JORDAN UNIVERSITY OF SCIENCE AND

TECHNOLOGY
Engineering Training Report

Mohammad Ahmed Abdulrahman

20120025051
Mechanical Engineering Department

King Abdullah University Hospital (KAUH)

From 16 November 2016 to 2 January 2017

7 January 2016
 1. Contents
List of Figures ................................................................................................ iii

Declaration......................................................................................................iv

Training summary .......................................................................................... v

2. Company profile and training outline .................................................... 1

3. Practical Training ..................................................................................... 2

3.1 First week .............................................................................................. 2

3.2 Second and third weeks ......................................................................... 2

3.2.1 Air Handling Unit (AHU) ............................................................ 3

3.2.2 Fan ............................................................................................... 3

3.2.3 Cooling Coil................................................................................. 4

3.2.4 Filters ........................................................................................... 4

3.2.5 Humidifiers .................................................................................. 5

3.2.6 Mixing Box .................................................................................. 5

3.2.7 Split Units .................................................................................... 6

3.2.9 Fan Coil Unit (FCU) .................................................................. 10

3.2.10 Chillers ....................................................................................... 12

3.3 Fourth week ......................................................................................... 15

3.3.1 Boilers ........................................................................................ 15

3.4 Fifth week ............................................................................................ 18

3.4.1 Pumps......................................................................................... 18

3.5 Sixth week ........................................................................................... 20

3.6 Seventh week....................................................................................... 21

4. Conclusions .............................................................................................. 23

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 List of Figures
Figure 2.1 King Abdullah University Hospital ................................................ 1
Figure 3.1 Air handling unit ............................................................................. 6
Figure 3.2 External Unit ................................................................................... 9
Figure 3.3 Fan Coil Unit ................................................................................. 11
Figure 3.4 Vapor Compressor Chiller. ........................................................... 14
Figure 3.5 Boiler. ............................................................................................ 16
Figure 3.6 Fire Tube Boiler. ........................................................................... 17
Figure 3.7 Pumps. ........................................................................................... 19
Figure 3.8 Control Room. ............................................................................... 20
Figure 3.9 Mechanical System Plan. .............................................................. 22

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 Declaration
This report was written by (Mohammad Ahmed Abdulrahman) a student in
the (Mechanical Engineering Department) at Jordan University of Science and
Technology (J.U.S.T.). It has not been altered or corrected as a result of
assessment and it may contain errors and omissions. The views expressed in it
together with any recommendations are those of the student(s).

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 Training summary
It is a hospital located in Al-Ramtha, Jordan. It is the largest medical
structure in the northern of the country, serving approximately one million
inhabitants from Irbid, Ajloun , Jerash , and Mafraq governorates. It is
also the teaching hospital affiliated with Jordan University of Science and
Technology (JUST) , located within the campus adjacent to the
university's Medical Faculties Complex . The hospital is staffed with full-
time physicians and surgeons who are faculty members of the JUST
Faculty of Medicine , in addition to many others from the Ministry of
Health , and the Royal Medical Services.
The overall area of various hospital buildings is 95,583 m. The hospital has
a bed capacity of 683 which can be increased to 800 beds in an
emergent situation.
Structurally , the hospital is composed of a 15 story high-rise building ,
in which all hospital beds are located, and a 3 story low-rise buildings in
which patient clinics , diagnostic and other services are located . The
hospital is connected to various health science faculties via the ground
floor of the low-rise building.
The cornerstone was laid by King Hussein , but he himself did not live
to see the completion of the massive hospital , named after his
grandfather , the founder of Transjordan , King Abdullah I . It was
inaugurated by his Majesty King Abdullah II on 28 November 2002.

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 2. Company profile and training outline
The hospital includes the following departments:
General Surgery , Special Surgery , Emergency Department , Pediatrics ,
Obstetrics and Gynecology , Internal Medicine and Dermatology , Cardiac
Center , Diagnostic X-Ray , Pathology and Laboratory , Endoscopy Unit ,
Ophthalmology , Physical Therapy and Rehabilitation , Physiology Function
Test , Neuroscience , Nursing and Information System Department .

Figure 2.1 King Abdullah University Hospital

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 3. Practical Training
1. General tour to the main systems that used in the hospital which is
referred to the mechanical department.
2. Explanation and maintenance of : split units , fan coil units
(FCU) and air handling units (AHU).
3. Explanation and maintenance of chillers and (AHU).
4. Explanation and maintenance of heating system and boilers.
5. Explanation and design of pumps working principle.
6. Explanation and maintenance of plumbing and water networks.
7. Explanation of medical gases network and doing maintenance.
8. Explanation about the hospital kitchen and laundry equipments and
general review of all systems in the hospital.

3.1 First week

In the first week of training at King Abdullah University Hospital
(KAUH) we did a general tour to see the main systems which is used in
hospital which is directly supervised by the mechanical section in the service
department to be familiar with it and we were introduced to the hospital
building to know the location of its departments and their functions.

3.2 Second and third weeks

In these two weeks we have learned everything about the different air
conditioning systems in hospital such as air handing units (AHU), split unit, fan
coil unit (FCU) and chillers and we have made many maintenance work to fix
the problems that happened with the different systems.
In two days of the second week we went to the air handing unit room and we
learned the principle of work for this machine and we get know the components
of the machine and the function of each component and we discovered the
different types of the (AHU) units and we compared between it.

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3.2.1 Air Handling Unit (AHU):
An Air Handling Unit (most of the times abbreviated to AHU), or Air
Handler, is a central air conditioner station that handles the air that, usually, will
be supplied into the buildings by the ventilation ductwork (connected to the
AHU).
Handling the air means that the air will be delivered into the building spaces
with thermo-hygrometric and IAQ (Indoor Air Quality) treatment. The accuracy
of the treatment will depend from the specificity of each project (offices,
schools, swimming-pools, laboratories, factories with industrial processes, etc).
This means, the Air Handling Unit treat the air by filtering, cooling and/or
heating, humidifying and/or dehumidifying.
The AHU is used to control the following parameters of the space.
Temperature
Humidity
Air Movement
Air Cleanliness
The main components of (AHU) unit
Housing
The housing that contains all the other components of an AHU is usually
make of metal, some are painted to prevent corrosion.
In sections where the fans and the coil are located, 1-2 inches of polyurethane
foam or PU is used to insulate them to prevent the condensation on the panel.
Drain pan is also used as a precaution in the event of condensation of water.
3.2.2 Fan
Centrifugal fan is used to circulate the air to the various parts of the sections
in the building. The typical types of fan available are Backward Inclined,
Backward Curved, Forward Curved and Airfoil.

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 The selection of the fan will depend on the air volume and the static pressure
required of the system. Usually, the designer of the system will use a
specialized software to do this selection.
In order to reduce the effect of vibration on the panel, the motor and the fan
are usually installed on the vibration isolator except when the drive assembly is
external to the fan casing.
In recent years, the use of variable air volume (VAV) system is becoming
more popular as the volume of the air being discharged can be varied depending
on the load condition. If the load is high, the fan speed will be higher and if the
load is lower, the speed of the fan will be lower.
3.2.3 Cooling Coil
Cooling Coil is used to cool and dehumidify the air. Both DX (direct
expansion) cooling and CW (chilled water) cooling coils are available for use
depending on the system design.
These coils are arranged in rows with different fin spacing. Aluminum fins
and copper tubes are used in the design of the coils. The corrosion resistance
hydrophilic fins are also used due to its lower cost and lower resistance to the
air velocity.
3.2.4 Filters
Filters are to remove particles and contaminants of various sizes from the air.
The type of air filter being used will very much depend on the application of the
system.
Panel Filter is a flat and rectangular in shape and provides a minimum low
efficiency filtration which is acceptable to the air conditioning industry. The
high velocity filter is arranged vertically whereas the low velocity filter is
arranged in V shape. Typical air velocity that moves through the filters is in the
range of 2-3 m/s.
HEPA Filter is very efficient and is able to achieve efficiencies up to 99.97%,
removing minute particles and airborne bacteria from the air. It is usually used

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in clean room applications such as semiconductor production floor, operating
theaters and critical processes.
Electrostatic Filter is used to remove particles from the air by using highly
charged electrodes that ionized the air. Bag Filter is able to remove dust
particles and is thrown away after use. Roll Filter is used for high velocity
filtration where the used part is rolled up automatically/manually.
3.2.5 Humidifiers
During winter, the humidity level of the air can be low hence causing
discomfort to the occupants. The humidity of the air is increased by using the
humidifiers. Here are the commonly used humidifiers:
Spray Type has a header and spray nozzles that spray water with a
pressure of 15 psi or more.
Steam Pan Type has a pan and a heating coil to heat up the water of the
pan. The evaporation of water caused by the heating will increase the
humidity level of the surrounding air.
Steam Grid Type has tiny holes on the pipe to distribute the steam that
flows through it. In this case, the water that is heated up to produce the
steam to be supplied to the grid is conditioned to prevent odor being
discharged to the room.
3.2.6 Mixing Box
This box has air inlets that is attached to the dampers. This is the place where
the outside air and the return air are mixed to provide the correct proportion of
air to be distributed to the space that is to be conditioned.

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 Figure 3.1 Air handling unit
An air handling unit where (1) is the supply air, (2) fan section, (3) vibration
isolator, (4) cooling coil, (5) filter and (6) mixed air duct.
During the second week, Ahmad Sami (an air conditioning technician) took
us to an AHU at the third floor to check the belts of the blower . This
check should be done periodically to avoid any problems.
The belt of the blower in the AHU needed to be changed so we
turned off the machine and changed it .
We also opened the AHU and cleaned the flat filter.
In a day of the second week we learned how the split unit works and we
discovered the different components and the function of each one and get know
the places that use this type of devices in hospital such as offices and waiting
rooms and we compared between the (AHU) and split unit .
3.2.7 Split Units
A split air conditioner consists of two main parts: the outdoor unit and the
indoor unit. The outdoor unit is installed on or near the wall outside of the room
or space that you wish to cool. The unit houses the compressor, condenser coil
and the expansion coil or capillary tubing. The sleek-looking indoor unit
contains the cooling coil, a long blower and an air filter.
The principle of work:

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 Gas, a refrigerant, is fed into the compressor where it is pressurized.
This also causes the heat in the gas to rise.
The pressurized gas then goes through a succession of tubes that are
meant to condense it into a liquid.
The liquid is still pressurized and travels through the condenser tubes
until they come to an expansion joint.
The pressurized liquid passes through this point in the process and
becomes a gas again as the pressure is rapidly reduced.
During the reduction of pressure the gas also releases a great deal of
heat and becomes much cooler (thus, refrigerant).

The gas then passes back to the compressor to repeat that process.
Air from the room is drawn into the unit and passes over the evaporator
coils.
This action cools the air significantly which is then forced back into
the room via the blower.
The air continues to circulate through the air conditioner until a set
temperature (set by the thermostat) is reached.
At this point the apparatus shuts off automatically.
The operation of a split air conditioner, as is shown through the points above,
is very much like that of any other air conditioner. The difference is that one
portion of the unit is completely contained on the outside of the home, while
another portion is on the inside.
The compressor, vent fan and condenser coils are on the outside of the
building in a self-contained unit, and the evaporator coils and blower are on the
inside. The two are connected via pipes or other tubing.
Central air conditioners are a type of split air conditioner, but the unit most
people see as a split unit has a smaller compressor/condenser coil box on the
outside and individual room units on the inside.

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 These are made to cool a room without the need for ducting. In some ways it
is a simpler system and allows better zone control.
During the third week , an employee in one department in KAUH called
the maintenance department and reported a malfunction in the split unit
used in the room .
We took the tools and went with Ibrahim ( the air conditioning
technician ) to the room to fix the problem .when he checked the external unit
he found a damage in the compressor so he decided to replace it by a second
hand compressor

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3.2.8 External unit

Figure 3.2 External Unit

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3.2.9 Fan Coil Unit (FCU)
The basic components of a fan coil unit are a heating/cooling coil, fan
section, and a filter. Units may stand alone within a single space or be ducted to
serve multiple spaces, and can be controlled by a manual switch, thermostat, or
building management system.
Fan coils are what they sound like. A fan blowing air over a coil. There can
be one or two coils - one for heating & one for cooling. Often, an office
building can have just cooling on the inside, while areas on the perimeter & top
floor need the heating.
So, in summer somewhere in the building, there will be a chilled (cold) water
plant that pumps cold water to all the coils, and in winter a hot water system -
could be a hot water heater or a heat exchanger connected to a central steam
plant - that pumps hot water to all the heating coils.
The fan blows air all the time. When it gets warm, the thermostat opens the
chilled water valve, and cold water goes through the coil, and cools the air being
blown by the fan. If it gets too cold, the heating coil works the same way.
There is two types of (FCU):
Two-pipe fan coil units have one supply and one return pipe. The supply
pipe supplies either cold or hot water to the unit depending on the time
of year
Four-pipe fan coil units have two supply pipes and two return pipes. This
allows either hot or cold water to enter the unit at any given time .
In KAUH all FCUs are of two-pipe type that work with hot and cold
water.

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 Figure 3.3 Fan Coil Unit
Third week is dedicated mainly for chillers and we did many of maintenance
works for (AHU) units.

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3.2.10 Chillers
Chiller System Overview
Chillers use either a vapor-compression or absorption refrigerant cycle to
cool a fluid for heat transfer. Both chiller types rely on three basic principles.
First - When a liquid is heated it vaporizes into a gas, and when a gas is
cooled it condenses into a liquid
Second - Lowering the pressure above a liquid reduces its boiling point
and increasing the pressure raises it
Third - Heat always flows from hot to cold.
1) Basic Cooling Cycle
The basic cooling cycle is the same for both vapor-compression and
absorption chillers. Both systems utilize a liquid refrigerant that changes phase
to a gas within an evaporator which absorbs heat from the water to be cooled.
The refrigerant gas is then compressed to a higher pressure by a compressor
or a generator, converted back into a liquid by rejecting heat through a
condenser and then expanded to a low- pressure mixture of liquid and vapor that
goes back to the evaporator section. The cycle is repeated.
Vapor Compressor Chiller
A vapor-compression chiller consists of four primary components of the
vapor-compression refrigeration cycle. They include a compressor, evaporator,
condenser and a metering device.
Vapor-compression chillers typically utilize HCFC or CFC refrigerants to
achieve a refrigeration effect. Compressors are the driving force in a vapor-
compression chiller and act as a pump for the refrigerant.
Compressed refrigerant gas is sent from the compressor to a condenser unit
that rejects the heat energy from the refrigerant to cooling water or air outside of
the system.
The transfer of heat allows the refrigerant gas to condense into a liquid which
is then sent to a metering device.

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 The metering device restricts the flow of liquid refrigerant which causes a
drop in pressure. The drop in pressure causes the warm refrigerant liquid to
change phase from liquid to gas and in doing so absorbs heat from the water to
be cooled due to adiabatic flash evaporation.
The metering device is positioned so that the expanding refrigerant gas is
contained within the evaporator, transferring the heat energy from the water to
be cooled into the refrigerant gas. The warm refrigerant gas is then sent back to
the compressor to start the cycle over again and the newly chilled water in the
separate loop can now be used for cooling.
The air conditioning system in KAUH uses seven air cooled chillers
all from Petra company .
The water enters a heat exchanger in the chiller and is cooled to
around 7 C and then pumped to building 7 ( the building of mechanical
stuff ) and enters the cold water tank there where it is pumped up to the
fan coils and AHUs in the hospital building after that it goes down
again to building 7 and pumped back to the chillers to complete the
cycle.

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Figure 3.4 Vapor Compressor Chiller.

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 3.3 Fourth week
In this we have learned all things about boilers including several types and
the main components and the function of each one and we noticed that there is 3
boilers in the hospital running alternately to convert water to steam which is
pumping to building 7 and collecting in huge containers .After that the steam is
pumped to the building that used the steam for cleaning in laundry and for
sterilization.
Part of this steam is used to heating the water in many arrays of heat
exchangers that locates in the building 7. After the steam is condensed it
goes to a tank and then a set of pumps is used to pump it to the
deaerator ( which is a device that is used to remove oxygen and other
dissolved gases from the condensed water ) and we discovered the different
systems that distribute the hot and cold water that using for cooling and heating
the air in (AHU) units .
3.3.1 Boilers
There is two types of boilers, water tube boiler and fire tube boiler .In
hospital the second one is used.
A fire-tube boiler is a type of boiler in which hot gases from a fire pass
through one or (many) more tubes running through a sealed container of water.
The heat of the gases is transferred through the walls of the tubes by thermal
conduction, heating the water and ultimately creating steam.
Fire tube boilers are used for low capacity steam production applications,
mainly for vessels having diesel engines as main propulsion system. On such
vessels, steam is required for auxiliary machinery. Such boilers have simple
operation and can run properly even with medium quality water. All these
boilers have large water capacity and are often known as tank boilers.

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 Most of the fire tube boilers now come in a complete package .The main
parts of the package are:
Oil burners.
Fuel pump.
Forced draft fan.
Feed pump.
Automatic control system.
Boiler mountings.
The most basic type of a package boiler is single passage three pass design.
One such boiler is shown in the figure. The first pass of the water will be
through the partly corrugated furnace and the cylindrical combustion chamber.
The second pass starts when the water converts into steam and flow from the
furnace into small bore smoke tubes located over the furnace. At the end of the
pass and near the central smoke box, the flow divides into two parts. The third
pass of the steam is through the smoke tubes located outside the main
arrangement and which opens at the exit on the rear of the boiler.

Figure 3.5 Boiler.

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 During the summer the amount of hot water required is low , so there
is only one boiler of the three is working .
The boilers had to be cleaned from the combustion products and there
was a lot of rust on the pipe so they needed to be cleaned too.

Figure 3.6 Fire Tube Boiler.

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 3.4 Fifth week
In this week we visited building 7 and we get know the different sets of
pumps that used to pumping either hot or cold water to the different places of
the hospital.
We have learned the principle of work and how it is coupled with drive motor
by special joints and we studied the system of lubrication for pump and the
cooling cycle for the oil that use in lubricating system.
One of these set is using to feed the upper floors with water , other set is
dedicated to move the water to lower floors and there is set of pump using in
firefighting system which is located at twelfth floor .
There is set of pumps are located beside the chiller due to transport the
chilled water to the building 7 and there is other set beside the boiler to pump
the condensed steam from building 7 to the dearator.
During the fifth week of training we replaced all of the horizontal pumps that
is referred to boilers by new vertical ones.
3.4.1 Pumps
The pumps used in the hospital are all of centrifugal type .
Centrifugal pumps are the most commonly used kinetic-energy pump.
Centrifugal force pushes the liquid outward from the eye of the impeller where
it enters the casing. Differential head can be increased by turning the impeller
faster, using a larger impeller, or by increasing the number of impellers. The
impeller and the fluid being pumped are isolated from the outside by packing or
mechanical seals. Shaft radial and thrust bearings restrict the movement of the
shaft and reduce the friction of rotation.

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Figure 3.7 Pumps.

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 3.5 Sixth week
We went to the workshop and we learned the principle of welding and we
have welded some parts in order to improve our skills and we fixed a cooler and
learned how it is work and how to clean it by water and flash.
We visited the building management system which is used to control the air
handing units (AHU) to see if there is any problem to coordinate with the
mechanical system to do the maintenance work.
We visited the room the contains the machines of elevators where is located
at the last floor and we discovered how it is work and how the maintenance
work is done.

Figure 3.8 Control Room.

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 3.6 Seventh week
We visited set the solar collectors which is used to provide hot water and it is
located at the third floor. Theses solar collectors saves energy and cost for
the hospital .The hot water is collected in huge containers where is located at
room in the -1 floor .

We get know how to use the different types of scheme that related to the
mechanical system in the hospital, and we tried to know the symbols in the
scheme.

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Figure 3.9 Mechanical System Plan.

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 4. Conclusions
I have learned many new things and have seen some mechanical
devices that I did not know about before . The training opened my eyes
to the practical side of my major and gave me an Idea about what types
of field I can choose to work in.
Skills and things I have learned during training:
1. I have improved my communication skills.
2. The working principle of some mechanical devices and have
known new devices I did not know about before.
3. I have improved my knowledge about air conditioning systems
and devices .
4. How to install an FCU.
5. How boilers work and the way they are connected with the hot
water network to provide hot water .
6. How to identify the problem and choose the appropriate solution
for it.

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