporative cooler, windows are opened part way to allow warm
indoor air to escape as it is replaced by cooled air. Air conditioning systems recirculate the same air, however evaporative coolers provide a steady stream of fresh
air into the area to be used.
Evaporative cooling is a common form of cooling buildings for thermal comfort since it
is relatively cheap and requires less energy than other forms of cooling. However,
evaporative cooling is only effective when the relative humidity is on the low side,
limiting its popularity to dry climates. Evaporative cooling raises the internal humidity
level significantly, which dry climate inhabitants may appreciate as the moist air rehydrates dry skin and sinuses. Evaporative coolers should not be used in humid
climates because they add humidity to the air in your home.
Water cooled option is also available. The water cooled condenser is located in the
indoor unit. The heat is rejected to water and thro pumps the water goes to the
cooling tower, rejects heat and goes back to the condenser for picking up more heat.
Packaged units are mainly used for offices and show rooms. Advantages are these
units are rugged, multiple units can be used for large areas, easy and fast installation,
can handle long duct runs and higher air quantity requirements, the services are
restricted to the unit room.
Disadvantages are multiple units for larger applications, floor space is required for
locating the units.
A variation of the above is the Ductable split units are mainly used for offices and
show rooms. In this version the indoor unit is ceiling suspended and comprises the
evaporator and expansion valve. The outdoor unit comprises of the compressor and
air-cooled condenser.
Advantages are this unit does not occupy floor space and can handle different areas.
Disadvantages are too many units are used for large spaces, restriction on the length
of refrigerant piping, too many outdoor units, limitations on static pressure available,
limitations on the air quantity available, difficulty in servicing/cleaning the coils, high
noise level in the work areas.
CENTRAL AIRCONDITIONING SYSTEM:
DX CENTRAL PLANT :
The system uses multiple scroll compressors and the capacity varies from 5 TR to 80
TR. In this system the refrigerant gas directly cools the air hence DX ( Direct
Expansion ). The AHU is customized hence it can be used for heavy duty and nonstandard applications.
They use air-cooled or water cooled condensers. A DX plant is most efficient from the
thermodynamic point of view since the heat transfer is directly between the
refrigerant and air.
CHILLER PLANT :
PACKAGED AIRCONDITIONERS
DX CENTRAL PANT :
CHILLER PLANT
AHU Room should be properly placed. Avoid placing it next to toilets / Canteen
etc. AHU door should be air tight and should be openable from outside. The
height of the AHU room should be the same as that of the area to be airconditioned.
Sufficient space to be provided below beam bottom to run the ducts. At least
450mm gap to be provided between bottom of beam and false ceiling for areas
less than 5000 sq.ft. For 5000 to 7500 sq.ft 600 mm is required. Beyond that
900 mm is required.
Return air is collected back to the AHU room through the void available between
false ceiling and ceiling. Hence proper space should be provided and should be
air tight.
If there is a shortage of return air then outside air starts coming to the AHU
room and will be waste of energy.
All the supply air ducts should be surrounded by return air otherwise
condensation happens.
All the supply air ducts should be thermally insulated from the external side of
the ducts.
Initial portion of supply air ducting ( until the first collar ) should have internal
acoustic insulation.
Only factory fabricated ducts should be considered. As far as possible avoid site
fabricated ducts.
The collar which connect the duct and terminals should be properly linked. In
many cases it is found that there is gap and this leads to improper cooling.
The walls of the AHU room adjoining the area to be air-conditioned should be
acoustically treated.
Fire dampers to close the supply ducts and return air entry to AHU room should
be provided for Fire Safety.
( VFD ) and in turn the VFD reduces the speed of the fan. For example by reducing 20
% of the speed we can expect 50 % reduction in the energy cost of the fan.
ALL WATER SYSTEMS :
In this system the Chilled water will be pumped to various small areas to be
individually air-conditioned. The chilled water will be sent to the Fan Coil Units for
each room. The conditioned air thus produced will be directly fed to the room without
any air distribution system. Ideal for multizone applications with small rooms like
Hotels, Hospitals etc.
In case of part load operation the chiller will get the message by sensing the return
water temperature . If the return water temperature is lower than the set point then
the plant senses that production can be reduced. The capacity control mechanism
ensures that the compressor will run only in part load and save energy. Consequently
all the downstream components need to run only in part load. This should be taken
care of in the first design itself. Many a times this is overlooked due to budget
constraints but a basic Return on Investment study will indicate that payback period is
mostly within 2 years.
Some of the energy saving devices which help in partload operation power savings
includes Variable Frequency Drives ( VFD) for Pumps.
Following care should be taken :
Drain pipes are very critical and should not run for long lengths as natural
gravity slope is required.
Sufficient space for carrying out piping work should be provided like space
above false ceiling and shafts crossing the floors.
Isolation Valve for each AHU and FCU to be provided. Most important - Isolation
valve for each floor has to be provided.
During the design stage itself pipe openings can be given in the beams itself.
Thus saving valuable space which will be occupied by chilled water pipes below
the beam.
Always design the pipes with low pressure drop. This will ensure that pumping
cost is reduced . Also any future expansion can be easily carried out without
major alterations.
TYPE OF EQUIPMENT
Min : 1 TR Max : 2 TR
Packaged Air-conditioners
Ductable Air-conditioners
DX-System -
Min : 12 TR Max : 90 TR
Min : 10 TR Max : 80 TR
Water
Chiller
Cooled
Cooled
.EQUIPMENT SPACING :
While planning for the space requirements of AC Equipment rooms the following
guidelines may be used.
TYPE OF EQUIPMENT
SPACE REQUIREMENT
3m x 2m Single unit
3m x 4 m Two units
3 m x 5 m Three units
AHU Rooms
4m x 3m upto 30 TR
4m x 5 m upto 60 TR
Dutable split units require minimum 600 mm clear space above false to locate the
indoor units and to run the ducts.
Equipment placing should be done with an eye on maintenance. Packaged unit should
have 1 m space in front of the unit for unit servicing . If it is water cooled 2 m at the
side also required for condenser tube cleaning.
Shafts should be sized properly for installing the pipes based on site conditions.
UNIT III : AIR CONDITIONING : DESIGN ISSUES AND HORIZONTAL DISTRIBUTION OF PIPES
Design Criteria for selecting the air conditioning system for large buildings :
DX CENTRAL PLANT :
When to use :
1. If requirement exceeds 400 sq.m.
2. For heavy duty offices, showrooms, industries etc.
3. Single zone areas.
When not to use :
1. Multizone areas.
2. When copper pipe length is more than 50 feet
CHILLER PLANT :
When to use :
1. If requirement does exceeds 2000 sq.m.
2. If used for heavy duty commercial and industrial applications like IT Parks, Star
Hotels, Hospitals, Major offices, Major showrooms, Industries, non-standard
application etc.
3. Multizone Zone areas.
4. If plant has to be located far way from usage
When not to use :
If requirement is highly variable and may go down to less than 40 %.
services, are served from the fire standpipe by horizontal piping that seldom exceeds
4 in. (100mm) in outside diameter. The spacing of the heads is coordinated with the
placement of walls and partitions; the maximum coverage per head is about 200
sq.ft(18.6m2) in light-hazard buildings. Coverage in industrial and storage buildings
ranges from 130 to 90 sq.ft(12.1 to 8.4 m 2) per head, depending on the substances
handled in the building;
Air conditioning ducts is the next priority. In the AHU room the return air will mix
with outside fresh air and then will be taken inside the AHU. The AHU will filter the air,
cool and dehumidify it and then feed it to the ductwork for further distribution. The
supply air ducts will be taken above the false ceiling and fed to the area to be airconditioned through grilles/diffuser. Return air is usually collected above the false
ceiling and the space available between the false ceiling and ceiling slab will act as
return air path to the AHU room.
Diffusers are generally required at the rate of one for every 150 sq.ft.
GROUP HORIZONTAL DISTRIBUTION IN CENTRAL CORRIDORS
Sometimes the major runs of ductwork, piping and wiring can be grouped in the
ceiling area above the central corridor of each floor of a building, leaving the ceilings
of the surrounding rooms essentially clean. This works especially well in hotels,
dormitories, and apartment buildings that rely on above ceiling all-water system. A
low corridor ceiling is readily accepted in exchange for high, unobstructed space in
the occupied rooms, where the structure may be left exposed as the finish ceiling,
saving cost and floor-to-floor height.
FLOORWISE HORIZONTAL DISTRIBUTION
In broad expanses of floor space, particularly where all electrical and
communications services must be available at any point in the area, an entire
horizontal layer of space is reserved on each story for mechanical and electrical
equipment.
SERVICES
BAY
OFFICE
AREA
Fire Sprinkers
Electrical wiring
Communication
Data
and
Plumbing
HVAC piping
HVAC ducts ( supply air, return air, fresh
air and exhaust air )
valuable in retrofitting old buildings for modern services. Though floors can be raised
to any desired height above the structural deck, heights of 300-450mm .
Undercarpet flat wiring may be used instead of a raised access floor in buildings with
moderate needs for future wiring changes. Flat wiring does not increase the overall height of
the building, as raised access floors usually do, but it does not offer the unlimited capacity
and complete freedom of wire location of the raised floors. Flat wiring is used in both new
buildings and retrofit work.
In case of any further assistance required please do not hesitate to get in touch with
the undersigned :
D.BALAJI
HVAC Consultant
shreesrb@yahoo.com
9600021111