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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.
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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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