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Industrial Air Conditioning System

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    ASSIGNMENT

    OF

    PLFD

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    AIR CONDITIONING IN GARMENT/OTHER INDUSTRIES

    Machines give off heat. For example, workers who use garment presses or die

    casting equipment are always near hot machines and materials. If the factory does

    not have good ventilation or a cooling system, the air around these machines can

    become dangerously hot.

    The best way to protect workers from too much heat is to keep the air inside the

    factory cool. If the outside air is very hot and humid, air conditioning may be the only

    way to keep the factory cool enough inside to be safe for all workers. The whole

    factory does not have to be air conditioned. Cooled air can be blown through ducts to

    the spot where each worker sits or stands. Most factory buildings can be kept cool

    with a good ventilation system, plenty of air space, insulation, and shade.

    AIR CONDITIONING

    Air conditioning includes both the cooling and heating of air. It also cleans the air and

    controls the moisture level.

    An air conditioner is able to cool a building because it removes heat from theindoor air and transfers it outdoors. A chemical refrigerant in the system absorbs the

    unwanted heat and pumps it through a system of piping to the outside coil. The fan,

    located in the outside unit, blows outside air over the hot coil, transferring heat from

    the refrigerant to the outdoor air.

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    Basic Operations

    Most air conditioning systems have five mechanical components:

    1. Compressor

    2. Condenser

    3. Expansion Device

    4. Evaporator

    1. Compressor:

    The compressor (which is controlled by the thermostat) is the "heart" of the

    system. The compressor acts as the pump, causing the refrigerant to flow

    through the system. Its job is to draw in a low-pressure, low-temperature,

    refrigerant in a gaseous state and by compressing this gas, raise the pressure

    and temperature of the refrigerant. This high-pressure, high-temperature gas

    then flows to the condenser coil.

    2. Condenser:

    The condenser coil is a series of piping with a fan that draws outside air

    across the coil. As the refrigerant passes through the condenser coil and the

    cooler outside air passes across the coil, the air absorbs heat from the

    refrigerant which causes the refrigerant to condense from a gas to a liquid

    state. The high-pressure, high-temperature liquid then reaches the expansionvalve.

    3. Expansion Device:

    The expansion valve is the "brain" of the system. By sensing the temperature

    of the evaporator, or cooling coil, it allows liquid to pass through a very small

    orifice, which causes the refrigerant to expand to a low-pressure, low-

    temperature gas. This "cold" refrigerant flows to the evaporator coil.

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    4. Evaporator:

    The evaporator coil is a series of piping connected to a furnace or air handler

    that blows indoor air across it, causing the coil to absorb heat from the air.

    The cooled air is then delivered to the house through ducting. The refrigerant

    then flows back to the compressor where the cycle starts over again.

    APPLICATION OF REFRIGERATION AND AIR CONDITIONING

    The largest application of refrigeration is for air conditioning. In addition, refrigeration

    embraces industrial refrigeration including the processing and preservation of food,

    removing heat from substances in chemical, petroleum and petrochemical plants,

    and numerous special applications such as those in the manufacturing and

    construction industries.

    In a similar manner, air conditioning embraces more than cooling. The comfort air

    conditioning is the process of treating air to control simultaneously its temperature

    humidity, cleanliness, and distribution to meet the comfort requirements of the

    occupants of the conditioned space. Air conditioning, therefore, includes entire

    heating operation as well as regulation of velocity, thermal radiation, and quality of

    air, including removal of foreign particles and vapours.

    Some applications of refrigeration and air conditioning are as follows :

    1. Air Conditioning of Residential and Official Buildings

    Most of the air conditioning units are devoted for comfort air conditioning that is

    meant to provide comfortable conditions for people. Air conditioning of building is

    required in all climates. In the summer, living/working spaces have to be cooled and

    in the winter the same have to be heated. Even in places where temperature

    remains normal, cooling of the building is required to remove the heat generated

    internally by people, lights, mechanical and electrical equipment. Further in these

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    buildings, for the comfort, humidity and cleanliness of air has to be maintained. In

    hospitals and other medical buildings, conditions on cleanliness and humidity are

    more stringent. There ventilation requirements often specify the use of 100 percent

    outdoor air, and humidity limits.

    2. Industrial Air Conditioning

    The term industrial air conditioning refers to providing at least a partial measure of

    comfort for workers in hostile environments and controlling air conditions so that they

    are favorable to processing some objects or materials.

    Some examples of industrial air conditioning are the following:

    Spot Heating

    In a cold weather it may be more practical to warm a confined zone where a worker

    is located. One such approach is through the use of an infrared heater. When its

    surfaces are heated to a high temperature by means of a burner or by electricity,

    they radiate heat to the affected area.

    Spot Cooling

    If a specific area has to be cooled, it will be unwise to cool entire room or factory. In

    this case, conditions may be kept tolerable for workers by directing a stream of cool

    air onto occupied areas.

    3. Environmental Laboratories

    The role of air conditioning may vary from one laboratory to the other. In one

    laboratory, a very low temperature, say 40oC must be maintained to test certain

    equipment at low temperatures, and in another, a high temperature and humidity

    may be required to study behaviour of animals in tropical climates.

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    4. Printing

    In printing industries, control of humidity is a must. In some printing processes the

    paper is run through several different passes, and air conditioning must be

    maintained to provide proper registration. If the humidity is not properly maintained

    the problems of static electricity, curling or buckling of paper or the failure of the ink

    to dry arise.

    5. Textiles

    Like paper, textiles are sensitive to changes in humidity and to a lesser extent

    changes in temperature. In modern textile plants, yarn moves at very high speeds

    and any changes in flexibility and strength of the yarn because of the change in

    humidity and temperature will thus affect the production.

    6. Precision Parts and Clean Rooms

    In manufacturing of precision metal parts air conditioning helps to (a) keep the

    temperature uniform so that the metal will not expand and contract, (b) maintain

    humidity so that rust is prevented and (c) filter the air to minimize dust.

    7. Photographic Products

    Raw photographic materials deteriorate fast in high humidity and temperatures.

    Other materials used in coating film also require a careful control of temperature.

    Therefore, photographic-products industry is a large user of refrigeration and air

    conditioning.

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    8. Computer Rooms

    In computer rooms, air conditioning controls temperature, humidity and cleanliness

    of the air. Some electronic components operate in a faulty manner if they become

    too hot. One means of preventing such localized high temperature is to maintain the

    air temperature in the computer room in the range of 20 to 23 0C. The electronic

    components in the computer functions favourably at even lower temperatures, but

    this temperature is a compromise with the lowest comfortable temperature for

    occupants. A relative humidity of about 65% is maintained for comfort condition.

    9. Air Conditioning of Vehicles

    For comfortable journey, planes, trains, ships, buses are air conditioned. In many of

    these vehicles the major contributor to the cooling load is the heat from solar

    radiation and in case of public transportation, heat from people.

    10. Food Storage and Distribution

    Many meats, fish, fruits and vegetables are perishable and their storage life can be

    extended by refrigeration. Fruits, many vegetables and processed meat, such as

    sausages, are stored at temperatures just slightly above freezing to prolong their life.

    Other meats, fish, vegetables and fruits are frozen for many months at low

    temperatures until they are defrosted and cooked by consumer.

    TYPES OF AIR CONDITIONING SYSTEMS USED IN INDUSTRIES

    1. HVAC SYSTEM

    Heating, Ventilating, and Air Conditioning (HVAC) equipment perform heating

    and/or cooling for residential, commercial or industrial buildings. The HVAC

    system may also be responsible for providing fresh outdoor air to dilute

    interior airborne contaminants such as odours from occupants, volatile

    organic compounds (VOCs) emitted from interior furnishings, chemicals used

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    for cleaning, etc. A properly designed system will provide a comfortable indoor

    environment year round when properly maintained.

    An air conditioner cools and dehumidifies the air as is passes over a cold coil

    surface. The indoor coil is an air-to-liquid heat exchanger with rows of tubes

    that pass the liquid through the coil. Finned surfaces connected to these tubesincrease the overall surface area of the cold surface thereby increasing the

    heat transfer characteristics between the air passing over the coil and liquid

    passing through the coil. The type of liquid used depends on the system

    selected. Direct-expansion (DX) equipment uses refrigerant as the liquid

    medium. Chilled-water (CW) can also be used as a liquid medium. When the

    required temperature of a chilled water system is near the freezing point of

    water, freeze protection is added in the form of glycols or salts. Regardless of

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    the liquid medium used, the liquid is delivered to the cooling coil at a cold

    temperature.

    In the case of direct expansion equipment, the air passing over the indoor

    cooling coil heats the cold liquid refrigerant. Heating the refrigerant causes

    boiling and transforms the refrigerant from a cold liquid to a warm gas. This

    warm gas (or vapour) is pumped from the cooling coil to the compressor

    through a copper tube (suction line to the compressor) where the warm gas is

    compressed. In some cases, an accumulator is placed between the cooling

    coil and the compressor to capture unused liquid refrigerant and ensures that

    only vapour enters the compressor. The compression process increases the

    pressure of the refrigerant vapour and significantly increases the temperature

    of the vapour. The compressor pumps the vapour through another heat

    exchanger (outdoor condenser) where heat is rejected and the hot gas is

    condensed to a warm high pressure liquid. This warm high pressure liquid is

    pumped through a smaller copper tube (liquid line) to a filter (or filter/dryer)

    and then on to an expansion device where the high pressure liquid is reduced

    to a cold, low pressure liquid. The cold liquid enters the indoor cooling coil and

    the process repeats.

    As this liquid passes through the indoor cooling coil on the inside of the heat

    exchanger, two things happen to the air that passes over the coils surface on

    the outside of the heat exchanger. The airs temperature is lowered (sensible

    cooling) and moisture in the air is removed (latent cooling) if the indoor air

    dew point is higher than the temperature of the coils surface. The total

    cooling (capacity) of an AC system is the sum of the sensible and latent

    cooling. Many factors influence the cooling capacity of a DX air conditioner.

    Total cooling is inversely proportional to outdoor temperature. As the outdoor

    temperature increases the total capacity is reduced. Air flow over the indoor

    cooling coil also affects the coils capacity and is directly proportional to the

    total capacity of an AC system. As air flow increases, the total capacity also

    increases. At higher air flow rates the latent capacity of the cooling coil is

    reduced. Indoor temperature and humidity also affect the total capacity of the

    AC system. As indoor temperatures increase, the sensible capacity also

    increases. Similarly, as indoor relative humidity increases the latent capacity

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    of the AC system increases. Manufacturers of AC equipment typically provide

    a performance map of specific equipment to show how total, sensible, and

    latent capacity change with changing indoor and outdoor temperatures and

    humidity. Power consumption and energy efficiency are also provided in these

    charts.

    Types of AC systems available in HVAC are:

    1) Cooling Only Split-System:

    A split system is a combination of an indoor air handling unit and an

    outdoor condensing unit. The indoor air handling unit contains a supply

    air fan and an air-to-refrigerant heat exchanger (or cooling coil), and

    the expansion device. The outdoor condensing unit consists of a

    compressor and a condenser coil. Split-systems are typically found in

    residential or small commercial buildings. These systems have the

    highest energy efficiency rating (EER) of all the available AC systems.

    Manufacturers are required to take the EER rating a step further and

    provide a seasonal energy efficiency rating (SEER) for use by

    consumers. SEER ratings vary widely and range from 10 to 20. The

    higher the SEER rating, the more efficient the AC system operates. If

    heating is required, an alternate method of heating the interior of the

    building must be used, usually in the form of electric or gas heating.

    2) Cooling Only Packaged-System

    A packaged system is a single unit combining all the components

    described in the split system. Since the unit is a package, it must be

    placed outside the building and indoor air is ducted from the building

    to the packaged system and back through an air distribution system.

    These units typically have SEER rating from 10 to 18. If heating is

    required, an alternate method of heating the interior of the building

    must be used, usually in the form of electric or gas heating.

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    3) Heat Pump

    Heat pumps are similar to cooling only systems with one exception. A

    special valve in the refrigeration piping allows the refrigeration cycle to

    be operated in reverse. A cooling only system cools the indoor air and

    rejects heat to the outdoors. A heat pump can also cool the indoor air,

    but when the valve is reversed, the indoor air is heated. A

    supplementary electric resistance heater may also be used to assist

    the heat pump at lower outdoor temperatures. In colder climates, heat

    pumps require a defrost period. During defrost times the electric heater

    is the only means of heating the interior of the building. These units are

    manufactured as either split or packaged systems.

    4) Chilled Water System

    In a chilled water system, liquid water is pumped throughout the

    building to chilled water coils. Since the liquid water needs to be at a

    cold temperature, a cooling plant is required. The plant is typically

    referred to as a chillier plant. Vapour compression equipment in the

    plant, similar to that described in How does my AC work, cool water

    to a cold temperature and pump the cold water to air-to-water heat

    exchangers where needed.

    5) Window Air Conditioners

    As the name implies, a window air conditioner is typically installed in a

    window or custom opening in a wall. The Window AC can only cool

    small areas and are not intended to provide cooling to multiple rooms

    or zones. These air conditioners are manufactured as cool only or can

    provide both cooling and heating. An optional damper in the unit can

    provide fresh outdoor air if necessary.

    6) Packaged Terminal Heat Pump

    Packaged terminal heat pumps (PTHP) are are similar to a window-

    mounted air conditioner. These units are typically installed in a sleeve

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    passing through the outdoor wall of an apartment, hotel, school

    classroom, etc. PTHPs are completely self contained and require only

    an electrical connection in addition to the opening in the building shell.

    They use the outdoor air as the heat source in winter and as a heat

    sink in summer. They also can provide ventilation air. Flexibility and

    lower installed cost are the primary advantages of the PTHP.

    Disadvantages include in-room maintenance, higher operating cost,

    relatively short life, imprecise "on-off" temperature control, and they

    can be rather noisy.

    How is humidity controlled with an AC system?

    Humidity is becoming more of a concern to building operators and owners. High

    indoor humidity leads to mold and mildew growth inside the building. There are

    several methods of controlling indoor humidity. The simplest (and most expensive)

    method is to connect a humidistat to an electric heater. When the humidity inside the

    building rises above the humidistat set point, the heater is turned on. The additional

    heat causes the air conditioning system to run longer and remove more moisture.

    A more efficient method of controlling humidity is to use the waste heat from the

    refrigeration cycle itself. Instead of rejecting the waste heat outdoors, the heat is

    directed inside when humidity control is required. One form of heat reclaim is called

    hot-gas reheat or refrigerant desuperheating where refrigerant is passed through a

    heat exchanger located downstream of the cooling coil. The hot high pressure

    vapour leaving the compressor passes through this heat exchanger prior to entering

    the condenser coil. This in turn heats the indoor air and again causes the AC system

    to run longer to meet the thermostat set point. Although more energy is used, this is

    much more efficient than turning on an electric heater. Another form of heat reclaim

    is called sub-cool reheat. This strategy takes the warm liquid refrigerant from the

    condenser and passes it through a heat exchanger located downstream of the

    cooling coil. Less heat is available using this method because the majority of the

    heat has already been rejected at the condenser. Since more energy is used to

    pump liquid (as opposed to a gas) through the heat exchanger it would appear that

    this method is less efficient than the hot-gas method, however, the liquid in the heat

    exchanger is sub-cooled in the cold supply air stream which increases the capacity

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    of the air conditioner. Since more capacity is available, the AC unit is able to meet

    the thermostat more quickly.

    Heat pipe heat exchangers or run-around coils perform a similar function when

    humidity control is required. Two heat exchangers are placed in the air stream, one

    upstream of the cooling coil and the other downstream of the cooling coil. These

    heat exchangers are connected together with piping. A heat transfer fluid, whether it

    be water or refrigerant, is either pumped or gravity fed from one heat exchanger to

    the other. The heat exchanger downstream of the cooling coil (re-heat coil) cools the

    liquid medium inside the heat exchanger and heats the air passing over the heat

    exchanger. The cold liquid inside the heat exchanger is moved to the heat

    exchanger upstream of the cooling coil (pre-cool coil) where it pre-cools the air

    passing over the heat exchanger and warms the liquid passing through the heat

    exchanger. The affect of a heat pipe or run-around coil is to reduce the sensible heat

    capacity of the AC system. The latent capacity of the AC system increases if direct-

    expansion equipment is used or remains relatively constant if chilled water

    equipment is used. Since the sensible capacity of the AC system has been reduced,

    the system must run longer to meet the thermostat set point thereby removing more

    moisture.

    How do refrigerants deplete the Ozone layer?

    Refrigerant 22 (R-22 or MonoChloroDiFlouroMethane, CHClF2) is one of the most

    common refrigerants and is used in a wide variety of applications such as

    refrigeration, aerosol propellants, cleaning solvents, and foaming agents for plastics.

    This refrigerant is believed to be partially responsible for damaging the earths ozone

    layer and its use is being phased out over the next two decades. The ozone layer is

    a result of sunlight reacting with oxygen to produce a layer in the stratosphere more

    than 10 km above the earths surface. As R-22 refrigerant escapes from an AC

    system through leaks or is released into the atmosphere by other means, the R-22

    molecule containing the chlorine atom (monochloro) rises in the atmosphere.

    Sunlight breaks down the R-22 molecule to yield a free chlorine radical (Cl-). The

    free chlorine radical combines with ozone (O3), decomposing it into normal oxygen

    (O2).

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    AC refrigerants come in many varieties. R-22 is the most common, however, due to

    interactions with the ozone layer R-22 is being phased out. Refrigerants

    manufactured as replacements for R-22 are HFC-134a, R-410a, R-410b to name a

    few. The new refrigerants do not contain the chlorine atom and are not harmful to the

    earths ozone layer.

    2. INDUSTRIAL AIR CONDITIONING SYSTEM

    In a commercial facility, personal comfort was often an adjunct to equipment

    maintenance; those who worked with or near equipment that needed to be

    kept cool were the incidental benefactors of industrial air conditioning. Much is

    made today, however, of what is known as sick building syndrome.

    They can relieve the discomfort of allergies by removing pollen from the air,

    make long commutes less taxing on drivers and passengers alike, and even

    help to preserve the health of patients in hospitals. In business and

    industry, air conditioning systems can improve the efficiency of workers,

    ensure uniformity in metal work, prevent too much or too little moisture from

    damaging fragile paper products during manufacture, and keep food fresh

    during longs periods of shipment and storage.

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    A deadly enemy of most electronic equipment and personal productivity is

    heat. Air conditioning is the mechanical replacement of heat with cooled air. In

    years past, most large commercial buildings and manufacturing facilities are

    equipped with industrial air conditioning units in part to alleviate the problems

    associated with overheating of electronic equipment such as computers,

    electronic testing instruments, and precision electronic manufacturing

    equipment. Machinery used to produce critical equipment, usually including

    precise measurements and tolerances, requires constant cooling to function

    properly. In a commercial facility, personal comfort was often an adjunct to

    equipment maintenance; those who worked with or near equipment that

    needed to be kept cool were the incidental benefactors of industrial air

    conditioning.

    Much is made today, however, of what is known as sick building syndrome.

    This term refers to office buildings, schools, manufacturing, production, and

    testing facilities where air quality is such that workers, students, customers,

    clients, and visitors to these facilities were becoming ill simply from remaining

    in such buildings for any length of time. These various illnesses were the

    result of breathing and absorbing unhealthful vapors and contaminants

    emitted by materials used in the construction of the building, as well as

    inadequate heating, ventilation or air conditioning (HVAC) equipment. Thus,

    industrial air conditioning is now critical to individual comfort and personal

    health, not to mention optimum productivity of workers as well as equipment.

    Nearly all modern industrial air conditioning units are now either ductless

    orsplit air conditioning systems, or a combination of both. The cooling

    machinery, fans, compressors, condensers, cooling towers, air handling,condensate recovery and discharge components are located at a remote

    location outside the building or facilities, either on the roof or grounds of the

    facility. The actual discharge of cooled air is accomplished by small, compact

    units located in various rooms, offices and spaces throughout the interior of

    the building. Often these room units are separately controlled via individual

    thermostats. Such is the beauty ofductless air conditioning. Ducted

    equipment, on the other hand, usually involves an inefficient dampening oflouvers to maintain individual room temperature.

    http://www.wisegeek.com/what-are-air-conditioning-units.htmhttp://www.wisegeek.com/what-are-the-different-types-of-manufacturing-equipment.htmhttp://www.wisegeek.com/what-are-the-different-types-of-manufacturing-equipment.htmhttp://www.wisegeek.com/what-is-split-air-conditioning.htmhttp://www.wisegeek.com/what-is-ductless-air-conditioning.htmhttp://www.wisegeek.com/what-is-ductless-air-conditioning.htmhttp://www.wisegeek.com/what-is-split-air-conditioning.htmhttp://www.wisegeek.com/what-are-the-different-types-of-manufacturing-equipment.htmhttp://www.wisegeek.com/what-are-the-different-types-of-manufacturing-equipment.htmhttp://www.wisegeek.com/what-are-air-conditioning-units.htm
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    The size and capacity of industrial air conditioning equipment is, obviously

    dependant on the size and design of the facility to be cooled. Industrial air

    conditioning units commonly range from some two tons, or 24,000 British

    Thermal Units (BTU) to 150 tons to 150 tons (1,800,000 BTU). A BTU is the

    amount of heat necessary to raise the temperature of a pound of water one

    degree, Fahrenheit.

    3. Direct Expansion Air Conditioning

    A direct expansion air conditioning (DX) system uses a refrigerant vapour

    expansion/compression (RVEC) cycle to directly cool the supply air to an

    occupied space.DX systems (both packaged and split) directly cools the air supplied to the

    building because the evaporator is in direct contact with the supply air,

    Expansion refers to the treatment of the refrigerant (a valve reduces its

    pressure and temperature) prior to it entering the evaporator. DX systems

    can come equipped with all the components in the unit (packaged system)

    intended for installation on the rooftop or by the side of a building; or it may

    have some components installed inside the building and some outside (split

    system). DX systems require a ventilation fan to distribute the cool air and

    resupply/re-circulate it.

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    A RVEC cycle has four basic components; an evaporator, compressor, condenser,

    and thermal expansion control device. The evaporator (located inside the supply air

    ductwork) absorbs heat through the process of expanding the refrigerant flowing

    within it. The refrigerant then flows to a compressor which compresses it causing it to

    condense in the condenser and release the heat it removed from the supply air. The

    condensed liquid refrigerant then flows through the thermal expansion control device

    which controls the flow and pressure of the refrigerant back into the evaporator.

    Packaged Systems Packaged DX units contain all 4 parts of the RVEC

    system, as well as fans and internal ducting. These units are designed to be

    installed easily to serve local zones cooling needs; multiple units can be

    installed to service multiple zones in a building.

    Split Systems These systems generally have the evaporator and fans inside

    the building, while the rest of the refrigerant vapour expansion/compression

    (RVEC) system components are a separate unit placed outside the building.

    This allows system designs that are more flexible, allowing performance that

    can satisfy greater variations on system demands. Split units are made to an

    incremental performance scale, meaning only certain working load sizes are

    available.

    Benefits:

    DX systems are less expensive to install, and uses less space in mechanical

    and electrical rooms than centralized cooling systems

    DX systems can be expanded in an incremental fashion to match changing

    building requirements

    Packaged Systems have standardized operating performances per unit,

    allowing more precise system sizing

    Packaged Systems generally require less ventilation, and do not require

    dedicated condensate lines

    Packaged Systems occupy less space than comparable split systems

    Split Systems tend to be larger allowing for fewer units, and therefore less

    maintenance costs than a comparable Packaged system

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    Split Systems have lower noise levels because the compressor unit is located

    further away from the cooling load area

    Split Systems may allow vertical duct shafts to be smaller in size.

    REFERENCES

    1. http://www.hesperian.org/wp-

    content/uploads/pdf/factory/Work_Dangers_5_other_dangers.pdf

    2. http://www.estesair.com/Products/Air_Conditioning_Products/Air_Conditioning

    _Basics/

    3. http://www.ignou.ac.in/upload/Unit%201-32.pdf

    4. http://www.fsec.ucf.edu/en/consumer/buildings/commercial/hvac.htm

    5. http://www.wisegeek.com/what-is-industrial-air-conditioning.htm

    6. http://www.nrgmanagement.ca/direct-expansion-air-conditioning-

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