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Tce Dsign Guidepdf PDF

This document provides guidelines for designing HVAC systems for green buildings to meet various prerequisites and credits under LEED rating systems. It outlines requirements for refrigerants, equipment efficiencies, insulation, ventilation rates, duct sealing, and more. Designs should minimize refrigerants' impact on ozone depletion and global warming. Equipment, ducts, and piping must meet specified insulation and sealing standards. Ventilation systems must provide minimum outdoor air flows and meet indoor air quality requirements.

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Tce Dsign Guidepdf PDF

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TATA CONSULTING ENGINEERS LIMITED SECTION:TITLE

TCE.M6-ME-811-319 DESIGN GUIDE FOR HVAC SYSTEM

SHEET i OF iv
FOR GREEN BUILDINGS

DESIGN GUIDE FOR HVAC SYSTEM

FOR GREEN BUILDINGS

FILE NAME:M6ME319R0

REV. NO. R0
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY RST Sd

CHD. BY PRJ Sd
R0
APD. BY GSK Sd

DATE 24.06.2010
FILE NAME: F020R4.DOC TCE FORM NO. 020 R4
TATA CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M6-ME-811- 319
DESIGN GUIDE FOR HVAC SYSTEM SHEET ii OF iv O

FOR GREEN BUILDINGS

CONTENTS

SL. SH.
NO. TITLE NO.
1.0 INTRODUCTION 1

2.0 SCOPE 1

3.0 DESIGN REQUIREMENTS 1

4.0 REFERENCES 16

APPENDICES

APPENDIX SH.
TITLE
NO. NO.
1 REFRIGERANT IMPACT CALCULATION 17

2A BUILDING ENVELOPE REQUIREMENTS AS PER ECBC-2007 19

BUILDING ENVELOPE REQUIREMENTS AS PER ASHRAE
2B 20
90.1.2007
ASSEMBLY U FACTORS & SHGC FOR UNLABELED
3 21
VERTICAL FENESTRATION & SKYLIGHTS
4 EQUIPMENT EFFICIENCIES AS PER ECBC-2007 22

5 EQUIPMENT EFFICIENCIES AS PER ASHRAE 90.1.2007 23

5A AIR CONDITIONERS & CONDENSING UNITS 23

5B WATER CHILLING PACKAGES 25

5C PACKAGE UNITS 26

5D HEAT REJECTION EQUIPMENTS 28

5E NON-STANDARD CENTRIFUGAL CHILLERS UPTO 150 TR 29

NON-STANDARD CENTRIFUGAL CHILLERS FROM 151 TR
5F 30
TO 300 TR
5G NON-STANDARD CENTRIFUGAL CHILLERS BEYOND 301 TR 31

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6 PSYCHROMETRIC CHART (FREE COOLING SYSTEM) 32

7 FAN POWER LIMITATION PRESSURE DROP ADJUSTMENT 33

8 DUCT INSULATION 34

9 PIPING INSULATION 35

10 MINIMUM DUCT SEAL LEVEL 36

11 OUTDOOR AIR FLOW CALCULATION 37

12 A MINIMUM VENTILATION RATES 38

12 B MINIMUM EXHAUST RATES 40

12 C ZONE AIR DISTRIBUTION EFFECTIVENESS 41

12 D SYSTEM VENTILATION EFFICIENCY 42

13 MINIMUM SEPARATION DISTANCE 43

14 LIGHTING POWER DENSITIES 44

15 VOC LIMITS 47

16 VENTILATION RATE PROCEDURE (VRP) CALCULATION 48

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REVISION STATUS

REVISION DATE DESCRIPTION

NO.

R0 24.06.2010 First issue

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FOR GREEN BUILDINGS

1.0 INTRODUCTION
The built environment has a profound impact on our natural environment,
economy, health, and productivity. Breakthroughs in building science,
technology, and operations are now available to designers, builders,
operators, and owners who want to build green and maximize both economic
and environmental performance.
The green building movement offers an unprecedented opportunity to
respond to the most important challenges of our time, including global climate
change, dependence on non sustainable and expensive sources of energy,
and threats to human health.
Green building is the practice of increasing the efficiency with which buildings
use resources -- energy, water, and materials — while reducing building
impacts on human health and the environment during the building's lifecycle.

2.0 SCOPE
This document gives guidelines for design of HVAC system for Green
Buildings.

3.0 DESIGN REQUIREMENTS

Following requirements should be met for the HVAC system for Green
Buildings to acquire various prerequisites & credits as per LEED (Leadership
in Energy and Environmental Design) rating system:

3.1 REFRIGERANTS

3.1.1 Minimum requirement: Zero use of CFC based refrigerants in new building
HVAC & R systems. In case of renovations or using existing HVAC & R
equipments, identify existing equipments that uses CFC refrigerants &
schedule for replacement of these refrigerants.

3.1.2 As per Indian Green Building Council (IGBC)-LEED rating system, equipment
that do not contain HCFCs should be used for getting additional credits.
Whereas as per LEED-USGBC HVAC&R equipment must comply with the
following formula, which sets a maximum threshold for the combined
contributions to ozone depletion and global warming potential:

LCGWP + LCODP x 105 100

Where
LCODP = [ODPr x (Lr x Life +Mr) x Rc] / Life
LCGWP = [GWPr x (Lr x Life + Mr) x Rc] / Life
LCODP : Lifecycle Ozone Depletion Potential (lb CFC 11/Ton-Year)
LCGWP : Lifecycle Direct Global Warming Potential (lb CO2/Ton-Year)
GWPr : Global Warming Potential of Refrigerant (0 to 12,000 lb
CO2/lbr)
ODPr : Ozone Depletion Potential of Refrigerant (0 to 0.2 lb CFC
11/lbr)
Lr : Refrigerant Leakage Rate (0.5% to 2.0%; default of 2%
unless otherwise demonstrated)
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Mr : End-of-life Refrigerant Loss (2% to 10%; default of 10%

unless otherwise demonstrated)
Rc : Refrigerant Charge (0.5 to 5.0 lbs of refrigerant per ton of
gross ARI rated cooling capacity)
Life : Equipment Life (10 years; default based on equipment type,
unless otherwise demonstrated)

In case of multiple type of equipment average of all equipment must be

calculated using following formula :

(LCGWP + LCODP x 105 ) x Qunit 100

QTotal
Where

Qunit : ARI rated cooling capacity of individual refrigeration / HVAC

unit (TR)

QTotal : Total ARI rated cooling capacity of all refrigeration / HVAC

unit (TR)

Sample Calculation for the same is shown in APPENDIX 1.

3.1.3 Select HVAC&R equipment with reduced refrigerant charge and increased
equipment life. Maintain equipment to prevent leakage of refrigerant to the
atmosphere.

3.2 BUILDING ENVELOPE

3.2.1 The exterior building envelope shall be designed with either Residential or
Non-residential requirements in APPENDIX 2, Building Envelope
Requirements, (excerpts from American Society of Heating, Refrigerating and
Air-Conditioning Engineers (ASHRAE) 90.1.2007 & Energy Conservation
Building Code (ECBC)). As per green building requirements stringent
requirements of the above (ASHRAE or ECBC) shall be followed.

For all opaque surfaces, compliance to standard shall be demonstrated by

either Minimum rated R values of insulation or Maximum U factor.

3.2.2 The total vertical fenestration area shall be less than 40% (as per ASHRAE
90.1.2007) of the gross wall area. In ECBC vertical fenestration area limit is
up to 60% of the gross wall area. The total skylight area shall be less than 5%
of the gross roof area as per ASHRAE 90.1.2007 and ECBC.

3.2.3 Design building envelope so that space conditions are maintained within the
range specified in ASHRAE standard 55-2004, Thermal comfort Conditions
for Human Occupancy. Documentation shall be as under (Excerpts from
ASHRAE standard 55-2004, Section 6.1.1)

(i) The design criteria of the system in terms of indoor temperature, humidity,
including any tolerance based on stated design outdoor ambient
conditions and total indoor loads should be stated.
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FOR GREEN BUILDINGS

(ii) The system input or output capacities necessary to attain the design
indoor conditions at design outdoor ambient conditions should be stated
along with system supplied and installed capacities.

(iii) The limitations of the system to control the environment of the zone(s)
should be stated.

(iv) The overall space supplied by the system should be shown in a plan view
layout, with all individual zones within it identified. All terminal units should
be shown with type and flow.

(v) Items affecting indoor comfort (such as decor, significant structural items)
should be shown. Notes should be provided to identify areas and location
within space relative to grilles, diffuser, sensors which should not be
obstructed.

(vi) Areas within any zone that lie outside the comfort area, where people
should not be permanently located, should be identified.

(vii) Location of all occupant adjustable controls should be identified and each
should be provided with a legend describing which zone(s) and function it
controls, how it is to be adjusted, the range of effect it can have and
recommended setting for various times of day, season or occupancy load.

(viii) A block diagram control schematic should be provided with sensors,

controls and actuators identified for each zone.

(ix) The general maintenance, operation and performance of the building

systems should be state, followed by more specific comments on
maintenance and operation of automatic controls and manually adjustable
controls and the response of the system to each. Where necessary,
specific seasonal settings of manual controls should be stated and major
system changeovers that are required to be performed by a professional
service agency should be identified.

(x) Specific limits in the adjustment of manual controls should be stated.

Recommendations for seasonal settings on these controls should be
stated. A maintenance and inspection schedule for all thermal
environmental related systems should be provided.

(xi) Assumed electrical load for lighting and equipment in occupied spaces
(including diversity considerations) used in HVAC load calculations
should be documented along with any other significant thermal and
moisture loads assumed in HVAC load calculations and any other
assumptions based upon which HVAC and control design is based.

3.2.4 Fenestration and Doors

Where fenestration and doors are used in the building envelope, it shall
comply with following requirements:

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3.2.4.1 The U factor, SHGC & air leakage rate shall be determined by a laboratory
accredited by a nationally recognized accreditation organization such as
National Fenestration Rating Council (NFRC).

3.2.4.2 U factors & SHGC for the overall fenestration product shall be determined in
accordance with ISO 15099 as per ECBC or NFRC 100 & NFRC 200
respectively as per ASHRAE 90.1.2007. Or alternatively U factors & SHGC
from APPENDIX 3, Assembly U factors & SHGC for unlabeled vertical
fenestration & skylights, are acceptable.

3.2.4.3 U factors for unlabeled opaque doors shall be as under

(a) Un-insulated single layer metal swinging or non-swinging doors, including

single layer un-insulated access hatches : 1.45 Btu/hr ft2 °f

(b) Un-insulated double layer metal swinging or non-swinging doors, including

double layer un-insulated access hatches : 0.75 Btu/hr ft2 °f

(d) Wood doors , minimum nominal thickness of 1.75” including panel doors
with minimum panel thickness of 1.125” , solid core flush doors, & hollow
core flush doors :0.50 Btu/hr ft2 °f

(e) Any other wood door : 0.60 Btu/hr ft2 °f

3.2.4.4 The U factor & the air leakage rate shall be identified on a permanent
nameplate installed on the product by the manufacturer.

3.2.5 Air Leakage Rates

3.2.5.1 All openings in the building envelope such as joints around doors &
fenestrations, corners, utility services penetrations, openings shall be sealed,
gasketed or weather stripped to minimise air leakage.

3.2.5.2 Air leakage shall not exceed 1 cfm/ft2 for glazed swinging entrance doors &
0.4 cfm/ft2 for all other products.

3.2.6 Insulation

Where insulation is used in the building envelope it shall comply with following
requirements:

3.2.6.1 The rated R value of the insulation shall be clearly identified by the
manufacturer on each piece of building envelope insulation

3.2.6.2 Insulation material shall be installed as per manufacturer’s recommendation,

in substantial contact with inside surface & in such a manner so as to achieve
the rated R value of the insulation.

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3.2.6.3 Roof insulation shall not be installed on a suspended ceiling with removable
ceiling panels.

3.2.6.4 Loose fill insulation shall not be used in attic roof spaces when slope of the
ceiling is more than 3:12

3.2.6.5 Insulation material in ground contact shall have water absorption rate no
greater than 3%when tested in accordance with ASTM C272

3.2.6.6 Flexible bat insulation installed in floor cavities shall be supported in a

permanent manner by supports no greater than 24” on centre.

3.2.6.7 Any equipment, fixtures shall not be recessed in such a manner as to affect
the insulation thickness.

3.2.6.8 Exterior insulation shall be covered with protective material to prevent

damage from moisture, sunlight, wind, maintenance.

3.2.6.9 Insulation shall extend over the full component area to the required rated R
value of insulation.

3.3 HVAC EQUIPMENTS

3.3.1 Equipment Efficiencies

3.3.1.1 HVAC equipments shall have minimum performance as per APPENDIX 4,

Minimum Equipment Efficiency requirements as per ECBC-2007 or
APPENDIX 5, Minimum Efficiency requirements as per Ashrae 90.1.2007,
whichever is stringent, at specified rating conditions when tested in
accordance with specified test procedure. Where multiple rating conditions or
performance requirements are provided, the equipment shall satisfy all rated
conditions. APPENDIX details are as under :

APPENDIX 4 Minimum Efficiency Requirement As per ECBC

APPENDIX 5 Minimum Efficiency Requirement as

per ASHRAE 90.1.2007 as under

APPENDIX 5 A Air Conditioners & Condensing Units

APPENDIX 5 B Water Chilling Packages

APPENDIX 5 C Package Units

APPENDIX 5 D Heat Rejection Equipments

Water cooled Centrifugal Chillers that are not designed for operation at ARI
standard 550/590 test conditions shall have performance requirements (full
load COP & NPLV) as per following APPENDICES:

APPENDIX 5 E Chiller Capacity < 150 TR

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APPENDIX 5 F 150 TR Chiller Capacity < 300 TR

APPENDIX 5 G Chiller Capacity 300 TR

The table values are applicable over the following full load design range :

Leaving Chilled water temperature :40°F to 48°F

Entering Condenser water temperature :75°F to 85°F

Condenser water temperature rise :5°F to 15°F

3.3.1.2 Equipment efficiencies information provided by the manufacturer shall be

verified by certified programme & data furnished by manufacturer

3.3.1.3 Equipments shall carry a permanent label installed by manufacturer stating

that the equipment complies with the requirements of ASHRAE standard 90.1

3.3.2 Air and Water Economizers

3.3.2.1 Each individual cooling fan system that has a design supply capacity over
2500 cfm and a total mechanical cooling capacity over 6.3 TR shall include
either air side or water side economizer(as per para 5.3.1 of ECBC). Projects
in Hot dry and Warm humid climate zones are exempt and individual ceiling
mounted fan systems (<6500 cfm) are exempt.

3.3.2.2 Free Cooling: When the enthalpy of the outside air is less than the enthalpy of
the mixing air (outside air + return air), conditioning the outside air is more
energy efficient than conditioning mixing air. Air economizer can be used to
implement the scheme. Air economizer consists of modulating outdoor air
damper, return air damper, exhaust air dampers and control system to
operate them. Operating characteristic of the economizer system is illustrated
below for different conditions (Case I, Case II & Case III). Also refer attached
psychrometric chart, APPENDIX 6.

Case I - When the enthalpy of outside air (hos) is higher than the
mixing air enthalpy (hmc), hos > hmc

(i) The outdoor air damper is opened to a minimum position,

taking minimum outdoor air required for ventilation.

(ii) Return air damper is fully open and exhaust air damper is
opened to a minimum position.

(iii) Refrigeration plant is working to cool the mixing air to the

supply air temperature.

Case II - When the enthalpy of outside air is equal to or lower than

the mixing air enthalpy but more than the supply air enthalpy (hsa), hsa
< hos ≤ hmc

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FOR GREEN BUILDINGS

(i) The outdoor air damper and exhaust air damper both are fully
open.

(ii) Return air damper is closed.

(iii) Refrigeration plant is working to cool the outdoor air to the

supply air temperature.

Case III - When the enthalpy of outside air is lower than the supply air
enthalpy, hos ≤ hsa

(i) The outdoor air damper and Return air damper both are
modulated to achieve the supply air temperature.

(ii) Exhaust air damper is also modulated.

(iii) Refrigeration plant is switched off

Careful analysis is required for designing & implementing the above scheme
considering outside conditions throughout the year.

3.3.3 Each HVAC system having a total fan system motor nameplate hp exceeding
5 hp shall meet the following :

3.3.3.1 Each HVAC system at fan system design conditions shall not exceed the
allowable fan system motor nameplate hp (Option 1) or fan system bhp
(Option 2) as shown below

Limit Constant Volume Variable Volume

Option1 Allowable hp ≤ CFM0.0011 hp ≤ CFM0.0015

nameplate
Motor HP

Option2 Allowable bhp ≤ CFM0.00094+A bhp ≤ CFM0.0013+A

fan system
BHP

where CFM is the maximum design supply air flow rate to conditioned spaces
served by the system in cfm and A is the sum of (PD x CFM (through each
device) / 4131). PD shall be as given in the APPENDIX 7

3.3.3.2 The selected fan motor shall be no larger than the first available motor size
greater than the bhp.

3.3.3.3 Individual VAV fans with motors 10 hp or larger shall meet one of the
following requirement

(a) The fan shall be driven by a mechanical or electrical variable speed

drive

(b) The fan shall be a vane axial fan with variable pitch blades.
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(c) The fan shall have other controls and devices that will result in fan motor
demand of no more than 30% of design wattage at 50% of design air
volume when static pressure set point equals one third of the total
design static pressure based on manufacturers certified fan data.

3.3.4 HVAC hydronic systems having a total pump power exceeding 10 hp shall
meet following provisions

3.3.4.1 HVAC pumping systems that include control valves designed to modulate or
step open and close as a function of load shall be designed for variable fluid
flow and shall be capable of reducing pump flow rates to 50% or less of the
design flow rate. Individual pumps serving variable flow systems having a
pump head in excess of 100 ft and motor exceeding 50 hp shall have controls
and/or devices (such as variable speed control) that will result in pump motor
demand of no more than 30% of design wattage at 50% of design water flow.
The devices shall be controlled as a function of desired flow or to maintain a
minimum required differential pressure. Differential pressure shall be
measured at or near the most remote heat exchanger requiring the greatest
differential pressure.

3.3.4.2 When a chilled water plant includes more than one chiller, provisions shall be
made so that the flow in the respective chiller can be automatically stopped
when a chiller is shut down.

3.3.5 Each fan of heat rejection equipment (whose energy usage is not included in
equipment efficiency tables listed in Sr. No. 3.3.1.1) of motor rating 7.5 hp or
larger shall have the capability to operate at 2/3rd of full speed or less and
shall have speed controls to control the leaving fluid or condensing
temperature or pressure of the heat rejection equipment.

3.3.6 Individual fan systems that have both a design supply air capacity of 5000
cfm or greater and have a minimum outdoor air supply of 70% or greater of
the design supply air quantity shall have an energy recovery system with at
least 50% recovery effectiveness (i.e. Change in enthalpy of the outdoor air
supply equal to 50% of the difference between the outdoor air and return air
at design conditions).

3.3.7 Kitchen exhaust hoods larger than 5000 cfm shall be provided with makeup
air sized for at least 50% of exhaust air volume.

3.3.8 Building with fume hood systems having a total exhaust rate greater than
15000 cfm shall include at least one of the following features

3.3.8.1 VAV hood exhaust and room supply systems capable of reducing exhaust
and makeup air volume to 50% or less of design values

3.3.8.2 Direct make up air supply equal to at least 75% of the exhaust rate, cooler to
no cooler than 3°F above room set point and heated no warmer than 2°F
below room set point, no humidification added, no simultaneous heating and
cooling used for dehumidification control.

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3.3.8.3 Heat recovery system to precondition makeup air from fume hood exhaust in
accordance with Sr. No. 3.3.6

3.3.9 Controls

3.3.9.1 Design the HVAC system (heating & cooling both) to provide individual
comfort controls to allow adjustments to suit individual needs. Also provide
comfort controls for all shared multi-occupant spaces to enable adjustments
that meet group needs. Conditions of thermal comfort shall be as described in
ASHRAE standard 55-2004.

3.3.9.2 Controls for metering the energy used shall be included in the design.

3.3.9.3 Temperature range or dead band for controls shall be 5°F except for special
applications

3.3.9.4 When HVAC systems are not intended to operate continuously , HVAC
system shall be designed with controls (i) that shall start and stop the system
under different time schedule , (ii) an occupant sensor that is capable of
shutting the system off when no occupant is sensed for a period of 30
minutes, (iii) a manually operated timer capable of bring adjusted to operate
the system for upto two hours, (iv) an interlock with the security system that
shuts the system off when the security system is activated.

3.3.9.5 Individual HVAC systems having capacity in excess of 10000 cfm shall have
the optimum start control, the control algorithm as a minimum shall be a
function of difference between space temperature and occupant set point and
amount of time prior to scheduled occupancy.

3.3.9.6 HVAC systems serving zones that may operate non simultaneously shall be
divided into isolated areas. Zones shall be grouped so that no individual zone
exceeds 25000 ft2 of conditioned floor area. Controls shall be provided for
automatic shutting off the system in particular zone when system is not in
use.

3.3.9.7 Stair and shaft vents shall be equipped with motorized dampers that are
capable of being automatically closed during normal building operation & are
interlocked to open when required by fire and smoke detection system. All
outdoor supply air and exhaust air systems shall be equipped with motorised
dampers that will automatically shut down when the spaces served are not in
use.

3.3.9.8 Outdoor air supply & exhaust dampers shall have a maximum leakage rate
not more than 4 cfm / ft2 @ 1” SP for motorized dampers & no leakage at 1”
SP for non motorized damper. However damper smaller than 24” in either
dimension may have leakage of 40 cfm/ft2

3.3.10 Insulation

3.3.10.1 All supply & return ductwork insulation shall be in accordance with
APPENDIX 8, Duct Insulation

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3.3.10.2 All piping insulation shall be in accordance with APPENDIX 9, Piping

Insulation

3.3.10.3 Insulation exposed to weather shall be protected by aluminium, sheet metal,

painted canvas or plastic cover.

3.3.11 Ductwork and plenum shall be sealed in accordance with APPENDIX 10,
Minimum Duct Seal Level

3.3.12 Ductwork that is designed to operate at static pressures in excess of 3” w.c.

shall be leak tested for 25% of the installed duct area. The maximum
permitted leakage shall be

Lmax = CL x P0.65 where

Lmax =Maximum permissible leakage , cfm / 100 ft2 duct surface area

CL =Duct leakage class, cfm / 100 ft2 at 1” W.C.

6 for rectangular sheet metal / fibrous & round flexible ducts

3 for round/flat oval sheet metal / fibrous glass duct

P =test pressure (design duct pressure)

3.3.13 Completion Requirements

Following construction documents shall be provided to building owner or

representative within 90 days of acceptance of the system:

(a) As built drawings

(b) Operation & Maintenance Manual

(c) Air & Water balancing reports

3.3.14 HVAC Electrical equipment & cabling

(a) All Motors shall have a minimum acceptable nominal full load motor
efficiency not less than IS 12615 standard for energy efficient motors

(b) Feeder conductors shall be sized for a maximum voltage drop of 2% at

design load. Branch circuit conductors shall be sized for a maximum
voltage drop of 3% at design load

3.4 VENTILATION FOR ACCEPTABLE INDOOR AIR QUALITY

3.4.1 Outdoor Air Quality

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3.4.1.1 Outdoor air quality shall be evaluated for the project site prior to completion of
ventilation system design for checking the outdoor air contamination levels. A
survey of the building site & its immediate surroundings shall be conducted
during hours the building is expected to be normally occupied to identify local
contaminants from surrounding facilities. The observations of the survey shall
be documented (as per ASHRAE 62.1.2004) & discussed with the building
owner or their representatives.

3.4.1.2 If the outdoor air is judged to be unacceptable in accordance with ASHRAE

62.1.2004, ventilation system that provides outdoor air through a supply fan
shall comply with the following :

(a) Air filters having MERV of 6 or higher shall be provided

(b) Air cleaning devices having minimum volumetric ozone removal efficiency
of 40% for ozone shall be provided when outdoor ozone levels are
expected to exceed 0.16 ppm. Air cleaning devices for ozone are not
required when outdoor air intake results in 1.5 ACPH or less

3.4.2 Mechanical Ventilation

3.4.2.1 As a minimum requirement for green buildings, mechanical ventilation

systems shall be designed using the Ventilation Rate Procedure (VRP) or the
applicable local code whichever is more stringent. Refer APPENDIX 11, for
Ventilation Rate Procedure details. Further additional credit points can be
acquired by increasing the ventilation rates to all occupied spaces by at least
30% above minimum rates required by ASHRAE standard 62.1.2004.
Minimum ventilation rates are given in APPENDIX 12 A. One example is
given in APPENDIX 16.

3.4.2.2 Various tables required for calculation in ventilation rate procedure are given
as under :

APPENDIX 12 A - Minimum Ventilation Rates for Breathing Zone

APPENDIX 12 B - Minimum Exhaust Rates

APPENDIX 12 C - Zone Air Distribution Effectiveness

APPENDIX 12 D - System Ventilation Efficiency

3.4.2.3 Demand control ventilation (DCV) is required for spaces larger than 500 ft2
and with design occupancy for ventilation of greater than 40 people per 1000
ft2 of floor area and served by systems with either an air side economizer or
automatic modulating control of the outside air damper or both.

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DCV is a system that adjusts the amount of outside air based on the number
of occupants and the ventilation demands that those occupants create. DCV
systems uses CO2-based sensors, which measure the buildup of CO2 from
the occupants present and control the outside air flow. In this system CO2
sensors monitor CO2 levels in the air inside a building or occupied areas, and
an air-handling system uses this data from the sensors to regulate the
amount of ventilation air admitted.

3.4.2.4 Use heat recovery, where appropriate, to minimize the additional energy
consumption associated with higher ventilation rates.

3.4.2.5 Indoor Air Quality (IAQ) procedure can be used as an alternative to VRP
(described at Sr. No. 3.4.2.1) as per Ashrae standard 62.1. IAQ procedure
allows credit to be taken for controls that remove contaminant. It is also used
where the design is intended to attain specific target contaminant
concentrations or levels of acceptability of perceived indoor air quality. Air
purification equipment are used in the HVAC systems enabling a reduction in
ventilation air flow rates from the levels required by VRP.

3.4.2.6 Use of controlled injection of ozone can help reduce the quantity of fresh air.
Ozone is a powerful oxidant, which removes odour, Volatile Organic
Compounds (VOC) and even fungi by oxidation. This reduces the oxygen
requirement in the form of ventilation and air is mainly required for diluting
CO2. With ozone generators, ozone is injected into the central air conditioning
system (ducts) & concentration is controlled by sensors activated by excessive
VOC concentrations & turned off by excess ozone concentration sensors.
Ozone concentration is required to be kept below harmful limit (0.05 ppm as
per Ashrae).

3.4.3 Natural Ventilation

3.4.3.1 Naturally ventilated spaces shall be permanently open to and within 8 m of

operable wall or roof openings to the outdoors. Openable area shall be
minimum of 4% of the net occupiable floor area.

3.4.3.2 An engineered natural ventilation system when approved by the authority

having jurisdiction need not meet the above requirement

3.4.3.3 Credits may be acquired by designing natural ventilation system to meet

recommendations set forth in the Chartered Institution of Building Services
Engineers (CIBSE) Application manual 10:2005, follow flow diagram process
shown in figure 2.8 of CIBSE Application Manual 10 OR

3.4.3.4 Follow 8 design steps, as under, described in Carbon Trust Good Practice
Guide 237

(a) Develop design requirements

(b) Plan air flow paths

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(d) Determine ventilation requirement

(e) Estimate external driving pressures

(f) Select types of ventilation devices

(g) Size ventilation devices

(h) Analyze the design

OR Use public domain software such as NIST’s CONTAM, Multizone

modelling software, along with LoopDA, Natural ventilation sizing tool, to
analytically predict room by room airflows.

3.4.4 Smoking rooms designed to contain, capture & remove environmental

tobacco smoke (ETS) from the building must be directly exhausted to the
outdoors, away from air intakes and building entry paths with no recirculation
of ETS containing air. Exhaust shall be sufficient to create negative pressure
differential with the surrounding spaces of at least an average of 0.02” of
water gauge & minimum of 0.004” of water gauge when doors to smoking
rooms are closed. Corridors common to ETS & ETS free areas shall be
supplied with outdoor air at the rate of 0.1 cfm/ft2. Differential pressure
generally used is 0.05” WC.

3.4.5 Sufficiently exhaust each space where hazardous gases or chemicals may be
present or used to create negative pressure with respect to adjacent spaces
when the doors to the room are closed. Exhaust rate must be at least 0.5 cfm
/ ft2 with no air recirculation. The pressure differential with the surrounding
spaces must be at least an average of 0.02” & minimum of 0.004” when doors
to the rooms are closed. Filters having MERV of 13 or higher must be
provided for mechanically ventilated buildings. This requirement is used to
acquire credit points and is not a mandatory requirement.

3.4.6 Minimum outdoor air intake shall be greater than the design maximum
exhaust airflow when the mechanical air-conditioning are dehumidifying.

3.4.7 ASHRAE Standard 62.1 includes a design requirement intended to limit

relative humidity in zones. To comply with this, designers must analyze the
performance of the proposed air conditioning system at relatively severe
latent load conditions, namely, with outdoor air at dehumidification design
condition (design dew point and mean coincident dry-bulb temperature) and
with no zone sensible-heat gain due to solar load. This analysis tests the
dehumidification capability of the HVAC system configuration and control. It
must show that zone relative humidity does not exceed 65% RH at these
conditions. Some systems in some buildings in some climates can meet this
requirement without direct humidity control, e.g., VAV systems that supply
cool, dry primary air at all conditions. Other systems, however, such as
traditional single-zone constant volume systems, supply warmer, moister air
at part-sensible load and cannot maintain 65% RH or less without some
enhancement. To comply with Standard 62.1, these systems must be
reconfigured, to limit relative humidity indirectly, or using a zone humidistat
and local reheat.
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3.4.8 Location of outdoor air intakes shall be such that the shortest distance from
the intake to any specific potential outdoor contaminant source shall be equal
to or greater than the separation distance listed in APPENDIX 13, Minimum
Separation distance

3.4.9 Outdoor air intakes that are part of the mechanical ventilation system shall be
designed to manage Rain entrainment, Rain intrusion, Snow entrainment in
accordance with the ASHRAE standard 62.1.2004

3.4.10 Air shall be classified and its recirculation shall be limited in accordance with
the following :

(a) Class 1 air : Air with low contaminant concentration, low irritation intensity
and inoffensive odour, may be recirculated or transferred to any space.

(b) Class 2 : Air with moderate contaminant concentration, mild irritation

intensity and mild offensive odour, may be recirculated within the space of
origin or transferred or recirculated to other class 2 or class 3 or class 4
spaces utilized for similar purpose.

(c) Class 3 : Air with significant contaminant concentration, irritation intensity

and offensive odour, may be recirculated within the space of origin. Shall
not be transferred or recirculated to any other space.

(d) Class 4 : Air with highly objectionable fumes or gases & at harmful
concentrations, Shall not be transferred or recirculated to any other space
nor recirculated within space of origin.

Classification of air leaving each space shall be in accordance with

APPENDIX 12 A, Minimum Ventilation Rates for Breathing Zone

3.4.11 Mechanical ventilation systems shall include controls, manual or automatic,

that enable fan system to operate whenever the spaces served are occupied.
The system shall be designed to maintain the minimum outdoor airflow under
any load condition.

3.4.12 The system may be designed to reset the design outdoor air intake flow as
operating conditions change, these conditions include but are not limited to :

3.4.12.1Variation in occupancy or ventilation rate or CO2 levels (DCV as described at

Sr. No. 3.4.2.3) in one or more individual zones.

3.4.12.2 A higher fraction of outdoor air in the supply due to intake of additional
outdoor air for free cooling or exhaust air make up.

3.4.12.3 All air stream surfaces in equipments and ducts shall be designed and
constructed in accordance with ASHRAE standard 62.1.2004, Resistance to
mould growth & erosion

3.5 LIGHTING POWER DENSITIES

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Lighting power densities must not exceed the densities for the classified zone
given in ANNEXURE 12, Lighting Power Densities

3.6 LOW EMITTING MATERIALS

3.6.1 Specifications shall clearly state the VOC limits as given in ANNEXURE 13,
VOC Limits, for coatings, adhesives & paints that may be used in construction
/ installation of HVAC system. All adhesives and sealants must comply with
South Coast Air Quality Management District Rule 1168

3.7 BUILDING PERFORMANCE

As a minimum requirement for Green building, at least one of the following
requirements shall be met.

3.7.1 LEED India requires establishing the minimum level of energy efficiency for
the base building and systems and requires the building project to comply
with mandatory provisions and prescriptive provisions of ASHRAE standard
90.1.2004 which are described above in earlier sections. Project should also
comply with the final version of ECBC.

Whereas as per LEED (USGBC) rating system it is required to demonstrate a

10% improvement in the proposed building performance rating for new
buildings, or a 5% improvement in major renovations to existing buildings,
compared with the baseline building performance rating. Baseline building
performance rating is calculated according to the building performance rating
method of ASHRAE Standard 90.1-2007 using a computer simulation model
for the whole building project. Ashrae Standard 90.1-2007 requires that the
energy analysis done for the building performance rating method include all
energy costs associated with the building project.
OR
3.7.2 Comply with the prescriptive measures of ASHRAE Advanced Energy Design
Guide for Small Office Buildings 2004 / Small Retail Buildings 2006 / Small
Warehouses & Self Storage Building 2008 or Core Performance Guide
3.7.3 Further, additional credits may be acquired by improving the performance of
the proposed building (Ref 3.7.1). Credits are available up to 42% (48% as
per LEED USGBC) improvement in performance of proposed building. This
can be achieved by whole building energy simulation (using the Building
Performance Rating Method in Appendix G of the ASHRAE standard 90.1) or
prescriptive compliance path described in 3.7.2 above.

3.8 Green building design requirements also encourages use of onsite renewable
energy such as Solar, Wind, Geothermal, Bio mass & Bio gas strategies.
However this is not a mandatory requirement at present and is used to
acquire additional credit points for Green building certification.

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4.0 REFERENCES

4.1 LEED 2009 for New Construction and Major Renovations

4.2 Reference Guide for New Construction and Major Renovations (LEED-India
NC) Version 1.0

4.3 ASHRAE Standard 90.1.2007, Energy Standard for Buildings except Low
Rise Residential Buildings

4.4 ASHRAE Standard 62.1.2004, Ventilation for Acceptable Indoor Air Quality

4.5 Energy Conservation Building Code 2007

4.6 ASHRAE Standard 55-2004, Thermal comfort Conditions for Human

Occupancy

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APPENDIX 1

REFRIGERANT IMPACT CALCULATION

Sample calculation for arriving at the refrigerant impact is given here.

Assumptions made for the calculation are as under

Total no. of systems in complete project :3 (System-1,2 and 3)

Refrigerant for Systems :R-134a for System-1, 2 and 3

CALCULATION TABLE

Description of system System-1 System-2 System-3 Total

Refrigerant R-134a R-134a R-134a

System Capacity TR 1000 1400 1400 3800
GWPr 1320 1320 1320
ODPr 0 0 0
Rc lb 3300 3990 3990
Life years 23 23 23
Lr % 2 2 2
Mr % 10 10 10
LCGWP 106059 128235 128235
LCODP 0 0.00 0.00
LCGWP + LCODP x
106059 128235 128235 362529
105
Total impact 95.4

Where
LCODP = [ODPr x (Lr x Life +Mr) x Rc] / Life
LCGWP = [GWPr x (Lr x Life + Mr) x Rc] / Life
LCODP : Lifecycle Ozone Depletion Potential (lb CFC 11/Ton-Year)
LCGWP : Lifecycle Direct Global Warming Potential (lb CO2/Ton-Year)
GWPr : Global Warming Potential of Refrigerant (0 to 12,000 lb
CO2/lbr). Values taken from Refrigerant Reference Guide,
National Refrigerants
ODPr : Ozone Depletion Potential of Refrigerant (0 to 0.2 lb CFC
11/lbr). Values taken from Refrigerant Reference Guide,
National Refrigerants
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Lr : Refrigerant Leakage Rate (0.5% to 2.0%; default of 2%

unless otherwise demonstrated)
Mr : End-of-life Refrigerant Loss (2% to 10%; default of 10%
unless otherwise demonstrated)
Rc : Refrigerant Charge (0.5 to 5.0 lbs of refrigerant per ton of
gross ARI rated cooling capacity). Values taken from
equipment Manufacturer.
Life : Equipment Life, Values taken from
equipment Manufacturer

Total impact (LCGWP + LCODP x 105 ) x Qunit 100

QTotal

Conclusion

1.0 Project satisfies minimum requirement of zero use of CFC refrigerant as

specified in Sr. No. 3.1.1

2.0 Project will get the additional credit as it satisfies the requirement of total
impact less than 100.

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APPENDIX 2 A

BUILDING ENVELOPE REQUIREMENTS AS PER ECBC 2007

Walls & Roofs

Climate 24 Hour use buildings Daytime use buildings
Zones* Hotels, Hospitals etc Other Building Types
Assembly Insulation Assembly Insulation
Max U Min R Value Max Min R Value
Btu/hr ft2 °f hr ft2 °f / Btu Btu/hr ft2 °f hr ft2 °f / Btu
Roofs
Composite 0.0460 R-19.8 0.0715 R-11.9
Hot & Dry 0.0460 R-19.8 0.0715 R-11.9
Warm & Humid 0.0460 R-19.8 0.0715 R-11.9
Moderate 0.0715 R-11.9 0.0715 R-11.9
Cold 0.0460 R-19.8 0.0715 R-11.9
Walls
Composite 0.0775 R-11.9 0.0775 R-11.9
Hot & Dry 0.0775 R-11.9 0.0775 R-11.9
Warm & Humid 0.0775 R-11.9 0.0775 R-11.9
Moderate 0.0759 R-10.2 0.0699 R-11.4
Cold 0.0650 R-12.5 0.0620 R-13.3

Fenestrations
Climate Maximum Maximum SHGC
Zones* U Factor WWR 40% 40%=WWR 60%
Btu/hr ft2 °f
Vertical Fenestration
Composite 0.58 0.25 0.20
Hot & Dry 0.58 0.25 0.20
Warm & Humid 0.58 0.25 0.20
Moderate 1.22 0.40 0.30
Cold 0.58 0.51 0.51

Skylights
Maximum U Factor Maximum SHGC
Climate With Curb W/o Curb 0 to 2% SRR 2.1 to 5% SRR
Zones* Btu/hr ft2 °f Btu/hr ft2 °f

Composite 1.98 1.36 0.40 0.25

Hot & Dry 1.98 1.36 0.40 0.25
Warm & Humid 1.98 1.36 0.40 0.25
Moderate 1.98 1.36 0.61 0.40
Cold 1.98 1.36 0.61 0.4

*Climate Zones as per ECBC , Climate Zone Map of India

Definitions :
WWR : Window to Wall Ratio, SRR : Skylight Roof Ratio

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APPENDIX 2 B

BUILDING ENVELOPE REQUIREMENTS* AS PER ASHRAE 90.1.2007

Opaque Non-Residential Residential

Elements Assembly Insulation Assembly Insulation
Max U Min R Value Max Min R Value
Btu/hr ft2 °f hr ft2 °f / Btu Btu/hr ft2 °f hr ft2 °f / Btu
Roofs
Insulation above deck 0.063 R-15 0.048 R-20
Metal Building 0.065 R-19 0.065 R-19
Attic & Other 0.034 R-30 0.027 R-38

Walls, Above grade

Mass 0.58 NR 0.151 R-5.7
Metal Building 0.113 R-13 0.113 R-13
Steel framed 0.124 R-13 0.124 R-13
Wood framed or other 0.089 R-13 0.089 R-13

Walls, Below grade C-1.14 NR C-1.14 NR

Floors
Mass 0.322 NR 0.322 NR
Steel Joist 0.35 NR 0.35 NR
Wood framed & other 0.282 NR 0.282 NR

Fenestration 0 to 40% of wall

Normal framing 1.2 1.2
Metal framing 1.2 1.2
(Curtainwall/Storefront) SHGC 0.25 all SHGC 0.25 all

*For Climate Zone 1 (A,B) & Prescriptive Building Envelope Option

Notes : (1) Either above U values can be specified / used or alternatively U values for pre-calculated assemblies can be used from APPENDIX A
of ASHRAE 90.1.2007. (2) For Min. R value, specifications listed in APPENDIX A shall be used to determine compliance. For Max. U value , the
values for typical construction assemblies listed in APPENDIX A shall be used to determine compliance. (3) Component U factors for other
assemblies (not listed in APPENDIX A) can be determined in accordance with Section A9 of ASHRAE 90.1.2007
Definitions :
mass wall : a wall with heat capacity exceeding (1) 7 Btu/ft 2 °F or (2) 5 Btu/ft2 °F, provided that the wall has a material unit weight not greater
3
than 120 lb/ft
metal building wall : a wall whose structure consists of metal spanning members supprted by steel structural members (i.e., does not include
spandrel glass or metal panels in curtain wall systems)
steel framed wall : a wall with a cavity (insulated or otherwise) whose exterior surfaces are separated by steel framing members (i.e. typical steel
stud walls & curtain walls system)
wood framed & other walls : all other wall types, including wood stud walls.

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APPENDIX 3

ASSEMBLY U FACTORS & SHGC FOR UNLABELED

VERTICAL FENESTRATION & SKYLIGHTS

(A) FOR VERTICAL FENESTRATION

Frame Glazing Clear Glass Tinted Glass

Type Type U Factor SHGC U Factor SHGC
Btu/hr ft2 °f Btu/hr ft2 °f

All frame types Single glazing 1.25 0.82 1.25 0.70

Wood, vinyl or Double glazing 0.60 0.59 0.60 0.42

fibreglass frames

Metal & other frames Double glazing 0.90 0.68 0.90 0.50

(B) FOR SKYLIGHTS

To determine the default U factor for unlabeled sloped glazing & skylights without a
curb multiply the values in the above APPENDIX 3 by 1.2

To determine the default U factor for unlabeled sloped glazing & skylights on a curb
multiply the values in the above APPENDIX 3 by 1.6

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APPENDIX 4

MINIMUM EQUIPMENT EFFICIENCY REQUIREMENT AS PER ECBC 2007

Sr. no. Equipment Class Minimum Minimum Test

COP IPLV Standard

1 Air Cooled Chillers < 530 kW 2.9 3.16 ARI 550 / 590
(<150 TR) 1998

2 Air Cooled Chillers > = 530 kW 3.05 3.32 ARI 550 / 590
(> = 150 TR) 1998

3 Centrifugal Water Cooled Chiller < 530 kW 5.8 6.09 ARI 550 / 590
(<150 TR) 1998

4 Centrifugal Water Cooled Chiller > = 530 kW & <1050 kW 5.8 6.17 ARI 550 / 590
(> = 150 TR & < 300 TR) 1998

5 Centrifugal Water Cooled Chiller >= 1050 kW 6.3 6.61 ARI 550 / 590
(> = 300 TR) 1998

6 Reciprocating Compressors, Water Cooled Chillers all sizes 4.2 5.05 ARI 550 / 590
1998

7 Rotary Screw & Scroll Compressor, Water Cooled Chillers 4.7 5.49 ARI 550 / 590
< 530 kW (< 150 TR) 1998

8 Rotary Screw & Scroll Water Cooled Chiller > = 530 kW 5.4 6.17 ARI 550 / 590
& <1050 kW ( > = 150 TR & < 300 TR) 1998

9 Rotary Screw & Scroll Water Cooled Chiller >= 1050 kW 5.75 6.43 ARI 550 / 590
(> = 300 TR) 1998

Notes: Heating & Cooling equipment not listed here shall comply with Ashrae 90.1 standard.
Unitary Air conditioner shall meet IS 1391 Part 1
Split conditioner shall meet IS 1391 Part 2
Packaged air conditioner shall meet IS 8148

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APPENDIX 5 A

EQUIPMENT EFFICIENCIES – AIR CONDITIONERS

AND CONDENSING UNITS (ASHRAE 90.1.2007)

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APPENDIX 5 B

EQUIPMENT EFFICIENCIES

WATER CHILLING PACKAGES

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APPENDIX 5 C

EQUIPMENT EFFICIENCIES – PACKAGE UNITS

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APPENDIX 5 D

EQUIPMENT EFFICIENCIES

HEAT REJECTION EQUIPMENTS

Equipment Rating Performance Test

Type Conditions Requireda,b Procedure

Propeller or axial 95°F entering water

fan cooling towers 85°F leaving water = 38.2 gpm / hp CTI ATC-105c &
75°F wb outdoor air CTI STD-201d

Centrifugal fan 95°F entering water CTI ATC-105 &

cooling towers 85°F leaving water = 20 gpm / hp CTI STD-201
75°F wb outdoor air

Air cooled 125°F condensing temp.

condensers R-22 test fluid = 1,76,000 Btu/hr.hp ARI 460
190°F entering gas temp
15°F subcooling
95°F entering db

a
Cooling tower performance is defined as the maximum flow rating of the tower divided by the fan nameplate rated motor power
b
Air cooled condenser performance is defined as the heat rejected from the refrigerant divided by the fan nameplate rated motor power
c
Cooling Technology Institute , Acceptance Test Code for Water Cooling Towers
d
Cooling Technology Institute , Stndard for Certification of Water Cooling Towers Thermal Performance

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APPENDIX 5 E

EQUIPMENT EFFICIENCIES

NON-STANDARD CENTRIFUGAL CHILLERS UPTO 150 TR

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APPENDIX 5 F

EQUIPMENT EFFICIENCIES

NON-STANDARD CENTRIFUGAL CHILLERS FROM 151 TR TO 300 TR

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APPENDIX 8
DUCT INSULATION

Duct Required Insulationa As Per ECBC Required Insulation As Per ASHRAE 90.1
Location Supply Duct Return Duct Supply Duct Return Duct
hr ft2 °f / Btu hr ft2 °f / Btu hr ft2 °f / Btu hr ft2 °f / Btu

Exterior R-7.9 R-3.4 R-6 R-3.5

Ventilated Attic R-7.9 R-3.4 R-7 R-3.5
Unventilated Attic w/o Roof
R-7.9 R-3.4 R-8 R-3.5
Insulation
Unventilated Attic with Roof
R-3.4 No Requirement R-3.5 No Requirement
Insulation
Unconditioned Space R-3.4 No Requirement R-3.5 No Requirement
Indirectly Conditioned Space No Requirement No Requirement No Requirement No Requirement
Buried R-3.4 No Requirement R-3.5 No Requirement

a
Insulation R value is measured on a horizontal plane in acoordance with ASTM C518 at a mean temperature of 75°F at installed thk.

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APPENDIX 9

PIPING INSULATION

Design Required Insulation

Operating Temperature R-Value
hr ft2 °f / Btu

Temp > = 140°F (Heating Systems) R-4

139°F >= Temp > 104°F (Heating Systems) R-2
59°F >= Temp. > 40 (Cooling Systems) R-2

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APPENDIX 10

MINIMUM DUCT SEAL LEVEL

Table 1 - Duct Seal Levels

Seal Sealing Requirements

Level
All transverse joints, longitudinal seams and duct wall
penetrations. Pressure sensitive tape shall not be used
A
as primary sealant, unless it has been certified to comply
with UL-181A or B by an independent testing laboratory
All transverse joints, longitudinal seams. Pressure
sensitive tape shall not be used as primary sealant,
B
unless it has been certified to comply with UL-181A or B
by an independent testing laboratory
C Transverse joints only

a
Table 2 - Minimum Duct Seal Level

Duct Supply Duct Return Exhaust

Location Upto 2" w.c. > 2" w.c. Duct Duct
Static Pressure Static Pressure

Outdoor A A A C
Unconditioned Spaces B A B C
Conditioned Spaces C B C B
a
Refer Table-1 for description of seal level

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Shipping/Receiving - 0.12 B - 1
Transportation waiting 7.5 0.06 100 8 1
Warehouses - 0.06 B - 2
Public Assembly Spaces
Auditorium seating area 5 0.06 150 5 1
Places of religious workshop 5 0.06 120 6 1
Courtrooms 5 0.06 70 6 1
Legislative chambers 5 0.06 50 6 1
Libraries 5 0.12 10 17 1
Lobbies 5 0.06 150 5 1
Museums (Childrens) 7.5 0.12 40 11 1
Museums/gallaries 7.5 0.06 40 9 1
Retail
Sales (except as below) 7.5 0.12 15 16 2
Mall common areas 7.5 0.06 40 9 1
Barber shop 7.5 0.06 25 10 2
Beauty and nail salons 20 0.12 25 25 2
Pet shops (animal areas) 7.5 0.18 10 26 2
Supermarket 7.5 0.06 8 15 1
Coin-operated Laundries 7.5 0.06 20 11 2

Sports and Entertainment

Sports area(play area) - 0.3 - 1
Gym, stadium (play area) - 0.3 30 2
Spectator areas 7.5 0.06 150 8 1
Swimming (pool and deck) - 0.48 C - 2
Disco/dance floors 20 0.06 100 21 1
Health club/aerobics room 20 0.06 40 22 2
Health club/weight rooms 20 0.06 10 26 2
Bowling alley(seating) 10 0.12 40 13 1
Gambling casinos 7.5 0.18 120 9 1
Game arcaes 7.5 0.18 20 17 1
Stages, studios 10 0.06 D 70 11 1
GENERAL NOTES FOR TABLE 6.1
1 Related Requirements: The rate in this table are based on all other applicable requirements of this standard being met.
2 Smoking: This table applies to non-smoking areas. Rates for smoking permitted spaces must be determined using other
methods. See section 6.2.9 of Ashrae 62.1.2007 for ventilation requirement in smoking areas.
3 Air density: Volumetric airflow rates are based on an air density of 1.2 Kg/m3 which corresponds to dry air at a barometric
pressure of 1 atm (101.3 kPa) and an air temperature of 21 deg C. Rates may be adjusted for actual density but such
adjustment is not required for compliance with this standard.
4 Default Occupant Density: The default occupant density shall be used when actual occupant density is not known.
5 Default Combined Outdoor Air Rate (per person): This rate is based on default occupant density.
6 Unlisted Occupancies: If the occupancy category for a proposed space or zone is not listed, the requirement for the listed
occupancy category that is most similar in terms of occupant density, activities and building construction shall be used.
7 Healthcare facilities : Rates shall be determined in accordance with Appendix E.
ITEM-SPECIFIC NOTES
A For high school and college libraries, use values shown for public spaces , library.
B Rates may not be sufficient when stored materials include those having potentially harmful emissions.
C Rates does not allow for humidity control. Additional ventilation or dehumidification may be required to remove moisture
D Rate does not include special exhaust for stage effects, e.g. dry ice vapors, smoke.
E No class of air has been established for this occupancy category.

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APPENDIX 12 B

MINIMUM EXHAUST RATES

Occupancy Category Exhaust Notes Air Class

Air Rate cfm/ft2
Arenas 0.5 B 1
Art Classrooms 0.7 2
Auto repair rooms 1.5 A 2
Barber shops 0.5 2
Beauty & nail Salons 0.6 2
Cells with toilets 1 2
Copy, printing rooms 0.5 2
Darkrooms, Educational Science Labs 1 2
Janitor closets, trash rooms, recycling 1 3
Kitchenettes 0.3 2
Kitchens - Commercial 0.7 2
Locker/dressing rooms 0.25 2
Locker rooms 0.5 2
Paint spray booths -- F 4
Parking garages 0.75 C 2
Pet shops (animal areas) 0.9 2
Refrigerating machinery rooms -- F 3
Residential Kitchens 50 / 100 per unit G 2
Soiled laundry storage rooms 1 F 3
Storage rooms, chemical 1.5 F 4
Toilets - private 25 / 50 per unit E 2
Toilets - public 50 / 70 per unit D 2
Woodwork shop/classroom 0.5 2
Notes : A Stands where engines are run shall have exhaust systems that directly connect to the
engine exhaust & prevent escape of fumes
B When combustion equipment is intended to be used on the playing surface additional dilution
ventilation and/or source control shall be provided
C Exhaust not required if two or more sides comprise walls that are atleast 50% open to the outside
D Rates are per water closet and / or urinal. Provide higher rates where periods of heavy use are
expected, such as toilets in theatres, schools , sports facilities etc
E Rates is for toilet room intended to be occupied by one person at a time. For continuous system
operation during normal hours of use, the lower rate may be used, otherwise use higher rate.
F See other applicable standard for exhaust rate.
G For continuous system operation, the lower rate may be used. Otherwise use higher rate.

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APPENDIX 12 C

ZONE AIR DISTRIBUTION EFFECTIVENESS

Air Distribution Configuration Ez

Ceiling supply of cool air 1

Ceiling supply of warm air & floor return 1
Ceiling supply of warm air 15°F or more 0.8
above space temperature
Floor supply of cool air and ceiling return 1
provided that the 150 fpm supply jet
reaches 4.5 ft or more above floor (Note:
most underfloor air distribution systems)
Floor supply of warm air & ceiling return 0.7
Make up supply drawn in on the opposite 0.8
side of the room from the exhaust and /
or return
Make up supply drawn in near to the 0.5
exhaust and / or return location

Ez = Zone air distribution effectiveness

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APPENDIX 12 D

SYSTEM VENTILATION EFFICIENCY

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APPENDIX 13

AIR INTAKE MINIMUM SEPARATION DISTANCE

Minimum
Object
Distance (ft)

Significantly contaminated exhaust 15

Noxious or dangerous exhaust (Note 1) 30
Vents, chimneys & flues from combustion appliances & equipments 15
Garage entry, automobile loading area, or drive in queue (Note 2) 15
Truck loading area or dock, bus parking / idling area (Note 2) 25
Driveway, street or parking place (Note 2) 5
Thoughroughfare with high traffic volume 25
Roof, landscaped grade,or other surface directly below intake (Note3) 1
Garbage storage / pickup area 15
Cooling tower intake or basin 15
Cooling tower exhaust 25

Note 1 : Laboratory fume hood exhaust air outlets shall be in compliance with NFPA 45 & ANSI std
Note 2 : Distance measured to closest place that vehicle exhaust is likely to be located.
Note 3 : No min. separation distance applies to surfaces that are sloped more than 45 degrees from horizontal or that are less
than 1" wide. Where snow accumulation is expected, distance listed shall be increased by expected avergae snow depth.

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APPENDIX 14

LIGHTING POWER DENSITIES

Table- 1 Building Area Method

Building area type W/ft2

Automotive faciltiy 0.9

Convention Center 1.2
Courthouse 1.2
Dining : bar lounge/leisure 1.3
Dining : family 1.6
Dormitory 1.0
Exercise Center 1.0
Gymnasium 1.1
Health care clinic 1
Hospital 1.2
Hotel 1
Library 1.3
Manufacturing facility 1.3
Motel 1
Motion picture theater 1.2
Multifamily 0.7
Museum 1.1
Office 1
Parking Garage 0.3
Penitentiary 1
Performing arts theater 1.6
Police/Fire station 1.0
Post Office 1.1
Religious Building 1.3
Retail 1.5
School / University 1.2
Sports arena 1.1
Town hall 1.1
Transportation 1
Warehouse 0.8
Workshop 1.4

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Table- 2 Space by Space Method

Common space types W/ft2 Building specific space types W/ft2

Office 1.1 Gym / Exercise center

Conference / Meeting / Multipurpose 1.3 Playing area 1.4
Classroom / Lecture / Training 1.4 Exercise area 0.9
Lobby 1.3 Courthouse/Police Station
For Hotel 1.1 Courtroom 1.9
For Performing Art Theater 3.3 Confinement Cells 0.9
For Motion Picture Theater 1.1 Judges Chambers 1.3
Audience / Seating area 0.9 Fire Stations
For Gymnasium 0.4 Engine room 0.8
For Exercise center 0.3 Sleeping quarters 0.3
For Convention center, Penitentiary 0.7 Post Office - Sorting area 1.2
For Religious building 1.7 Convention center-Exhibit space 1.3
For Sports arena 0.4 Library
For Performing Art Theater 2.6 Card file & cataloging 1.1
For Motion Picture Theater 1.2 Stacks 1.7
For Transportation 0.5 Reading area 1.2
Atrium - First Three floors 0.6 Hospital
Atrium - each additional floor 0.2 Emergency 2.7
Lounge / Recreation 1.2 Recovery 0.8
For Hospital 0.8 Nurses station 1.0
Dining area 0.9 Exam / Treatment 1.5
For Hotel, Penitentiary 1.3 Pharmacy 1.2
For Motel 1.2 Patient room 0.7
For Bar Lounge / Leisure dining 1.4 Operating room 2.2
For Family dining 2.1 Nursery 0.6
Food preperation 1.2 Medical supply 1.4
Laboratory 1.4 Physical Therapy 0.9
Restrooms 0.9 Radiology 0.4
Dressing / locker / fitting room 0.6 Laundry-washing 0.6
Corridor / Transition 0.5 Automotive-Service repair 0.7
For Hospital 1.0 Manufacturing
For Manufacturing facility 0.5 Low bay (<25ft ht) 1.2
Stairs - Active 0.6 High bay (=25ft ht) 1.7
Active storage 0.8 Detailed manufacturing 2.1
For Hospital 0.9 Equipment room 1.2
Inactive storage 0.3 Control room 0.5
For Museum 0.8 Hotel/Motel Guest rooms 1.1
Electrical / Mechanical 1.5 Dormitory-Living quarters 1.1
Workshop 1.9 Museum
Sales area (except accent lighting) 1.7 General exhibition 1.0
Restoration 1.7
Bank office-Banking activity area 1.5
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Religious Buildings
Worship pulpit, choir 2.4
Fellowship hall 0.9
Retail
Sales area (except accent lighting) 1.7
Mall concourse 1.7
Sports arena
Ring sports area 2.7
Court sports area 2.3
Indoor playing field area 1.4
Warehouse
Fine material storage 1.4
Medium/Bulky material storage 0.9
Parking Garage 0.2
Transportation
Airport concourse 0.6
Air/Train/Bus-Baggage area 1.0
Terminal-Ticket counter 1.5

Note : Either of the above methods shall be used for determining lighting power densities.

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APPENDIX 15

VOC LIMITS

Item VOC limit

g/L less water
SPECIALITY APPLICATIONS
PVC Welding 510
CPVC Welding 490
ABS Welding 325
Plastic Cement Welding 250
Adhesive, Primer or Plastic 550
Contact Adhesive 80
Special purpose contact adhesive 250
Structural wood member adhesive 140
Sheet applied rubber lining operations 850
Top & trim Adhesive 250
SEALANTS
Architectural 250
Non-membrane Roof 300
Roadway 250
Single Ply Roof Membrane 450
Other 420
SEALANT PRIMERS
Architectural Non porous 250
Architectural porous 775
Other 750
SUBSTRATE SPECIFIC APPLICATIONS
Metal to Metal 30
Plastic foams 50
Porous Material except wood 50
Wood 30
Fibre glass 80
ARCHITECTURAL APPLICATIONS
Indoor carpet adhesives 50
Carpet pad adhesives 50
Wood flooring adhesives 100
Rubber floor adhesives 60
Sub floor adhesives 50
Ceramic tile adhesives 65
VCT & Asphalt adhesives 50
Drywall & panel adhesives 50
Cove base adhesives 50
Multipurpose construction adhesives 70
Structural glazing adhesives 100

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APPENDIX 16

VENTILATION RATE PROCEDURE (VRP) CALCULATION

Sample calculation for arriving at ventilation rate is given here.

Assumptions made for the calculation are as under

Two restaurants with lift lobby at intermediate floor of multi-storey commercial

complex are considered for this outdoor air flow rate calculation. It is assumed that
this area is served by one common air handler.

CALCULATION TABLE

Conclusion

1.0 Project satisfies minimum requirement of mechanical ventilation system

design using VRP.

2.0 Project will get the additional credit as Voal is selected as out door air quantity
which is 30% more than minimum requirement.

Note

(1) Similar calculations need to be performed for all air handlers in the project.

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TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M1-ME-127-201 BASIC STUDY GUIDE FOR
SHEET i OF iii
COOLING TOWER MAKE-UP SYSTEM

BASIC STUDY GUIDE FOR

COOLING TOWER MAKE-UP SYSTEM

FLOPPY NO. : TCE.00000-ME-FP-139

REV.NO. R0 R1 R2 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY TSR Sd/- SDP Sd/- SDP

CHD.BY TSR Sd/- TSR Sd/- TSR R2

APD.BY KG Sd/- RL Sd/- RL

DATE 92.03.31 98.07.24 01.07.16

TCE FORM NO. 020R2
TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M1-ME-127-201 BASIC STUDY GUIDE FOR
SHEET ii OF iii
COOLING TOWER MAKE-UP SYSTEM

FILE NAME : M1ME201R2.DOC

REV.NO. R0 R1 R2 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY TSR Sd/- SDP Sd/- SDP

CHD.BY TSR Sd/- TSR Sd/- TSR R2

APD.BY KG Sd/- RL Sd/- RL

DATE 92.03.31 98.07.24 01.07.16

TCE FORM NO. 020R2
TCE CONSULTING ENGINEERS LIMITED
SECTION: CONTENTS
TCE.M1-ME-127-201 BASIC STUDY GUIDE FOR
SHEET ii OF iii
COOLING TOWER MAKE-UP SYSTEM

CONTENTS

SL.NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 INTRODUCTION 1

3.0 SYSTEMS 1

4.0 INPUT DATA 2

5.0 DESCRIPTION 2

APPENDIX 1 SCHEMATIC DIAGRAMS FOR 9

COOLING WATER SYSTEMS
APPENDIX 2 FACTOR ‘A’ FOR TOTAL 10
DISSOLVED SOLIDS (TDS)

APPENDIX 3 FACTOR ‘B’ FOR HOT WATER 11

TEMPERATURE

APPENDIX 4 FACTOR ‘C’ FOR CALCIUM HARDNESS 12

(AS CaCO3)

APPENDIX 5 FACTOR ‘D’ FOR TOTAL ALKALINITY 13

(AS CaCO3)

APPENDIX 6 EQUILIBRIUM pH VALUE DETERMINED 14

FROM TOTAL ALKALINITY
(AS CaCO3)

APPENDIX 7 SCALING SEVERITY KEYED TO PSI 15

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REVISION STATUS

REV.NO. DATE DESCRIPTION

R0 92.03.31 --

R1 98.07.24 Generally revised.

R2 01.07.16 Generally revised.

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1.0 SCOPE

This basic study guide outlines various methods adopted for the Cooling Tower
Make-Up System.

2.0 INTRODUCTION

The water chemistry, treatments and operational control methods discussed in this
guide apply specifically to open re-circulating cooling water systems containing
cooling towers. The air-water contact in the cooling towers affects, both directly and
indirectly, the system water chemistry. Air borne dust is scrubbed from air ,
increasing suspended solids concentration of the cooling water, and the water is
continuously inoculated with air borne micro-organisms. Evaporation of water in the
cooling tower causes the dissolved and suspended matter in the make-up water to
be concentrated in the recirculating water. These processes influence the corrosion,
scaling, deposition and micro-biological fouling potential of the system. The
objective of this guide is to give general overview of recirculating cooling water
operations, guidelines for calculating make-up water quantity and chemical
treatment. For format, structure and other guidelines for preparation of basic study
refer TCE.M9-PCS-25.

3.0 SYSTEMS

3.1 The following are the various cooling water systems adopted in chemical, industrial
and power plants etc. : (Refer Appendix 1)

(a) Once-through system

(b) Open or cooling tower re-circulating system

(c) Closed loop system

(d) Recirculation system using spray ponds

3.2 In the case of once-through system, make-up water is not required. Hence this
system is not considered further, in this study. Requirements of items (b) and
(c) are studied hereunder. Requirement of (d) is not covered as same is not used
now-a-days because of space constraints.

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4.0 INPUT DATA

Following data needs to be collected :

(a) Analysis of the water which is to be used as make-up. Refer TCE.M1-ME-

612-202 Basic Study Guide For Water Treatment System. Analysis shall
contain values of Total Dissolved Solids (TDS) in mg/l, total alkalinity in
mg/l as CaCO3, calcium hardness in mg/l as CaCO3. Due to seasonal
variation for ground water, total hardness may be more in summer. Hence
total hardness and alkalinity of summer shall be considered.

(b) Maximum cooling water return temperature,

(c) Materials of construction of process plant equipment using the cooling

water,

(d) Range of cooling in cooling tower

(e) Availability of make-up water and

(f) Cooling water quality if given by process collaborator or equipment supplier

5.0 DESCRIPTION

5.1 COOLING TOWER CIRCULATING SYSTEM (CT SYSTEM)

Cooling water is pumped through a point of heat exchange or heat transfer

equipment, increasing the temperature of the cooling water from recooled water
temperature to hot water temperature. The hot water flows through the recirculating
lines to the cooling tower deck , from which the water falls by gravity through the
tower packing to the tower basin. Heat is rejected to the atmosphere by means of
evaporation as cooling water droplets are broken up in the packing. Air passes
upward by means of mechanical or natural draft. The rejection of heat in the
recirculating water by evaporation (E) restores the cooling water temperature T1 at
which the cooling cycle begins again.
In the operation of cooling tower, water is continuously evaporated and replaced
with fresh make-up water. This results in an increase in the concentration of
dissolved solids in the recirculating water. The ratio of the total dissolved solids in
the recirculating water to the total dissolved solids in the make-up water
(TDSR/TDSM) is called “Cycles of Concentration” (COC). Increase in COC
results in formation of scale. To prevent the formation of scale, a portion of the
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concentrated recirculating water is blown down or bled from the system and
replaced with make-up water. In addition to blowdown some water droplets
containing concentrated dissolved solids are carried through the evaporation
equipment in the cooling tower and lost to the atmosphere. This windage or drift
loss(D) may vary from one cooling tower to another.

Thus, the following contribute to the loss of water from the cooling water system of
cooling tower :
(a) Evaporation,

(b) Drift (physical carry-over of the water particles),

(c) Blowdown adopted to control concentration of dissolved solids in the circuit

and

(d) Miscellaneous losses like pump gland leakage etc.

5.2 CLOSED LOOP SYSTEM

Closed loop cooling water system is also called as primary circuit. Cooling of
primary circuit water is through heat exchanger. Elements of loss i.e. evaporation
and drift are not present. Loss due to occasional blowdown and pump gland
leakage etc. is minimal and hence make-up for the system is very low. Since closed
loop system is adopted due to process requirement and also since the make-up
quantity is small, normally Demineralised (DM) water or soft water or municipal
water is used for make-up depending upon process requirements. Also corrosion-
cum-scale inhibitors are dosed to prevent corrosion. Make-up water quantity shall
be generally 1.5% to 5% of total circulating flow.

5.3 QUALITY OF WATER USED FOR CT SYSTEM

Quality of water in cooling water circuit shall be such that it does not have tendency
to form any scale on heat transfer surfaces or elsewhere. Scale forming
characteristics of the circulating water can be predicted by calculating the Puckorius
Scaling Index (PSI). It is also called Predictable Scaling Index. PSI is worked out
for various COC based on :
(a) Total dissolved solids (TDS) X COC - Factor A
(b) Hot water temperature - Factor B

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(c) Calcium hardness X COC - Factor C

(d) Alkalinity X COC - Factor D

Factors A, B, C and D are derived from the appendices 2, 3, 4 and 5 respectively.

If soft water is used, normally calcium hardness of 5 mg/l is to be considered.
Calcium carbonate saturation index (pHs) and PSI are worked out as follows :

(a) pHs = 9.3 + A + B - (C + D)

(b) PSI = 2 pHs – pHeq

pHeq is taken from the Appendix 6.

If the PSI is less than 6.0, the water has scale forming tendency. Characteristics of
water versus PSI can be read from Appendix 7. While designing the system, PSI
shall be around 6.5.

5.4 QUANTITY OF MAKE-UP WATER FOR CT SYSTEM

5.4.1 For Chemical Plants, Industrial Plants and Oil Fired Power Plants

(a) If as per 5.3, the untreated raw water for COC upto 1.3 has scale forming
characteristic, soft water shall be used as make-up to the system. In the
case of both raw water and/or softened water, used as make-up, highest
cycle of concentration is selected, after calculation of PSI with cycles of
concentration 1.5, 2.0, 2.5 etc. on trial basis such that the characteristics of
circulation water remains non-scale forming. COC is generally limited to 3.0
to 3.5 as beyond this make-up quantity changes marginally.

(b) Cycles of concentration is related to blowdown by the following formula

E+B+D
COC = , where
B+D
COC = Cycles of concentration

E = Evaporation - taken as 1% of circulation flow rate for

every 5.56 0C (10 0F) temperature range across
cooling tower - M3/Hr.

B = Blowdown - M3/Hr.

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D = Drift taken as 0.1% of circulation water flow rate -

M3/Hr.

Make-up water to cooling tower system is the sum of E + B + D in M3/Hr. A

margin of 10% is considered for design purposes.

5.4.2 For Coal Fired Power Plant

The blowdown from the system is governed by the end use of the blowdown. For
instance, in case of coal fired power plants, blowdown is utilised for ash handling
system. Hence, depending upon the water requirement for ash handling system, the
blowdown shall be determined and for this blowdown, concentration ratio shall be
calculated and with this concentration ratio the PSI shall be determined to ascertain
need or otherwise of the treatment.

Following two (2) alternatives may be considered.

(a) If, for example, the concentration ratio with the blowdown as above is 1.8
and this results in slight scaling, a lower concentration ratio of upto 1.3 may
be considered and if this concentration ratio does not call for any treatment,
same may be adopted, provided adequate quantity of make-up water is
available to meet the increased blowdown.

(b) If lower concentration ratio as suggested in (a) above cannot be adopted

due to non-availability of water or even the lower concentration results in
scaling, adopt make-up water treatment. Once the type of treatment is
decided, adopt as high a concentration ratio as permissible which leads to
minimum blowdown. Additional water (over this blowdown) required for
the ash handling system shall be supplied from other source.

5.4.3 While selecting the maximum concentration ratio, care shall be taken to ensure that
the silica, chloride and sulphate values of circulating water do not exceed the limits
given in IS 8188.

5.4.4 Normally, cooling tower blowdown is led to effluent treatment plant. Any treatment
and/or dilution to meet the pollution standard criteria at the final disposal point shall
be carried out in effluent treatment plant.

5.5 POINTS OF CONSIDERATION FOR CT SYSTEM

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5.5.1 Based on PSI, if raw water without treatment is used, it is advisable to use filtered
water for make-up especially for chemical plants (considering small quantity of
make-up).

5.5.2 In other process plants and power plants with splash type fill for cooling tower and
where large quantity of make-up is required, raw water without treatment is used as
make-up based on PSI. In process and power plants where film type fill is used for
cooling tower, clarified water shall be used. Side stream filtration may be adopted
for both the above cases. (Appendix 1)

5.5.3 Cooling water system is dynamic system, due to variation in make-up water
analysis, temperatures and possible contamination from process and atmosphere
etc. Hence in order to make sure that the system remains non- scaling and non-
corrosive, scaling and corrosion inhibitors may be required to be dosed. These
inhibitors are of proprietory nature and manufacturer shall be consulted for dosage
etc. Manufacturer invariably carries out actual tests at site to finalise the dosage,
etc.

5.5.4 In case good quality water is available in adequate quantity in or nearby the plant ,
this water can be used directly or after some treatment instead of using raw water.
For example, if clarified water is to be used for process requirement, this can be
used instead of raw water.

5.6 SCALE INHIBITORS

Based on PSI if raw water is to be treated, for controlling scaling, the following
methods are available :
(a) External side stream or full flow treatment of the circulating water,

(b) Chemical treatment

The optimum scale control programme developed for any specific system must
depend upon the make-up water composition and its availablity, operating
parameters in the cooling system , the number of COC to be carried in the
circulating system and sometimes on effluent considerations.

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COOLING TOWER MAKE-UP SYSTEM

(a) External Pre-Treatment of the Make-Up Water

This can be through ion-exchange, de-alklisation or cold lime clarifier

methods. Ion-exchange method removes all the hardness and minimises
scaling. However, the use of very low or zero hardness make-up is
generally not desirable as the treated water tends to be corrosive and may
need corrosion inhibitor. However, for small to medium cooling water
systems, this can be blended with raw water.

Cold lime clarifier involves large reaction vessel and hence high initial cost.
This removes most of bicarbonate hardness, which is the aim of treatment
for cooling tower make-up and reduces turbidity and suspended solids also.
The treated water is high in pH and may need pH control. Hence this
method is normally adopted for very large cooling water systems only.

For medium and large systems, where the water contains very high
bicarbonate hardness, de-alkalisation may be adopted. This is a form of
external acid dosing, and consists of cation exchanger or cation-cum-
softener combination and a decarbonator. A suitable corrosion inhibitor and
pH conditioning equipment is needed.

(b) Chemical Treatment

In this method bicarbonate content of water is converted to sulphate form,

by dosing sulphuric acid. Use of corrosion inhibitor is a must. In this
method number of COC in cooling tower circuit is decided based on
solubility limit of calcium sulphate. It is necessary to incorporate
sophisticated pH control equipment with automation and skilled operational
staff. This method is generally not considered since handling of sulphuric
acid is difficult. Hence it is advisable to adopt this method only for medium
to large systems.

Scale suppressant can be used without softening with due care that very high
concentration of hardness and pH does not occur. In this system poly
phosphates, with or without acid dosing for reduction of alkalinity, or
synthetic organic material like phosphonates may be used.

5.7 CORROSION INHIBITORS

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Corrosion inhibitors are almost universally used to control deterioration of carbon

steel and other alloys in cooling systems. Various corrosion inhibitors
such as polyphosphates, orthophosphates, chromate, zinc, organic phosphorous
compounds, molybdate are generally employed as corrosion inhibitors for cooling
tower system. Mixture of corrosion inhibitors are often synergistic and provide
excellent protection at costs far lower than would be required for individual
components. Selection of a specific corrosion inhibitor must be based on
compatibility of the inhibitor with other chemicals in the system, materials of
construction, operating conditions in the system and formulation considerations in
preparing the complete inhibitor package. Many of these products are protected by
patents.

5.8 MICRO-BIOLOGICAL GROWTH CONTROL

Chlorine is generally used for micro-biological growth control. It is effective for the
control of bacteria, algae and fungi. Chlorine may be purchased as a compressed
gas, solid calcium hypochlorite or sodium hypochlorite soluion.

Refer following design guides for further details :

(a) Design Guide for Water Treatment Plant TCE.M6-ME-612-203
(b) Design Guide for Bulk Chemicals Storage TCE.M6-ME-612-205
and Handling

5.9 OTHER RECENT CONCEPTS

Pollution control regulations and shortage of water has prompted industries to adopt
zero blowdown concept and recycling of water for reuse and near zero drift of
cooling towers.

Recycling is done on case to case basis, by segregation of various waste water

streams including cooling tower blowdown and further treatment such as
clarification, reverse osmosis etc.

Zero blowdown concept is further step to the recycling i.e. not only water is
recovered for reuse but the concentrated stream is totally converted to water for
reuse and solid waste. This results in zero waste water from the plant.

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COOLING WATER MAKE-UP SYSTEM

APPENDIX 1 SCHEMATIC DIAGRAMS FOR

COOLING WATER SYSTEMS

PROCESS
EQUIPMENT
LIKE
CONDENSER
ETC.

COOLING WATER-OUT
TO DRAIN OR
LARGE WATER BODY
ONCE THROUGH SYSTEM

COOLING TOWER (CT)

PROCESS CT SUMP
EQUIPMENT
SIDE
STREAM
FILTER
SYSTEM
OPEN OR COOLING TOWER RE-CIRCULATING SYSTEM

COOLING TOWER

C T SUMP

PROCESS HEAT
EQUIPMENT EXCHANGER

ISSUE
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APPENDIX 2

FACTOR ‘A’ FOR TOTAL DISSOLVED SOLIDS (TDS)

TDS, mg/l VALUE OF ‘A’

50 0.07
75 0.08
100 0.10
150 0.11
200 0.13
300 0.14
400 0.16
600 0.18
800 0.19
1000 0.20
1500 0.21
2000 0.22
2500 0.23
3000 0.24
4000 0.25
5000 0.26

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APPENDIX 3

FACTOR ‘B’ FOR HOT WATER TEMPERATURE

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APPENDIX 4

FACTOR ‘C’ FOR CALCIUM HARDNESS (AS CaCO3)

mg/l VALUE OF FACTOR ‘C’

↓ tens→
→ 0 1 2 3 4 5 6 7 8 9
0 - - - 0.08 0.20 0.30 0.38 0.45 0.51 0.56
10 0.60 0.64 0.68 0.72 0.75 0.78 0.81 0.83 0.86 0.88
20 0.90 0.92 0.94 0.95 0.98 1.01 1.02 1.03 1.05 1.06
30 1.06 1.09 1.11 1.12 1.13 1.15 1.16 1.17 1.18 1.19
40 1.20 1.21 1.23 1.25 1.25 1.25 1.26 1.27 1.28 1.29
50 1.30 1.31 1.32 1.33 1.34 1.34 1.35 1.36 1.37 1.37
60 1.38 1.39 1.39 1.40 1.41 1.42 1.42 1.43 1.43 1.44
70 1.45 1.45 1.46 1.47 1.48 1.48 1.49 1.49 1.49 1.50
80 1.51 1.51 1.52 1.53 1.53 1.53 1.54 1.54 1.55 1.55
90 1.56 1.56 1.57 1.57 1.58 1.58 1.58 1.59 1.59 1.60
100 1.60 1.61 1.61 1.61 1.62 1.62 1.63 1.63 1.64 1.64
110 1.64 1.65 1.65 1.65 1.65 1.66 1.67 1.67 1.67 1.68
120 1.68 1.68 1.69 1.70 1.70 1.70 1.70 1.71 1.71 1.71
130 1.72 1.72 1.72 1.73 1.73 1.73 1.74 1.74 1.74 1.75
140 1.75 1.75 1.75 1.76 1.76 1.77 1.77 1.77 1.77 1.78
150 1.78 1.78 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.80
160 1.81 1.81 1.81 1.81 1.82 1.82 1.82 1.82 1.83 1.83
170 1.83 1.84 1.84 1.84 1.84 1.85 1.85 1.85 1.85 1.85
180 1.86 1.86 1.86 1.86 1.87 1.87 1.87 1.87 1.88 1.88
190 1.88 1.88 1.89 1.89 1.89 1.89 1.89 1.90 1.90 1.90
200 1.90 1.91 1.91 1.91 1.91 1.91 1.92 1.92 1.92 1.92

mg/l VALUE OF FACTOR ‘C’

↓ hundreds→
→ 0 10 20 30 40 50 60 70 80 90
200 1.90 1.92 1.94 .196 1.98 2.00 2.02 2.03 2.05 2.06
300 2.08 2.09 2.11 2.12 2.13 2.15 2.16 2.17 2.18 2.19
400 2.20 2.21 2.23 2.25 2.25 2.26 2.26 2.27 2.29 2.29
500 2.30 2.31 2.32 2.33 2.34 2.34 2.35 2.36 2.37 2.37
600 2.38 2.39 2.39 2.40 2.41 2.42 2.42 2.43 2.43 2.44
700 2.45 2.45 2.45 2.47 2.47 2.48 2.48 2.49 2.49 2.50
800 2.51 2.51 2.52 2.52 2.53 2.53 2.54 2.54 2.55 2.55
900 2.56 2.56 2.56 2.57 2.57 2.58 2.58 2.59 2.59 2.60
ISSUE
Example : For 144 mg/l calcium hardness as CaCO3, C= 1.76. R2
TCE FORM NO. 120 R1
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SECTION: APPENDIX
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SHEET 13 OF 15
COOLING TOWER MAKE-UP SYSTEM

APPENDIX 5

FACTOR ‘D’ FOR TOTAL ALKALINITY (TA) ( AS CaCO3)

mg/l VALUE OF FACTOR ‘D’

↓ tens→
→ 0 1 2 3 4 5 6 7 8 9
0 - 0.00 0.30 0.45 0.60 0.70 0.78 0.85 0.90 0.95
10 1.00 1.04 1.08 1.11 1.15 1.18 1.20 1.23 1.26 1.29
20 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.43 1.45 1.46
30 1.48 1.49 1.51 1.52 1.53 1.54 1.56 1.57 1.58 1.59
40 1.60 1.61 1.62 1.63 1.64 1.65 1.67 1.67 1.68 1.69
50 1.70 1.71 1.72 1.72 1.73 1.74 1.75 1.76 1.76 1.77
60 1.78 1.79 1.80 1.81 1.81 1.82 1.83 1.83 1.83 1.84
70 1.85 1.85 1.86 1.86 1.87 1.88 1.88 1.89 1.89 1.90
80 1.90 1.91 1.91 1.92 1.92 1.93 1.93 1.94 1.94 1.95
90 1.95 1.96 1.96 1.97 1.97 1.98 1.98 1.99 1.99 2.00
100 2.00 2.00 2.01 2.01 2.02 2.02 2.03 2.03 2.03 2.04
110 2.04 2.05 2.05 2.05 2.05 2.06 2.06 2.07 2.07 2.08
120 2.08 2.08 2.09 2.09 2.09 2.10 2.10 2.10 2.11 2.11
130 2.11 2.12 2.12 2.12 2.13 2.13 2.13 2.14 2.14 2.14
140 2.14 2.15 2.15 2.16 2.16 2.16 2.16 2.17 2.17 2.17
150 2.18 2.18 2.18 2.18 2.19 2.19 2.19 2.20 2.20 2.20
160 2.20 2.21 2.21 2.21 2.21 2.22 2.22 2.23 2.23 2.23
170 2.23 2.23 2.23 2.23 2.23 2.24 2.24 2.25 2.25 2.26
180 2.26 2.26 2.26 2.26 2.26 2.27 2.27 2.27 2.27 2.28
190 2.28 2.28 2.28 2.29 2.29 2.29 2.29 2.29 2.30 2.30
200 2.30 2.30 2.30 2.31 2.31 2.31 2.31 2.32 2.32 2.32

mg/l VALUE OF FACTOR ‘D’

↓ hundreds→
→ 0 10 20 30 40 50 60 70 80 90
200 2.32 2.32 2.34 2.36 2.38 2.40 2.42 2.43 2.45 2.45
300 2.48 2.49 2.51 2.52 2.53 2.54 2.56 2.57 2.58 2.59
400 2.60 2.61 2.62 2.63 2.64 2.65 2.66 2.67 2.68 2.69
500 2.70 2.71 2.72 2.72 2.73 2.74 2.75 2.76 2.76 2.77
600 2.78 2.79 2.80 2.81 2.81 2.81 2.82 2.83 2.83 2.84
ISSUE
700 2.85 2.85 2.86 2.86 2.87 2.88 2.88 2.89 2.89 2.90 R2

TCE FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED
SECTION: APPENDIX
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COOLING TOWER MAKE-UP SYSTEM

800 2.90 2.91 2.91 2.92 2.92 2.93 2.93 2.94 2.94 2.95

APPENDIX 6

EQUILIBRIUM pH VALUE (pH eq) DETERMINED FROM

TOTAL ALKALINITY (TA) (AS CaCO3)

alkalinity, VALUE OF pHeq

↓ mg/l
hundreds→ 0 10 20 30 40 50 60 70 80 908
0 - 6.00 6.45 6.70 6.89 7.03 7.14 7.24 7.33 7.40
100 7.47 7.53 7.59 7.64 7.68 7.73 7.77 7.81 7.84 7.88
200 7.91 7.94 7.97 8.00 8.03 8.05 8.08 8.10 8.15 8.15
300 8.17 8.19 8.21 8.23 8.25 8.27 8.29 8.30 8.32 8.34
400 8.35 8.37 8.38 8.40 8.41 8.43 8.44 8.46 8.47 8.48
500 8.49 8.51 8.52 8.53 8.54 8.56 8.57 8.58 8.59 8.60
600 8.61 8.62 8.63 8.64 8.65 8.66 8.67 8.67 8.68 8.70
700 8.71 8.72 8.73 8.74 8.74 8.75 8.76 8.77 8.78 8.79
800 8.79 8.80 8.81 8.82 8.82 8.83 8.84 8.85 8.85 8.86
900 8.87 8.88 8.88 8.89 8.90 8.90 8.91 8.92 8.92 8.93

pH eq = 1.465 log TA + 4.54 where TA denotes total alkalinity.

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APPENDIX 7

SCALING SEVERITY KEYED TO PSI

PSI CONDITION
3.0 EXTREMELY SEVERE
4.0 VERY SEVERE
5.0 SEVERE
5.5 MODERATE
5.8 SLIGHT
6.0 STABLE WATER , NO SCALING , NO
TENDENCY TO DISSOLVE SCALE
6.5 NO SCALING, VERY SLIGHT
TENDENCY TO DISSOLVE SCALE
7.0 NO SCALING, SLIGHT TENDENCY
TO DISSOLVE SCALE
8.0 NO SCALING, MODERATE
TENDENCY TO DISSOLVE SCALE
9.0 NO SCALING, STRONG TENDENCY
TO DISSOLVE SCALE
10.0 NO SCALING, VERY STRONG
TENDENCY TO DISSOLVE SCALE

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AIR-CONDITIONING SYSTEM

BASIC STUDY GUIDE FOR

AIR-CONDITIONING SYSTEM

REV. NO. R2 R3 R4 R5
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY HRK Sd/- HRK Sd/- HRK Sd/- IYM

CHD. BY PRJ Sd/- PRJ Sd/- PRJ Sd/- PRJ

R5
APD. BY RL Sd/- RL Sd/- RL Sd/- RL

DATE 27.09.1999 06.04.2001 15.01.2003 22.08.2003

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M1-ME-811-301 BASIC STUDY GUIDE FOR
SHEET i OF iv
AIR-CONDITIONING SYSTEM

FILE NAME: M1ME301R5.DOC

REV. NO. R2 R3 R4 R5
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY HRK Sd/- HRK Sd/- HRK Sd/- IYM

CHD. BY PRJ Sd/- PRJ Sd/- PRJ Sd/- PRJ

R5
APD. BY RL Sd/- RL Sd/- RL Sd/- RL

DATE 27.09.1999 06.04.2001 15.01.2003 22.08.2003

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M1-ME-811-301 BASIC STUDY GUIDE FOR
SHEET ii OF iv
AIR-CONDITIONING SYSTEM

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 INPUT DATA 1

3.0 SYSTEM DESIGN AND SELECTION 2

4.0 ENTHALPY CONTROL SYSTEM 10

5.0 HEAT RECOVERY SYSTEM 12

6.0 OPERATION AND CONTROL SCHEME 13

7.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS 13

8.0 EQUIPMENT AND ELECTRICAL LOAD LIST 14

9.0 UTILITY AND SPACE REQUIREMENTS 15

10.0 PROCUREMENT STRATEGY 15

APPENDICES

1. OUTSIDE DESIGN CONDITIONS OF IMPORTANT CITIES OF 16

INDIA

2. RECOMMENDED INSIDE DESIGN CONDITIONS- SUMMER 21

AND WINTER

3. HEAT GAIN FROM PEOPLE 22

4. DEFAULT VALUES FOR SOME DESIGN PARAMETERS 24

5. COMPARISON BETWEEN RECIPROCATING, SCREW, 27

CENTRIFUGAL CHILLING UNITS AND VAMs

6. CHILLED WATER/BRINE CLOSED LOOP SINGLE PUMPING 30

SYSTEM-(ALTERNATIVE 1)

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7. CHILLED WATER/BRINE CLOSED LOOP SINGLE PUMPING 31

SYSTEM-(ALTERNATIVE 2)

CONTENTS (CONTD.)

8. CHILLED WATER/BRINE OPEN LOOP SINGLE PUMPING 32

SYSTEM-(ALTERNATIVE 1)

9. CHILLED WATER/BRINE OPEN LOOP SINGLE PUMPING 33

SYSTEM-(ALTERNATIVE 2)

10. CHILLED WATER/BRINE OPEN LOOP DOUBLE PUMPING 34

SYSTEM

11. COMPARISON BETWEEN CLOSED, OPEN LOOP SINGLE AND 35

DOUBLE PUMPING SYSTEMS

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REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 29.12.1980 ----------------

R1 11.05.1994 Contents sheet and sheet number 4 revised.

R2 27.09.1999 Completely revised.

R3 06.04.2001 Para 5.0 added.

R4 15.01.2003 Paras 4.0 and 5.0 added.

R5 22.08.2003 Para 7.0 revised.

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AIR-CONDITIONING SYSTEM

1.0 SCOPE

This document gives guidelines for carrying out a basic study for air-conditioning system for
chemical, industrial, power plants and high-rise buildings. For format, structure and other
guidelines refer TCE.M9-PCS-25. The basic study shall form the basis for procurement
and detailed engineering of the air- conditioning system.

2.0 INPUT DATA

Following input data shall be collected from various sources like client, process
collaborator, other groups in the mechanical department, other departments, bidders and
vendors.

2.1 Location of the site

2.2 Latitude and altitude of the site

2.3 Names of areas to be air-conditioned

2.4 Equipment layout drawings of the areas to be air-conditioned

2.5 Architectural drawings and civil Reinforced Cement Concrete (RCC) or structural
steel drawings of the areas to be air-conditioned
2.6 Outside design conditions like Dry Bulb Temperature (DBT), Wet Bulb
Temperature (WBT) and Relative Humidity (RH) for summer, monsoon and winter and
daily temperature range

2.7 Inside design conditions for each of the areas to be air-conditioned

(a) DBT range
(b) RH range
(c) Lighting loads
(d) Sensible and latent equipment heat loads, of heat sources within and adjacent to
the air-conditioned areas with specific periodic loading patterns, if any
(e) Occupancy
(f) Fresh air and exhaust air requirements, if any
(g) Filtration and cleanliness requirements, if any
(h) Pressurisation requirements, if any
(i) Air flow pattern requirements, if any
(j) Acceptable noise and vibration levels
(k) Hazardous area classification
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2.8 Duration of air-conditioning for each of the areas to be air-conditioned

2.9 Availability of cooling water, make-up water, quality of water, inlet and outlet
pressures and temperatures

2.10 Electrical power supply voltage levels

2.11 Specific requirements like future expansion plans and provisions required to be
incorporated at present

Some of the input data indicated above may not be readily available at the time of the
preparation of the basic study. Appendices 1 to 4 of this document give guidelines for
assuming such data. These appendices are based on published literature and experience
gained over the years.

3.0 SYSTEM DESIGN AND SELECTION

3.1 Based on the input data collected or assumed as per guidelines given in appendices 1 to 4,
the cooling loads, the dehumidified air flow rate, Apparatus Dew Point (ADP) and heating
loads, if any, shall be calculated as per TCE.M6-ME-811-301 “Design Guide for Air-
Conditioning Cooling Load Calculations” for each of the areas to be air-conditioned.
3.2 Cooling load, dehumidified air flow rate, ADP and heating loads, if any, for each of the
area shall be tabulated. Table shall be made in such a way that areas which have similar
inside design conditions of DBT and RH and which are location-wise close to each other
are clubbed together. A typical format is given below:

SL. NAME INSIDE COOLING DEHUMI- ADP HEATING DURATION

NO. OF DESIGN LOAD DIFIED LOAD OF
REMARKS

AREA CONDITIONS AIR OPERATION

FLOW
RATE

DBT RH FROM TO
TR M 3/HR O
C KW
O
C % Hrs Hrs

3.3 The above table will enable grouping of the air-conditioned areas, selection of air-
conditioning system e.g. selecting the number of units for the total system, combining the
units for areas which are located in the proximity of each other and which are to be
maintained at similar inside design conditions etc. The table will also help in determining
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requirements and distribution of utilities like cooling water, chilled water, chilled brine,
instrument air and power etc.

3.4 AIR DISTRIBUTION DIAGRAMS

3.4.1 An air distribution diagram in the form of a single line diagram shall be prepared for supply
and return air circuits for each of the air-conditioned areas, which are grouped together.
This diagram is an internal document and not part of the basic study which is circulated to
other departments for review or submitted to client for review and approval. This air
distribution diagram shall include all the elements like Air Handling Units (AHUs), supply
air ducting with air outlets, return air ducting with return air inlets, supply or return air
plenums, volume control dampers in supply and return air ducting for unit isolation and air
flow adjustment. Elements like filters, cooling coils, heating coils, supply and return air fans
located within the AHU shall also be indicated in the air distribution diagram.
3.4.2 Typically, an air-conditioning air circuit is a closed loop system with air being routed from
the AHU to the air-conditioned area by supply air ducting and then routed back to the
AHU inlet by return air ducting. Supply air and return air ducting is generally routed to and
from the air-conditioned areas, above a false ceiling provided for aesthetic reasons. When
a false ceiling is provided, return air may be routed back to the AHU between the ceiling
or roof and false ceiling. In such cases the return air ducting may be eliminated.
The air-conditioned area is generally maintained at an over-pressure, i.e. a pressure slightly
above the ambient. As a result of this over-pressure, air will leak out of the air-conditioned
area through cracks and gaps between door and window frames and minimise outdoor or
un-conditioned air ingress into the area. Fresh air is taken into the system in the return air
path at the AHU inlet and this completes the circuit.
The most optimum design of an air-conditioning system attempts to minimise the loss of the
conditioned air from the room.
3.4.3 The air distribution diagram shall also indicate local exhaust or return air collection points.
Local air collections points may be provided for the following typical cases:

(a) Local Exhausts from Equipment

Such air collection points are provided to minimise the exhaust air so as to minimise
the loss of conditioned air from the room and consequently the cooling load.

(b) Local Return from Equipment

For equipment having high or concentrated heat dissipation loads, local return air
collection points are provided. These local return air collection points allow a higher
return air temperature than the room temperature. While this does not reduce the
total heat dissipation from the equipment, the heat dissipation to the room from the
equipment will reduce. Consequently the supply air flow rate required to be
supplied to the room will be lower.

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The measures described above will reduce equipment size and therefore the cost of the
system.

3.4.4 Based on the air distribution diagram, an air pressure diagram shall be prepared indicating
the air pressure at the inlet and outlet of each of the element in the air circuit as given
below.
(a) Start from the air-conditioned area for which the room over-pressure is defined as
per the input data collected or as per appendix 4.
(b) Proceed upstream along the air circuit towards the AHU. The pressure shall
increase progressively as the pressure drops in the individual elements in the air
path. Indicate the air pressure at the inlet and outlet of each of the elements in the air
path. The procedure shall be continued until the air circuit is completed. The
pressure drops to be considered in each of the elements are listed below. These
pressure drops are preliminary and shall be reconfirmed during further engineering,
with firm data from bidders and vendors. The pressure drop across the plenum
being negligible, may be ignored for the purpose of preliminary estimation.
(i) Volume control dampers : 3 mm WG
(ii) Filters in clogged condition

Pre-filters* : 12 mm WG
Fine filters* : 18 mm WG
HEPA filters* : 75 mm WG
(iii) Cooling coils* : 20 mm WG
(iv) Heating coils* : 10 mm WG
(v) Supply and return air ducting : 0.084 mm WG
per metre of duct length
(vi) Supply air outlets : 3 mm WG
(vii) Return air inlets : 2 mm WG
(viii) Pressure in area to be air-conditioned : 1 mm WG
(ix) Pressure in AHU room or at AHU inlet : (-) 3 mm WG
The differential pressure across the AHU inlet and outlet is the External Static Pressure
(ESP) for the AHU.
* Filters, cooling coils and heating coils are normally located within the AHU. Hence
pressure drops in these elements shall be considered for estimation of fan total static
pressure and motor rating. Pressure drops across these elements shall not be considered
for estimation of ESP for the AHU.
3.5 The guidelines for selection of suitable air-conditioning system for a particular
requirement or duty are given in the following paragraphs:
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3.5.1 Window Air-Conditioners

Window air-conditioning units are available in capacities of 0.75, 1.0, 1.5, 2.0 and 2.5TR.
Window units are generally preferred for comfort air-conditioning applications where
control on temperature within (±) 2 0C is acceptable and no RH and dust control are
required. The units require access to an external wall for the air-cooled condenser cooling
and therefore for proper air distribution to be achieved, the units have to be located such
that a uniform distribution of air can be achieved in the room. Multiple units may be used
for larger rooms. These units are designed to provide a throw of about 8 metres when
mounted at an elevation of about 3 metres, which normally is the bottom of beam elevation
for buildings. Considering this limitation window units may be recommended for installation
where the room widths are restricted to 8 metres with one external wall or with about 16
metres with units mounted on external walls on opposite sides.
3.5.2 Split Air-Conditioners

Split air-conditioning units are available in capacities of 1.0, 1.5, 2.0, 2.5, 3.0, 4.0, 5.0,
7.5 and 8.5 TR. These units are air-cooled and are available as ductable or non-ductable
units. These units may be recommended for installation where the temperature control
between (±) 2 0C is acceptable. The ductable units generally have dehumidified air blower
with ESP of 15 to 20 mmWG and their use for applications requiring fine filter installation,
which require higher ESP of about 35 to 40 mm WG, is not recommended. The non-
ductable units are available as decorative floor mounted or decorative or non-decorative
ceiling suspended or wall mounted units. These have in-built pre-filters and cannot be used
for applications requiring fine filters. Sufficient care shall be taken in selecting these units
and their installation to limit the refrigerant piping lengths to about 15 metres and ensuring
proper drainage of cooling coil condensate from the air-conditioned areas. To prevent
condensation on it’s surface, the condensate drain pipe shall be thermally insulated.

3.5.3 Packaged Air-Conditioners

Packaged air-conditioning units are available in nominal capacities of 5.0, 7.5, 10 and 15
TR. Nominal capacity is the Net Total Cooling Effect of a unit at temperature conditions
defined in IS 8148. These are ductable units and are available as water-cooled or air-
cooled units. Water-cooled units may be selected in case cooling water is available.
Alternatively, if cooling water is not available but make-up water is available, a dedicated
cooling water system comprising of cooling tower, cooling water pumps and inter-
connecting cooling water piping, may be selected. In case water is not available, air-cooled
units shall be selected. Refer relevant guides for the selection of the cooling tower and
cooling water pumps for the system.

These units may be used for applications having inside design conditions of temperature
between 220C and 280C with a tolerance of (±) 20C and RH control between 50% to

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70% with tolerance of (±) 5%. These units are not suitable for temperature below 220C
and RH below 50%.

Indigenous units available are generally for a dehumidified air blower ESP of about 25
mmWG. If specifically asked for, an ESP of 35 to 40 mmWG may also be available.
Considering this limitation, these units may be considered for applications requiring fine
filter installation, where duct lengths are restricted to match the available unit ESP. Special
imported precision type units are available with higher dehumidified air flow per TR than
those for standard applications. These units are intended for high sensible load applications,
e.g. computer and control rooms requiring stringent temperature and RH control. These
units are either in top or bottom discharge configuration. Special units are available for
capacities up to 25 TR and are equipped with in-built electric heaters and steam
humidifiers. Soft water is to be made available to the units for the steam humidifier.

The units are of standard construction, factory assembled and tested, mass-manufactured
and have shorter delivery periods, making them suitable for projects having short
schedules. The unit installation is relatively simple as skilled personnel are not required.
Packaged units are also available with in-built micro-processor based control panels which
display and monitor parameters such as current drawn, power consumption, temperature,
RH etc.

Multiple packaged units installation may be considered for cooling requirements up to 100
TR. Higher cooling capacity requirements may result in large number of units and
consequent higher installation and operating costs.
3.5.4 Central Direct Expansion (DX) Plant
DX plants comprise of a skid mounted compressor with drive motor, condenser
interconnected by refrigerant piping with an Air Handling Unit (AHU) located near the area
to be air-conditioned. The primary refrigerant expanding in the cooling coil, cools the air
which is supplied to the area to be air-conditioned, hence the name Direct Expansion
(DX).
These systems may be either water-cooled or air-cooled and may be used wherever the
cooling capacity requirements are beyond the range of packaged units with respect to
DBT, RH and ESP. The capacity of the condensing units ranges between 7 and 100 TR
for indigenously available equipment having single refrigerant circuit. The units may be
installed for low temperature applications like cold storage etc., with room temperatures of
about (-) 250C. High ESP is generally not a limitation with these units as these units are
specially assembled for a specific application.

Multiple unit installations though technically possible may be avoided due to maintenance
and operation difficulties. The units along with the AHUs are generally assembled at site.
Special care has to be taken during design and installation of the refrigerant circuit so as to
ensure proper distribution to each of the units (AHUs or DX units) installed in parallel.
Unless proper suction and oil pressure equalisation is ensured, oil and refrigerant suction

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gas flooding or starving of the individual DX unit compressors of oil and refrigerant suction
gas may lead to major damage to the compressors.

3.5.5 Central Chilled Water or Brine Systems

The plant comprises of the water or brine chilling unit (hereafter referred as chillers), chilled
water or brine pumps, and chilled water or brine piping inter-connecting the chilled water
or brine AHUs. The AHUs may be located adjacent or near the area to be air-conditioned
while the chillers may be installed in the plant room located conveniently in the utility area
for ease of maintenance and operation. Two categories of chillers are commercially
available as described below:

(a) Vapour Compression Chillers

These systems comprise of compressor, condenser, evaporator and inter-connecting

refrigerant piping. The chillers with evaporator having water or brine on the shell side
is called a DX chiller, whereas those with water or brine on the tube side is called a
flooded chiller. These chillers use primary refrigerants like R22, R134a, R123 or
R717 (ammonia), to chill a relatively cheaper and dispensable secondary refrigerant
like water which is circulated to the cooling coils in the AHUs to cool the air supplied
to the air-conditioned area. Refrigerants R11 and R12 which were commonly used
and are still in operation, are Chloro-Fluoro-Carbons (CFCs) and their use is being
restricted as per Montreal Protocol.

These chillers are available in capacities of 5 TR and higher. However, it is preferred

to recommend these units for cooling loads of 100 TR and higher or where the loads
are distributed over a number of areas requiring individual air- conditioning units.

Vapour compression chillers are available with the following types of compressors:

(i) Reciprocating compressors

(ii) Screw compressors
(iii) Centrifugal compressors

Reciprocating compressors for a capacity range of 5 to 150 TR, screw compressors

from 100 to 500 TR and centrifugal compressors from about 100 to 2,500 TR are
indigenously available. These chillers are available in water-cooled or air-cooled
construction.

Centrifugal chillers are not recommended for installation where load fluctuations
cause low loads below 40% for extended periods. These chillers reach the surge
limit at about 40% of the rated capacity unless a hot gas bypass arrangement is
provided. This arrangement provides an artificial load on the chillers, limiting the
lowering of load on the chiller to about 40%. This method is not energy efficient and
may be avoided as far as possible.
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The units are available in open type or in hermetic construction i.e. a hermetic motor
drives the compressor. In case the temperature to be maintained in the air-
conditioned areas requires a secondary refrigerant at a temperature lower than 50C a
pure liquid having a low freezing point or solution of water and brine is used as a
secondary refrigerant.

Screw chillers with lower specific power consumption at part loads as compared to
reciprocating or centrifugal chillers are available. However, these chillers may be
more expensive and the economics have to be studied before recommending for
installation.

(b) Vapour Absorption Chillers

Vapour absorption chillers or Vapour Absorption Machines (VAM) as they are

commonly known, are available between a capacity of 100 to 2,500 TR. VAM may
be steam, hot water or direct-fired machines operating on fuel oil or fuel gas. Steam
fired VAMs are available in double effect, requiring saturated steam at pressures of 3
to 8 Kg/cm2 (g), or in single effect construction requiring steam pressures in the range
of 0.5 to 3 Kg/cm2 (g). Direct oil fired chillers are available for capacities ranging
between 30 to 500 TR.

(c) A comparison of the various types of compressors available in these categories is

given in appendix 5.

(d) Types of Brines

Various types of brines normally used are given in the following table.

SL. NAME OF BRINE MAXIMUM LOWEST OPERATING REMARKS

NO. CONCENTRATION TEMPERATURE

0
% BY WEIGHT C

1. Sodium chloride 23.00 (-) 25.0

2. Calcium chloride 29.87 (-) 50.0

3. Aqueous ethylene glycol 60.00 (-) 43.0

4. Aqueous propylene glycol 60.00 (-) 45.0

5. Methylene chloride Used as pure liquid (-) 96.7

6. Trichloroethylene Used as pure liquid (-) 86.1

7. Polydimethylsiloxane Used as pure liquid (-) 73.3

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8. d-limonene Used as pure liquid (-) 96.7

The operating temperatures for sodium chloride brine, calcium chloride brine,
aqueous ethylene glycol and aqueous propylene glycol are 50C higher than their
freezing points. For concentrations exceeding 60% aqueous propylene glycol does
not have a freezing point but forms a glass (being an amorphous, under-cooled liquid
of extremely high viscosity having all the appearances of a solid). For further details
of the brines refer ASHRAE Handbook, Fundamentals may be referred.

The selection of brine shall be optimised wherever possible considering the process
requirements and the installation and operating costs. It is recommended that nitrogen
blanketing is provided for methylene chloride and trichloroethylene. Any other
specific requirements shall be examined and clearly indicated in the basic study.

(e) Various configurations of chilled water or brine systems are indicated in appendices
6 to 10. The relative merits of these configurations are given in appendix 11. The
configuration of the system shall indicate the number of pumps, their flow and head,
tanks and piping. The selection of the configuration shall be based on the relative
merits for the particular application.

3.6 Based on guidelines given in para 3.5 above, select a suitable system for the various areas.
The number of units may be selected considering the continuous minimum cooling load
available and also the economy of providing a standby unit. If more than one system could
be considered, carry out a brief economic analysis. Some of the features which may be
examined in the economic study to minimise installation and operating costs are as follows:
(a) Minimisation of the air-conditioning and refrigeration cooling load by use of better
insulation materials or building materials of construction, energy efficient lighting
systems etc.
(b) Optimum sizing of the equipment considering the maximum continuous total load on
the system rather than the total of peak individual loads which may not be
simultaneous. The optimum sizing of equipment may also be effected by use of
chemical dehumidifiers (for low RH applications so as to reduce the latent cooling
loads on the cooling coils), thermal storage systems like ice banks or chilled water or
brine storage tanks, to meet peak loads in a 24-hour cycle, etc. The thermal storage
arrangement is especially effective in case electrical tariffs are different during day
and night.
(c) Optimum selection of equipment considering the utilities available for the total project
configuration, so as to match the project philosophy. e.g. sizing of chillers so as to
restrict the motor rating within limits of 415 Volts power supply. This has to done in
consultation with the project electrical engineer.

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(d) Use of enthalpy control systems, which utilise the low outdoor air conditions
(temperature and enthalpy of air) to meet the refrigeration loads
(e) Use of heat-recovery systems, e.g. heat recovery wheels, variable speed drives to
minimise operating loads
A clear recommendation shall be made highlighting technical and commercial advantages of the
system proposed.

4.0 ENTHALPY CONTROL SYSTEM

4.1 The cooling load of an area to be air-conditioned is decided by the dimensions of the
building, its orientation, materials of construction and the internal heat loads etc. This
cooling load is imposed on the refrigeration system. The enthalpy control system utilises the
ambient air condition variation to minimise the cooling load of the area to be air-
conditioned. This system has been used very successfully for applications where the
internal loads are relatively high and the Effective Sensible Heat Factor (ESHF) is higher
than 0.9. The system operates in three (3) modes as described below:

(a) Mode 1

In this mode, the system draws fresh air at its design minimum requirement. This
could be the fresh air requirement for the maintenance of building pressurisation or
air quality in the area or by process requirements. The system operates in this
mode when the enthalpy of the outdoor air is at its maximum and is higher than the
room leaving air enthalpy. The load on the refrigeration system is at its maximum
during this mode.

(b) Mode 2

In this mode the system draws 100% fresh air. This mode operates when the
outdoor air enthalpy lies between the enthalpy of the air between the supply air
enthalpy and the room air enthalpy. The load on the refrigeration system varies
from close to the peak load to zero.

In this mode, the system draws fresh air in a proportion varying from 100%
downwards to a value depending upon the ambient air enthalpy. This mode of
operation is primarily in the winter conditions when outdoor air enthalpy is lower
than the supply air enthalpy.

4.2 The proportion of the fresh air drawn is modulated, using automatic dampers, so as to have
a mixed air enthalpy equal to the supply air enthalpy. In Indian conditions it has been found
that the lowest fresh air intake in Mode 3 is still well above the minimum design fresh air
intake. In cases where the ambient air winter conditions are low and fresh air proportion to

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obtain mixed air enthalpy equal to supply air enthalpy, is lower than the minimum fresh air
requirement, the minimum fresh air may be drawn, re-heated and then passed through an air
washer to arrive at the supply air conditions. The operation of this system necessitates the
use of an air washer.

4.3 For the operation of the enthalpy control system, the supply air, return air and outdoor air
enthalpies are measured. Based on these measurements the controller calculates and
compares the air enthalpies and controls the position of fresh air, exhaust air and re-
circulation air automatic dampers to operate the system in each of the modes described
above.

4.4 The enthalpy control system has been used extensively for the air-conditioning systems for
synthetic fibre plants and can be used effectively for air conditioning systems for other
applications also, provided the economic study for the application permits the same.

4.5 Schematic diagram given below illustrates the process.

ZONE 1

ZONE 2 OUTDOOR
SUMMER/
MONSOON
SUMMER/ CONDITIONS
MONSOON
LOAD ON
COOLING AIR MIXTURE
COIL CONDITIONS
HUMIDITY RATIO

CONSTANT
ENTHALPY
LINE

ZONE 3

SUPPLY AIR
CONDITIONS

AIR MIXTURE
CONDITIONS ROOM
CONDITIONS

OUTDOOR
WINTER
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5.0 HEAT RECOVERY SYSTEM

5.1 Another possible avenue for reduction of energy consumption is the effective use of heat
internal to the system. Heat recovery systems are being used for various applications in
HVAC systems, e.g. full fresh air systems and synthetic fibre plants etc. A typical case
study for such systems is discussed below:

5.2 For synthetic fibre plants the typical supply air conditions to the quench chamber and take-
up are typically as follows:

Quench air : 18°C DB±1°C , 14°C Dew point

Take-up : 20°C DB ± 1°C, 14°C Dew point

The air supply for both quench and take-up require to be provided with reheat. The return
air from quench (which is collected in the spinning area) and take-up are generally
combined together to form a common return air. Typically, the return air temperature is
about 33 to 34°C DB due to the high equipment load dissipation from the spinning
machinery.

The heat recovery system, installed in the plants, collects the sensible heat in the return air
and supplies it to the quench and take-up supply air, reducing the return air temperature to
about 28 to 29°C. This is achieved by circulating a heat recovery medium, e.g. water at a
supply temperature of 260C to quench and take-up supply air reheat coil. The water cools
to a temperature of about 230C and is circulated to a heat recovery coil in the return air
path. The return air is cooled to about 290C and the water heated to 26°C. This water is
now re-circulated back to the quench and take-up heating coils completing the circuit. This
system has been used effectively for synthetic fibre plants. Schematic diagram given below
illustrates the process.

RETUR EXHAUST DAMPER

5.3 N AIR 29°C
34°C
SPINNING RETURN AIR
26°C RE-
AREA 23°C CIRCULATION
RE-CIRCULATION
PUMP

SUPPLY
18°C
FILTER DAMPE
QUENCH 14°C
AREA

20°C FILTER
TAKE-UP
AREA CHILLED
HEAT WATER AIR-
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The use of heat recovery system for full fresh air air-conditioning applications has been
advocated and installed with satisfactory results.

6.0 OPERATION AND CONTROL SCHEME

Brief description of operation and control scheme of the proposed system shall be included
in the basic study. Project instrument engineer may be consulted, if necessary.

7.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS

As per National Building Code (NBC), a building having height more than 15 metres
above the surrounding ground level is called a High Rise Building. Following
requirements need to be incorporated while designing air-conditioning system for such a
building. While these requirements are mandatory for High Rise buildings, it is advisable
to follow these for any building.

7.1 Air-conditioning equipment except for window and split air-conditioners shall be
interlocked with fire detection and alarm system such that in case of fire, air-conditioning
equipment shall stop automatically.

7.2 For distribution of air, metallic ducts shall be provided.

7.3 Preferably, metallic ducts shall be provided for return air also, instead of using the space
above the false ceiling.

7.4 Non-combustible and fire retardant materials shall be used for the false ceiling and all
fixtures, if space above the false ceiling is used for return air.

7.5 Non-combustible and fire retardant materials shall be used for the acoustic and thermal
insulation of ducts and plenums.

7.6 Return air from areas like staircases and lift lobbies etc. shall not be taken to Air
Handling Units (AHUs) or AHU rooms.

7.7 If the air-conditioning duct passes through fire walls or floors, the open space around the
duct shall be sealed with fire resistant materials like asbestos rope or vermiculite
concrete etc.

7.8 Air-conditioning duct serving the main floor areas shall not be routed through the
staircase enclosure.

7.9 Preferably, separate AHUs and ducts shall be provided for each floor. Ducts for two
different floors shall not be interconnected.

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7.10 In case one AHU serves more than one floor, automatic fire dampers shall be provided
in both supply and return air ducts for isolation of ducts at every floor from the main riser
or downcomer.

7.11 Automatic fire dampers shall be provided in both supply and return air ducts at fire
separation walls

7.12 AHU fan shall be interlocked with automatic fire alarm system so that in case of fire, the
respective AHU fan is switched off automatically unless AHU is designed to exhaust the
smoke from the fire. In such a case, the AHU shall remain in operation in exhaust mode.

7.13 Non-combustible and fire retardant filter media shall be provided for air filters use in the
AHUs.

7.14 AHU room shall not be used for storage of any combustible material.

7.15 At appropriate locations, access doors shall be provided in the ducting to facilitate
maintenance of fire dampers.

7.16 If AHU room is located in the core of the building, the vertical shaft for the fresh air shall
be in masonry construction.

7.17 Each AHU shall serve maximum floor area of 750 square metres.

8.0 EQUIPMENT AND ELECTRICAL LOAD LIST

An appendix covering all equipment like window units, split units, packaged units, chillers,
AHUs, pumps, fans, blowers, tanks and vessels etc. with equipment tag numbers,
name/title/designation, major parameters, materials of construction and estimated ratings of
motor and other electric equipment shall be furnished in tabular form. Motor ratings may be
calculated as per the relevant design guides.

The motor rating would reflect the selected capacity of the equipment. While finalising per
unit capacity of equipment, available supply voltage is to be given due consideration. For
instance, while sizing the capacity for a water chilling unit of total requirement of 400TR,
considerations of heat load and recommended minimum reserve capacity may permit two
(2) alternatives namely:

(a) 2 X 400 TR capacity - Calling for 325 KW motor rating with 15%
centrifugal chillers margin on BKW @ 0.7KW/TR
including 1 standby

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(b) 4 X 135 TR capacity - Calling for 150 KW motor rating with 15%
reciprocating chillers margin on BKW @ 0.9KW/TR
including 1 standby

If power supply is available only at 415V, alternative (b) would be the preferred choice, as
motor rating is within the permitted 165KW limit for 415V supply voltage. The above shall
be decided in consultation with the project electrical engineer.

9.0 UTILITY AND SPACE REQUIREMENTS

Requirement of utilities like steam, cooling water, make-up water and instrument air with
the design parameters like flow rates, pressure, temperature and quality required at the
battery limit of the system shall be indicated in tabular form.
The space requirements and clear height for air-conditioning equipment plant rooms, and
for routing of ducting and piping etc. shall be indicated. Requirements of hoists, cranes and
monorails shall also be included. Preferably, a sketch giving the plant room layout shall be
included.
Bare bus-bars, conductors and electrical equipment shall not be located in areas where
there is a possibility of condensation of moisture and consequent malfunction.

10.0 PROCUREMENT STRATEGY

Proposed procurement strategy with number of enquiries and the scope for each shall be
clearly indicated.

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APPENDIX 1
OUTSIDE DESIGN CONDITIONS OF IMPORTANT CITIES OF INDIA
(SOURCE: DB, WB And LAT. from Voltas Air-Conditioning and Refrigeration Engineer’s Handbook-I, 1995 Edition. RH (%)
read from ASHRAE Psychrometric Chart No. 1. Daily Range and Altitude from ISHRAE HVAC Handbook 1997.
Part I
SUMMER MONSOON WINTER LAT(0N)
DAILY ALT.
CITY RANGE DB WB RH% DB WB RH% DB WB RH% FROM
MSL (M)
0
Agra F 26 108 75 22 96 83 58 48 43 67 27.10
0
C 14.44 42.2 23.9 35.6 28.3 8.9 6.1
May Jul Jan 169
0
Ahmedabad F 26 110 78 24 90 85 82 60 51 54 23.02
0
C 14.44 43.3 25.6 32.2 29.4 15.6 10.6
May Jul Dec 55
0
Ahmednagar F 29 108 75 22 101 88 60 50 43 55 19.05
0
C 16.11 42.2 23.9 38.3 31.1 10 6.1
May Jun Jan 657
0
Ajmer F 22 108 74 20 93 81 60 45 39 59 26.27
0
C 12.22 42.2 23.3 33.9 27.2 7.2 3.9
May Aug Jan 486
0
Aligarh F 26 108 75 22 96 83 58 48 43 67 27.53
0
C 14.44 42.2 23.9 35.6 28.3 8.9 6.1
May Jul Jan 169
0
Allahabad F 26 110 76 21 96 83 58 48 46 87 25.27
0
C 14.44 43.3 24.4 35.6 28.3 8.9 7.8
May Jul Jan 98
0
Ambala F 29 110 75 20 95 80 52 45 41 70 30.23
0
C 16.11 43.3 23.9 35.0 26.7 7.2 5.0
Jun Jul Jan 272
0
Asansol F 23 108 78 26 90 86 85 52 44 52 23.41
0
C 12.78 42.2 25.6 32.2 30.0 11.1 6.7
May Jul Jan 126
0
Aurangabad F 27 104 76 29 90 80 65 55 48 60 19.53
0
C 15.00 40.0 24.4 32.2 26.7 12.8 8.9
May Jul Dec 581
0
Bangalore F 22 96 78 45 82 78 82 58 54 78 12.58
0
C 12.22 35.6 25.6 27.8 25.6 14.4 12.2
Apr Sep Jan 921
0
Belgaum F 29 100 77 35 82 77 80 58 53 71 15.51
0
C 16.11 37.8 25.0 27.8 25.0 14.4 11.7
Apr Jul Jan 753
0
Bellary F 23 105 77 28 94 78 50 65 59 70 15.09
0
C 12.78 40.6 25.0 34.4 25.6 18.3 15.0
May Sep Dec 449

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SHEET 17 OF 35
AIR-CONDITIONING SYSTEM
0
Bhopal F 26 106 73 20 92 83 69 45 38 50 23.16
0
C 14.44 41.1 22.8 33.3 28.3 7.2 3.3
May Jul Jan 523

APPENDIX 1 (CONTD.)

SUMMER MONSOON WINTER LAT(0N)

DAILY ALT
CITY RANGE DB WB RH% DB WB RH% DB WB RH% FROM
MSL (M)
0
F 20 100 82 46 90 86 85 56 48 55 20.15
0
Bhubaneshwar C 11.11 37.8 27.8 32.2 30.0 13.3 8.9
May Aug Jan 27
0
F 20 100 83 49 90 86 85 56 48 55 22.32
0
Calcutta C 11.11 37.8 28.3 32.2 30.0 13.3 8.9
May Jul Dec 6
0
F 96 82 55 85 82 88 72 65 69 11.15
0
Calicut C 35.6 27.8 29.4 27.8 22.2 18.3
May Jul Jan
0
F 26 115 75 15 88 80 70 55 49 65 19.58
0
Chanda C 14.44 46.1 23.9 31.1 26.7 12.8 9.4
May Jul Dec 193
0
F 18 103 82 41 83 80 88 65 57 60 13.04
0
Chennai C 10.00 39.4 27.8 28.3 26.7 18.3 13.9
May Nov Jan 16
0
F 10 95 82 58 85 82 88 72 65 69 9.58
0
Cochin C 5.56 35.0 27.8 29.4 27.8 22.2 18.3
Apr Jul Jan 3
0
F 23 98 76 37 82 75 72 65 57 60 11.00
0
Coimbatore C 12.78 36.7 24.4 27.8 23.9 18.3 13.9
May Oct Dec 409
0
F 21 105 82 37 90 86 85 56 48 55 20.29
0
Cuttack C 11.67 40.6 27.8 32.2 30.0 13.3 8.9
May Aug Jan 27
0
F 26 105 75 25 90 80 65 42 38 70 30.19
0
Dehradun C 14.44 40.6 23.9 32.2 26.7 5.6 3.3
Jun Aug Jan 682
0
F 11 90 78 59 82 78 84 52 51 95 27.28
0
Dibrugarh C 6.11 32.2 25.6 27.8 25.6 11.1 10.6
Jun Jul Jan 106
0
F 23 108 78 26 90 86 85 52 44 52 23.14
0
Durgapur C 12.78 42.2 25.6 32.2 30.0 11.1 6.7
May Jul Jan 100
0
F 25 110 74 18 90 84 78 50 44 62 24.49
0
Gaya C 13.89 43.3 23.3 32.2 28.9 10.0 6.7
May Aug Jan 116

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AIR-CONDITIONING SYSTEM

APPENDIX 1 (CONTD.)

SUMMER MONSOON WINTER LAT(0N)

DAILY ALT
CITY RANGE DB WB RH% DB WB RH% DB WB RH% FROM
MSL (M)
0
F 9 90 82 70 84 81 88 65 60 76 15.25
0
Goa C 5.00 32.2 27.8 28.9 27.2 18.3 15.6
Apr Jun Jan 62
0
F 11 90 78 59 88 82 78 52 47 70 26.11
0
Guwahati C 6.11 32.2 25.6 31.1 27.8 11.1 8.3
Apr Jul Jan 55
0
F 14 106 78 28 85 81 82 55 48 60 17.86
0
Hyderabad C 7.78 41.1 25.6 29.4 27.2 12.8 8.9
May Sep Dec 545
0
F 30 106 77 27 90 82 70 50 45 69 22.43
0
Indore C 16.67 41.1 25.0 32.2 27.8 10.0 7.2
May Jul Jan 567
0
F 29 108 75 25 93 84 69 45 41 70 23.16
0
Jabalpur C 16.11 42.2 23.9 33.9 28.9 7.2 5.0
May Jul Dec 393
0
F 27 110 75 20 95 78 48 46 41 65 26.27
0
Jaipur C 15.00 43.3 23.9 35.0 25.6 7.8 5.0
May Aug Jan 390
0
F 20 100 80 43 85 81 84 55 49 65 22.29
0
Jamnagar C 11.11 37.8 26.7 29.4 27.2 12.8 9.4
May Jul Dec 23
0
F 27 110 78 24 90 84 78 50 46 75 22.49
0
Jamshedpur C 15.00 43.3 25.6 32.2 28.9 10.0 7.8
May Aug Dec 129
0
F 26 111 76 20 97 84 58 48 45 80 25.27
0
Jhansi C 14.44 43.9 24.4 36.1 28.9 8.9 7.2
May Jul Jan 251
0
F 29 110 77 23 95 80 52 46 39 52 26.18
0
Jodhpur C 16.11 43.3 25.0 35.0 26.7 7.8 3.9
May Aug Jan 224
0
F 18 103 82 41 83 80 88 65 57 60 16.57
0
Kakinada C 10.00 39.4 27.8 28.3 26.7 18.3 13.9
May Oct Jan 8
0
F 15 100 82 47 86 83 86 65 58 65 18.54
0
Kalyan C 8.33 37.8 27.8 30.0 28.3 18.3 14.4
Apr Jul Jan 10
0
F 29 109 77 23 97 84 58 45 42 75 26.26
0
Kanpur C 16.11 42.8 25.0 36.1 28.9 7.2 5.6
May Jul Jan 126
0
F 31 85 75 63 76 71 79 45 42 78 27.42
0
Kathmandu C 17.22 29.4 23.9 24.4 21.7 7.2 5.6
May Jul Jan 1324
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AIR-CONDITIONING SYSTEM

APPENDIX 1 (CONTD.)

SUMMER MONSOON WINTER LAT(0N)

DAILY ALT
CITY RANGE DB WB RH% DB WB RH% DB WB RH% FROM
MSL (M)
0
F 27 113 75 17 99 80 44 45 41 70 25.11
0
Kota C 15.00 45.0 23.9 37.2 26.7 7.2 5.0
May Jul Jan 257
0
F 23 108 80 30 93 81 60 60 53 62 15.50
0
Kurnool C 12.78 42.2 26.7 33.9 27.2 15.6 11.7
May Sep Dec 281

0
F 30 109 79 26 94 83 64 48 43 67 26.52
0
Lucknow C 16.67 42.8 26.1 34.4 28.3 8.9 6.1
May Aug Jan 111
0
F 20 101 78 36 94 78 49 68 62 72 9.55
0
Madurai C 11.11 38.3 25.6 34.4 25.6 20.0 16.7
May Oct Jan 133
0
F 11 96 82 55 85 82 88 70 64 72 12.52
0
Mangalore C 6.11 35.6 27.8 29.4 27.8 21.1 17.8
May Jul Jan 22
0
F 110 75 20 95 83 60 45 41 70 28.35
0
Meerut C 43.3 23.9 35.0 28.3 7.2 5.0
May Aug Jan
0
F 12 95 83 60 85 82 88 65 58 65 18.54
0
Mumbai C 6.67 35.0 28.3 29.4 27.8 18.3 14.4
Apr Jul Jan 11
0
F 21 100 78 38 85 77 69 66 60 70 12.18
0
Mysore C 11.67 37.8 25.6 29.4 25.0 18.9 15.6
Apr Oct Dec 767
0
F 26 112 76 18 85 81 82 60 52 58 21.09
0
Nagpur C 14.44 44.4 24.4 29.4 27.2 15.6 11.1
May Jul Dec 310
0
F 22 108 83 35 94 82 60 65 57 61 14.27
0
Nellore C 12.22 42.2 28.3 34.4 27.8 18.3 13.9
May Nov Jan 20
0
F 25 110 75 20 95 83 60 45 41 70 28.35
0
New Delhi C 13.89 43.3 23.9 35.0 28.3 7.2 5.0
May Aug Jan 216
0
F 22 73 60 48 66 58 62 38 33 60 11.24
0
Ootacamund C 12.22 22.8 15.6 18.9 14.4 3.3 0.6
May Jul - Oct Dec 2249
0
F 26 108 78 26 90 84 78 50 44 62 25.37
0
Patna C 14.44 42.2 25.6 32.2 28.9 10.0 6.7
May Aug Jan 53

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APPENDIX 1 (CONTD.)

SUMMER MONSOON WINTER LAT(0N)

DAILY ALT
CITY RANGE DB WB RH% DB WB RH% DB WB RH% FROM
MSL (M)
0
F 31 104 76 28 83 79 82 50 42 50 18.32
0
Pune C 17.22 40.0 24.4 28.3 26.1 10.0 5.6
Apr Jul Dec 559
0
F 107 79 29 93 82 62 60 54 69 16.12
0
Raichur C 41.7 26.1 33.9 27.8 15.6 12.2
May Sep Dec
0
F 25 110 77 22 92 83 68 50 45 70 21.14
0
Raipur C 13.89 43.3 25.0 33.3 28.3 10.0 7.2
May Jul Dec 298
0
Ranchi F 27 100 82 46 84 78 76 48 42 60 23.23
0
C 15.00 37.8 27.8 28.9 25.6 8.9 5.6
May Jul Jan 655
0
Rentachintala F 110 83 32 94 82 60 55 49 65 16.33
0
C 43.3 28.3 34.4 27.8 12.8 9.4
May Oct Dec
0
Rourkela F 28 110 78 25 87 82 81 54 44 41 21.28
0
C 15.56 43.3 25.6 30.6 27.8 12.2 6.7
May Jul Dec 148
0
Salem F 18 103 80 38 93 77 49 65 59 70 11.39
0
C 10.00 39.4 26.7 33.9 25.0 18.3 15.0
May Oct Jan 278
0
Sambalpur F 28 110 78 25 87 82 81 54 44 41 21.28
0
C 15.56 43.3 25.6 30.6 27.8 12.2 6.7
May Jul Dec 148
0
Shillong F 14 85 71 50 74 70 82 38 32 50 25.34
0
C 7.78 29.4 21.7 23.3 21.1 3.3 0.0
Apr Jun Jan 1500
0
Sholapur F 27 108 77 25 92 82 65 55 47 55 17.40
0
C 15.00 42.2 25.0 33.3 27.8 12.8 8.3
May Sep Jan 479
0
Thane F 15 100 82 47 86 83 86 65 58 65 18.54
0
C 8.33 37.8 27.8 30.0 28.3 18.3 14.4
Apr Jul Jan 10
0
Thiruchirapalli F 20 104 81 38 95 81 55 70 64 72 10.49
0
C 11.11 40.0 27.2 35.0 27.2 21.1 17.8
May Oct Jan 88
0
Thiruvanan- F 15 92 80 59 85 80 80 72 65 69 8.29
0
thapuram C 8.33 33.3 26.7 29.4 26.7 22.2 18.3
Mar Jun Jan 64
0
Vadodara F 26 110 78 24 88 79 68 50 43 55 22.18
0
C 14.44 43.3 25.6 31.1 26.1 10.0 6.1
May Jul Jan 34
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AIR-CONDITIONING SYSTEM

APPENDIX 1 (CONTD.)

SUMMER MONSOON WINTER LAT(0N)

DAILY ALT
CITY RANGE DB WB RH% DB WB RH% DB WB RH% FROM
MSL (M)
0
Varanasi F 29 109 76 25 94 83 64 50 47 80 25.18
0
C 16.11 42.8 24.4 34.4 28.3 10.0 8.3
May Aug Jan 76
0
Vijaywada F 24 110 83 32 94 82 60 55 49 65 16.33
0
C 13.33 43.3 28.3 34.4 27.8 12.8 9.4
May Oct Dec 106
0
Visakhapatnam F 11 92 82 65 87 82 81 65 57 60 17.42
0
C 6.11 33.3 27.8 30.6 27.8 18.3 13.9
May Oct Jan 3

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APPENDIX 2
RECOMMENDED INSIDE DESIGN CONDITIONS - SUMMER AND WINTER
(SOURCE: TABLE 4 – PART-1 HANDBOOK OF AIR-CONDITIONING SYSTEM DESIGN BY CARRIER AIR-CONDITIONING
TCE.M1-ME-811-301

COMPANY–1965 EDITION)

TYPE OF APPLICATION SUMMER WINTER

WITH WITHOUT
DELUXE COMMERCIAL
HUMIDIFICATION HUMIDIFICATION
PRACTICE
DB 0C RH % DB 0C RH % DB 0C RH % DB 0C

GENERAL COMFORT 50 to 45 25 to 26 50 to 45 23 to 24.5 35 to 30 24 to 25

23 to 24.5 (±1)
Apartment, House, Hotel, Office, (+5) (±1) (+5) (±1) (±5) (±1)
Hospital, School, etc.

RETAIL SHOPS (Short

term occupancy) Bank, 24.5 to 25.5 50 to 45 25.5 to 26.5 50 to 45 35 to 30 23 to 25
22 to 23
Barber or Beauty Shop, Dept. Store, (±1) (+5) (±1) (+5) (±5) (±1)
Supermarket, etc. (±1)
BASIC STUDY GUIDE FOR

LOW SENSIBLE HEAT FACTOR

AIR-CONDITIONING SYSTEM

APPLICATIONS 24.5 to 25.5 55 to 50 25.5 to 26.5 60 to 50 40 to 35 23.5 to 24.5

22 to 23
(High Latent Load) Auditorium, (±1) (+5) (±1) (+5) (±5) (±1)
(±1)
TCE CONSULTING ENGINEERS LIMITED

Church, Bar, Restaurant, Kitchen,

etc.
FACTORY COMFORT
25 to 27 55 to 45 26.5 to 29.5 60 to 50 20 to 22.5 35 to 30 21 to 23.5
Assembly Areas, Machining
(±1) (+5) (±1) (+5) (±1) (±5) (±1)
Rooms, etc.

NOTES
1. Tolerance limits are indicated within brackets.
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APPENDIX 3
HEAT GAIN FROM PEOPLE
(SOURCE TABLE 48 - PART-1 HANDBOOK OF AIR-CONDITIONING SYSTEM DESIGN BY CARRIER AIR-CONDITIONING
COMPANY - 1965 EDITION)
TCE.M1-ME-811-301

DEGREE OF TYPICAL METABOLIC AVERAGE ROOM DRY-BULB TEMPERATURE

0
ACTIVITY APPLICATIO RATE ADJUSTED C
N (ADULT METABOLI
MALE) C RATE
(NOTE 1) 28 27 26 24 21

WATTS WATTS WATTS WATTS WATTS

WATTS WATTS SENS- LAT- SENS- LAT- SENS- LAT- SENS- LAT- SENS- LAT-
IBLE ENT IBLE ENT IBLE ENT IBLE ENT IBLE ENT

Seated at rest Theatre, Grade 115 100 50 50 55 45 60 40 65 35 75 25

School

Seated, very High School 135 120 55 65 60 60 65 55 70 50 80 40

light work

Office worker Offices,

Hotels, Apts., 140 135 55 80 60 75 65 70 75 60 85 50
College
BASIC STUDY GUIDE FOR

Standing, Dept., Retail,

AIR-CONDITIONING SYSTEM

walking slowly or Variety 160 135 55 80 60 75 65 70 75 60 85 50

Store
TCE CONSULTING ENGINEERS LIMITED

Walking, Drug Store

160 145 55 90 60 85 65 80 75 70 85 60
seated

Standing, Bank
walking slowly 160 145 55 90 60 85 65 80 75 70 85 60

Sedentary Restaurant
work (NOTE 2) 150 160 55 105 65 95 70 90 85 75 95 65
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APPENDIX 3 (CONTD.)
TCE.M1-ME-811-301

DEGREE OF TYPICAL METABOLIC AVERAGE ROOM DRY-BULB TEMPERATURE

0
ACTIVITY APPLICATIO RATE ADJUSTED C
N (ADULT METABOLI
MALE) C RATE
(NOTE 1) 28 27 26 24 21

WATTS WATTS WATTS WATTS WATTS

WATTS WATTS
SENS- LAT- SENS- LAT- SENS- LAT- SENS- LAT- SENS- LAT-
IBLE ENT IBLE ENT IBLE ENT IBLE ENT IBLE ENT

Light bench work Factory, light

235 220 55 165 65 155 70 150 90 130 105 115
work

Moderate dancing Dance Hall 265 250 65 185 75 175 80 170 95 155 120 130

Walking, Factory, fairly

4.8 KMPH heavy work 295 295 80 215 90 205 95 200 110 185 135 160
BASIC STUDY GUIDE FOR

Heavy work Bowling

AIR-CONDITIONING SYSTEM

440 425 135 290 135 290 140 285 155 270 175 250
Alley, Factory
TCE CONSULTING ENGINEERS LIMITED

NOTES

1.0 Adjusted Metabolic Rate to be applied to a mixed group of people with a typical percent composition based on the following factors. This
heat dissipation is the total i.e. sensible + latent heat. The proportion of sensible to latent load is a function of the temperature and is listed
under “Room dry bulb temperature (OC).
(a) Metabolic rate for adult female = Metabolic rate of adult male x 0.85
(b) Metabolic rate for child = Metabolic rate for adult male x 0.75

2.0 Restaurant – Values for this application include 18 watts for food per individual inclusive of sensible and latent heat.
SHEET 24 OF 35

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AIR-CONDITIONING SYSTEM

APPENDIX 4
DEFAULT VALUES FOR SOME DESIGN PARAMETERS

1.0 LIGHTING LOADS

DESCRIPTION OF THE AREA Watts/M2

Office areas 15
Control rooms, Laboratories 20
Manufacturing areas :
Pharmaceutical areas 30
Machine, Assembly, Press shops 20
Commercial areas, Show rooms 50
Computer rooms 30

2.0 OCCUPANCY

DESCRIPTION OF THE AREA M2/PERSON

Office areas 5
Auditorium 2
Conference rooms 2.5
Manufacturing areas 10

3.0 FRESH AIR AND EXHAUST AIR REQUIREMENTS

DESCRIPTION OF THE AREA NUMBER OF AIR M3/Hr PER

CHANGES PER HOUR PERSON
Control rooms 1 -
Office areas 1 34
Pharmaceutical areas 4.5 to 6 -
Commercial areas, Show rooms, 2 air changes per hour or 25 M3/Hr per
Public areas person whichever is higher
Auditoriums 2 air changes per hour or 25 M3/Hr per
person whichever is higher
Conference rooms 2 air changes per hour or 42.5 M3/Hr per
person whichever is higher
NOTES

1. The fresh air requirement for pharmaceutical areas which require to be over-
pressurised is dictated by the pressurisation requirements and is to be calculated
from the air flow leakage through the door and window cracks and openings.
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AIR-CONDITIONING SYSTEM

APPENDIX 4 (CONTD.)

4.0 FILTRATION AND CLEANLINESS

4.1 Control rooms and Laboratories

(a) Pre-filters with filtering efficiency of 90% down to a particle size of 20 microns as
per IS 7613 test dust G2.

(b) Fine filters with filtering efficiency of 99% down to a particle size of 5 microns as
per IS 7613 test dust G3.

4.2 Office areas and areas air-conditioned for comfort – Pre-filters as per para 4.1(a).

5.0 OVER-PRESSURE

5.1 Comfort Air-Conditioning

Pressurisation to correspond to that achieved by the amount of fresh air taken into the
system.

5.2 Industrial Air-Conditioning

5.2.1 Pharmaceutical : 1 mmWG differential pressure between adjacent areas.

5.2.2 In certain areas negative differential pressure may be required to be maintained with
respect to the adjacent areas to ensure against cross contamination.

5.2.3 Synthetic Fibre Plants

(a) Quench air : 30 to 80 mmWG

(b) Spinning areas : 1.5 to 2 mmWG

5.3 Control Rooms and Laboratories : 1 mmWG

6.0 CIVIL CONSTRUCTION DETAILS

6.1 External walls out of 230 mm thick ordinary brick with 20 mm and 15 mm thick sand
cement plaster on outer and inner wall surfaces respectively.

6.2 Internal walls out of 115 mm thick ordinary brick with 15 mm thick sand cement plaster
on both sides of the wall.

6.3 Floor slab out of 100 mm thick RCC of density 2,500 Kg/M3 with 25 mm thick sand
cement mortar and 25 mm thick ceramic tile on the top. No plaster shall be considered
for the bottom surface of the floor slab.
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AIR-CONDITIONING SYSTEM

APPENDIX 4 (CONTD.)

6.4 Roof slab out of 100 mm thick RCC of density 2,500 Kg/M3 with asphalt roll water
proofing on top. No plaster shall be considered for the bottom of the roof slab.
Underdeck insulation out of 50 mm thick expanded polystyrene with thermal conductivity
of 0.034 W/M0C.

6.5 Glass for doors and windows shall be considered to be out of ordinary single glass pane.
For windows venetian blinds shall be considered.

6.6 False ceiling out of aluminium panels size 610 mm x 610 mm size. The false ceiling grid
shall be located centrally in the room.

ISSUE
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APPENDIX 5

COMPARISON BETWEEN RECIPROCATING, SCREW, CENTRIFUGAL CHILLING UNITS AND VAMs

SL. ITEM RECIPROCATING SCREW CENTRIFUGAL VAMs

TCE.M1-ME-811-301

NO. COMPRESSORS COMPRESSORS COMPRESSORS (LIBR-WATER)

1. Type of Compressor Positive displacement– Positive displacement- Roto dynamic action by No compressor
compression of compression of refrigerant centrifugal impeller
refrigerant by by progressive volume
reciprocating piston reduction between rotor
action in cylinder lobes along rotor length
during rotation of lobes in
operation

2. Capacity Range 5 to 150TR 100 to 500TR 100 to 2500TR 2.1 100 to 2500TR –
Available Indigenously for for steam fired
Water Chilling Duty
2.2 100 to 500 TR for hot
water fired
2.3 30 to 500 TR for direct
fired with fuel gas
2.4 100 to 500 TR for direct
fired with fuel oil
BASIC STUDY GUIDE FOR
AIR-CONDITIONING SYSTEM

3. Lowest Temperature Achievable

TCE CONSULTING ENGINEERS LIMITED

3.1 Chilled Water ( Note 1) 5 0C 5 0C 50C 5 0C

3.2 Chilled Brine (-) 30 0C (-) 30 0C Generally not possible Not possible
below 2 0C

4. Cooling Water Flow Rate 1 M 3/Hr per TR 1 M 3/Hr per TR 1 M 3/Hr per TR 1.35 M 3/Hr per TR
(Note 2)

5. Power Consumption for Water 0.8 to 0.9KW per TR 0.7KW per TR 0.65 to 0.7 KW per TR Power required is only 7.5 to
Chilling Duty 10 KW for solution and
SHEET 28 OF 35

(Note 2) refrigerant pump

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APPENDIX 5 (CONTD.)

SL. ITEM RECIPROCATING SCREW CENTRIFUGAL VAMs

NO. COMPRESSORS COMPRESSORS COMPRESSORS (LIBR-WATER)

6. Steam Consumption Not required Not required Not required 4.5Kg/Hr/TR for double
TCE.M1-ME-811-301

effect at about 3.0 to

8.0Kg/cm2(g) saturated
and 8.5Kg/Hr/TR for
single effect at about 0.5
to 3.0 Kg/cm2(g)
saturated
7. Fuel Gas Consumption Not required Not required Not required 0.31 TO 0.35 NM 3/Hr/TR
for direct fired machines

8. Fuel Oil Consumption Not required Not required Not required 0.35 to 0.45 Kg/Hr/TR
for direct fired machines

9. Hot Water Consumption Not required Not required Not required 0.86 M 3/Hr/TR

10. Maintenance Requirement High Low Moderate Moderate

11. Noise Level High Moderate Moderate Low

BASIC STUDY GUIDE FOR
AIR-CONDITIONING SYSTEM

12. Capacity Control In steps - by cylinder Continuous from Continuous from 40% Continuous from
TCE CONSULTING ENGINEERS LIMITED

unloading down to 10% to 100% (approx. - 10% to 100%

capacity given by the corresponding to surge
minimum number of limit) to 100%
cylinders required to be 10% to 100% with hot
kept in operation gas bypass
arrangement

13. Environment friendly R22, R717, R134a R22, R717, R134a R123, R134a Water with Lithium bromide
refrigerants generally used as solute or absorbent
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AIR-CONDITIONING SYSTEM

APPENDIX 5 (CONTD.)

NOTES

1. Vapour compression chillers and VAMs are suitable only for water chilling duty down to a
temperature of 50C. It is possible theoretically to design water chilling units for a chilled
water outlet temperature of 40C. During operation of the chiller the refrigerant suction
pressure and consequently the refrigerant evaporating pressure in the evaporator may vary
considerably with the variation in the cooling load on the chiller. At low load conditions
the evaporating pressure may drop well below the freezing point of water in the chiller. If
this manner of the operation is persisted for an extended period, it may cause icing and
severe damage to the evaporator due to rupture of tubes because of the expansion of ice
trapped within the tube spaces for DX chillers or within the tubes in case of flooded
chillers. Therefore for temperatures below 50C, brine reciprocating or screw compressor
chilling units are recommended.

2. The cooling water flow rate and power consumption for the chillers are indicated for
cooling water inlet and outlet temperature 32 and 35.70C and chilled water inlet and outlet
temperatures of 6 and 110C respectively. For air-cooled chillers the power consumption
for Mumbai outdoor design conditions i.e. 350C DBT, would be 15 to 20% higher than
that for water-cooled chillers. The power consumption for air-cooled chillers for ambient
DBT other than 350C shall be estimated from vendor data or from the Molier diagram for
the refrigerant used for the chiller.

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AIR-CONDITIONING SYSTEM

APPENDIX 6
CHILLED WATER/BRINE CLOSED LOOP
SINGLE PUMPING SYSTEM
(ALTERNATIVE 1)

CHILLED WATER/BRINE EXPANSION TANK

LOCATED ABOVE THE ELEVATION OF
HIGHEST CONSUMER

MAKE-UP AND
QUICK FILL LINE

CONSUMER

CHILLED WATER/BRINE RETURN HEADER

CHILLED WATER/BRINE SUPPLY HEADER

CONSUMER

CHILLER

CHILLED WATER/BRINE PUMP

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AIR-CONDITIONING SYSTEM

APPENDIX 7
CHILLED WATER/BRINE CLOSED LOOP
SINGLE PUMPING SYSTEM
(ALTERNATIVE 2)

CHILLED WATER/BRINE EXPANSION TANK

LOCATED ABOVE THE ELEVATION OF
HIGHEST CONSUMER

MAKE-UP AND
QUICK FILL LINE

CONSUMER CONSUMER

CONSUMER CONSUMER
CHILLED WATER/BRINE SUPPLY HEADER

CONSUMER CONSUMER

CHILLED WATER/BRINE
RETURN HEADER

CHILLED WATER/BRINE PUMPS

CHILLER

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AIR-CONDITIONING SYSTEM

APPENDIX 8
CHILLED WATER/BRINE OPEN LOOP
SINGLE PUMPING SYSTEM
(ALTERNATIVE 1)

CONSUMER

CHILLED WATER/BRINE RETURN HEADER

CHILLED WATER/BRINE SUPPLY HEADER

CONSUMER

CHILLED WATER/
BRINE STORAGE TANK

MAKE-UP CHILLER
AND
QUICK FILL

CHILLED WATER/BRINE PUMP

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AIR-CONDITIONING SYSTEM

APPENDIX 9
CHILLED WATER/BRINE OPEN LOOP
SINGLE PUMPING SYSTEM
(ALTERNATIVE 2)

CONSUMER CONSUMER
CHILLED WATER/BRINE SUPPLY HEADER

CONSUMER CONSUMER

CHILLED WATER/BRINE RETURN HEADER

CHILLED WATER/BRINE PUMPS

MAKE-UP AND CHILLER

QUICK FILL LINE

CHILLED WATER/BRINE
STORAGE TANK

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AIR-CONDITIONING SYSTEM

APPENDIX 10
CHILLED WATER/BRINE OPEN LOOP
DOUBLE PUMPING SYSTEM

CHILLED WATER/BRINE RETURN HEADER (TYP)

CONSUMER CONSUMER

CONSUMER CONSUMER
CHILLED WATER/BRINE SUPPLY HEADER (TYP)

CONSUMER CONSUMER

CHILLER

MAKE-UP AND
OVERFLOW QUICK FILL LINE
CHILLED WATER/BRINE
STORAGE TANK

COLD WELL HOT WELL

CHILLED WATER/BRINE
CHILLED WATER/BRINE PRIMARY PUMPS
SECONDARY PUMPS

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APPENDIX 11

COMPARISON BETWEEN CLOSED, OPEN LOOP SINGLE AND DOUBLE PUMPING SYSTEMS
TCE.M1-ME-811-301

SL. NO. ITEM CLOSED LOOP SINGLE OPEN LOOP SINGLE OPEN LOOP DOUBLE REMARKS
PUMPING PUMPING PUMPING

1. Installation cost Lowest as the number of High - as a tank is Highest as an additional -

equipment is limited to required to be introduced chilled water circuit is
chilled water pumps, and in the chilled water circuit. added, increasing the
piping in addition to the The pump head for this number of pumps, additional
chillers. configuration will be piping, tanks etc. in addition
higher than that for the to the head required to
closed loop single overcome the elevations of
pumping system so as to the equipment.
cater to the cooling
requirements of
equipment located at
higher elevations.

2. Operating cost Lowest as the High as the pumps are to Highest as both the number -
pumpinghead required is be sized for a head of pumps is higher, and the
only to overcome the corresponding to the overall pumping power
BASIC STUDY GUIDE FOR

friction head in the elevation of the consumer increases due to the

AIR-CONDITIONING SYSTEM

piping system. at the highest elevation. duplication of piping

elements like valves,
TCE CONSULTING ENGINEERS LIMITED

strainers and NRVs.

3. Operational Low as the minimum flow Low – similar to closed High as the chiller circuit is -
flexibility has to be continuously loop single pumping separated from the main
maintained, requiring a system chilled water supply circuit
flow element and flow to the process consumers
control valve to bypass and the flow variation to the
flow from the main chilled process can be from 0 to
water circuit. 100%
SHEET 36 OF 35

R5
SECTION: APPENDIX

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VENTILATION SYSTEM

BASIC STUDY GUIDE FOR

VENTILATION SYSTEM

REV. NO. R0 R1 R2 R3
ISSUE
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PPD. BY RMM Sd/- HRK Sd/- IYM Sd/- IYM

CHD. BY SCM/SJB Sd/-/Sd/- PRJ Sd/- PRJ Sd/- PRJ

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APD. BY DHNR Sd/- RL Sd/- RL Sd/- RL

DATE 29.12.1980 12.10.1999 19.04.2001 22.08.2003

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M1-ME-811-302 BASIC STUDY GUIDE FOR
SHEET i OF iii
VENTILATION SYSTEM

FILE NAME: M1ME302R3.DOC

REV. NO. R0 R1 R2 R3
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY RMM Sd/- HRK Sd/- IYM Sd/- IYM

CHD. BY SCM/SJB Sd/-/Sd/- PRJ Sd/- PRJ Sd/- PRJ

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APD. BY DHNR Sd/- RL Sd/- RL Sd/- RL

DATE 29.12.1980 12.10.1999 19.04.2001 22.08.2003

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M1-ME-811-302 BASIC STUDY GUIDE FOR
SHEET ii OF iii
VENTILATION SYSTEM

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 INPUT DATA 1

3.0 SYSTEM DESIGN AND SELECTION 2

4.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS 9

5.0 OPERATION AND CONTROL SCHEME 10

6.0 EQUIPMENT AND ELECTRICAL LOAD LIST 10

7.0 UTILITY AND SPACE REQUIREMENTS 11

8.0 PROCUREMENT STRATEGY 11

APPENDICES

1. LIST OF AREAS NORMALLY VENTILATED 12

2. OUTSIDE DESIGN CONDITIONS OF IMPORTANT CITIES OF 13

INDIA

3. DEFAULT VALUES FOR SOME DESIGN PARAMETERS 18

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REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 29.12.1980 ----------------

R1 12.10.1999 Completely revised.

R2 19.04.2001 Paras 3.4.1 and 3.11 modified. Appendix 4 added.

R3 22.08.2003 Para 4.0 added. Para 3.11 of R2 issue merged with Para 4.0
of R3 issue. Paras 3.4.1 and 3.10.1 of write-up and para 4.4
of Appendix 3 revised. Appendix 4 deleted.

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1.0 SCOPE

This document gives guidelines for carrying out a basic study for ventilation system for
chemical, industrial and power plants. For format, structure and other guidelines refer
TCE.M9-PCS-25. The basic study shall form the basis for procurement and detailed
engineering of the ventilation system.

2.0 INPUT DATA

Following input data shall be collected from various sources like client, process
collaborator, other groups in the mechanical department, other departments, bidders and
vendors.

2.1 Location of the site

2.2 Latitude and altitude of the site

2.3 Names of areas to be ventilated

2.4 Equipment layout drawings of the areas to be ventilated

2.5 Architectural drawings and civil Reinforced Cement Concrete (RCC) or structural steel
drawings of the areas to be ventilated

2.6 Outside design conditions like Dry Bulb Temperature (DBT), Wet Bulb Temperature
(WBT) and Relative Humidity (RH) for summer, monsoon and winter and daily
temperature range

2.7 The prevailing wind direction and speed for most time of the year

2.8 Inside design conditions indicating the DBT and RH for each of the areas to be ventilated

2.9 Lighting loads

2.10 Sensible and latent equipment heat loads, of heat sources within and adjacent to the
ventilated areas with specific periodic loading patterns, if any. The local concentration of
these loads, if any, is particularly important and shall be obtained.

2.11 Occupancy in the ventilated areas and the type of human activity envisaged

2.12 Supply air and exhaust air requirements, if any

2.13 Filtration and cleanliness requirements, if any

2.14 Pressurisation requirements, if any

2.15 Air flow pattern requirements, if any

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2.16 Acceptable noise and vibration levels

2.17 Hazardous area classification

2.18 Duration of working of the ventilation system for each of the areas

2.19 Availability of soft or filtered water, make-up water, quality of water, inlet and outlet
pressures and temperatures

2.20 Specific requirements like future expansion plans and provisions required to be
incorporated at present

Some of the input data indicated above may not be readily available at the time of the
preparation of the basic study. Appendices of this document give guidelines for assuming
such data. These appendices are based on published literature and experience gained
over the years.

3.0 SYSTEM DESIGN AND SELECTION

3.1 Ventilation is required to be provided for:

(a) Removing heat from the working areas so as to maintain the temperature within
acceptable limits

(b) Removing toxic vapour generated by process equipment or components so as to

maintain their concentration within acceptable limits

(c) Removing hazardous vapour emitted or leaking from process equipment or

components so as to maintain their concentration within acceptable limits

(d) Removing obnoxious fumes, vapour, odour etc. from process equipment or
components so as to maintain their concentration within acceptable limits

Recovery of recyclable volatile substances or powders either leaking from or

emitted by process equipment or components. The details of these systems are not
covered in this basic study guide.

For details of recyclable powders refer Industrial Ventilation - A Manual of

Recommended Practice - 1980 edition.

The selection of type of recovery system for recyclable volatile substances shall be
studied and decided on a case to case basis considering the requirements of the
process and properties of the substances.

3.2 Ventilation load calculations shall be carried out as per TCE.M6-ME-811-309 “Design
Guide for Ventilation Heat Load Calculations”. The air flow requirements and any special

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requirements for the ventilated area shall be indicated by the load calculations. Following
paragraphs describe various types of ventilation systems.

3.3 NATURAL VENTILATION

This can be achieved by providing adequate wall openings, windows and doors so as to
allow free air movement and cross ventilation due to wind pressures. Natural ventilation is
also possible where the height of the buildings is sufficiently large with a temperature
difference adequate to provide the driving force for the air movement. Refer TCE.M6-
ME-811-317 “Design Guide for Natural Ventilation” for details.

3.4 FORCED VENTILATION

These systems comprise of fans, air distribution system, filters etc. Various types of
systems are described in para 3.6. The types of fans used in ventilation systems are
described in the following sub-paras and estimation of fan static pressure is covered in
para 3.5.

3.4.1 Propeller fans

These fans are generally mounted on the wall and are designed for low static pressures
upto 12.5 mmWG. Propeller fans are not suitable where the air is required to be
distributed by an air distribution system consisting of filters, ducting, supply or return air
grills, volume control dampers etc. These fans are available in the capacity range from 500
to about 23,500 M3/Hr. The capacity of 23,500 M3/Hr is at a static pressure 2.5 mm
WG. The fan impeller sizes generally range from 200 to 900 mm in diameter.

3.4.2 Tube-Axial Fans

These fans are axial flow fans, which can generate static pressures up to 40 mm WG.
Special fans with variable pitch angle for the blades and variable speed can be designed
for higher static pressures and air flow control, but these are more expensive and
economical only for large capacities of the order of 2,00,000 M3/Hr and larger. Tube
axial fans are generally specified for pressurised ventilation systems where the ventilated
area is to be supplied with filtered air to maintain a dust-free environment. Tube axial fans
are available in the capacity range from about 3,000 to 1,50,000 M3/Hr, with a static
pressure of 5 to 110 mm WG. The impeller diameters for these capacities range from 300
to 2,000 mm or more. The fan selection shall ensure that fan motor synchronous speeds
do not exceed 1,500 RPM for impeller diameters up to 450 mm and 1,000 RPM for
impeller diameters greater than 450 mm.

Tube axial fans are generally noisier than propeller or centrifugal fans. These fans shall be
selected for operating speeds within the speed limits given above so as to ensure that
noise levels are maintained within acceptable limits. The efficiency of tube axial fans is
generally lower than that of centrifugal fans and considering that the noise level also is
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generally much higher, it is recommended that tube axial fan static pressures be limited to
40 mm WG.

A variation of this fan configuration is the roof extractor, which is primarily a tube axial fan
provided with a hood for protection from the rain or sunshine. Roof extractors are
available in the capacity range of 5,000 to 45,000 M3/Hr with static pressure upto 7 mm
WG.

3.4.3 Centrifugal Fans

These fans are used for applications requiring fan static pressures of 40 mmWG and
higher. The impellers for these fans may be of the following types:

(a) Airfoil Backward Curved Vanes

These fans have non-over loading characteristics and have the highest efficiency of
all types of centrifugal impeller types.

(b) Backward Curved or Inclined Vanes

These impellers like airfoil backward curved vanes have non-overloading

characteristics and efficiencies only slightly lower than airfoil vanes. These fans are
relatively cheaper than airfoil impeller fans and are generally preferred over other
types of impellers.

(c) Forward Curved or Inclined Vanes

These fans are generally used for smaller capacities upto about 1,000 M3/Hr or for
static pressures of 75 mm WG or less. These fans are also used for AHUs. The
motor rating shall be at least 15% above the power requirement at duty point or
10% higher than the maximum power requirement at selected speed whichever is
higher, considering that the power consumption rises continuously from shut-off to
free delivery.

(d) Radial Vanes

These fans are generally used in material handling applications or for applications
requiring high static pressure of around 1,000 mm WG, e.g. fans for vacuum
cleaning system. These fans are generally not used for ventilation applications.

Centrifugal fans can be Single Inlet-Single Width (SISW) or Double Inlet- Double Width
(DIDW). These fans are generally belt driven by an electric motor drive.

SISW fans have a single impeller with air intake from one side of the fan casing with the
fan drive arrangement located on the other side of the casing. The process gas or air
handled may be ducted to the inlet of the fan; i.e. the fan may be used for systems where
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the process gas or air to or from the process or ventilated area is ducted to the fan
suction. This is advantageous, as the drive motor for this fan is completely external to the
fan gas circuit and can be approached for routine maintenance without exposure to the
gas. The single impeller of the SISW fan necessitates a thrust bearing to take care of the
thrust generated by the one-sided air intake.

DIDW fans are provided with a double impeller placed back-to-back, allowing air intake
from both sides of the fan casing. As a result of this configuration, the process air or gas
cannot be ducted to the DIDW fan inlet due to the drive arrangement being located on
either of sides of the casing. The DIDW fans along with the belt drive and motor
necessarily have to be located within the process gas or ventilated air stream. Due to the
air intake from both sides of the casing, DIDW fans are balanced as compared to SISW
fans, obviating the need for thrust bearings and resulting in relatively lower maintenance.

For a given air flow and static pressure the impeller diameter for DIDW fans is smaller,
having a smaller height but larger floor space as compared to SISW fans. For
commercially available fans, SISW fans generally have an efficiency about 5% to 20%
higher than that for DIDW fans, depending upon the capacity and static pressure and
outlet velocity selected for the fan. As compared to SISW fans, which are ducted at the
intake, for DIDW fans, the fan heat gain to the process air or gas may be as much as 18%
higher than the fan brake power. The break-up of this heat gain is given in the table at the
end of this para.

The type of fan whether SISW or DIDW may be selected considering the above and the
requirements of the particular application.

Centrifugal fans are available for a capacity range from 500 to 400,000 M3/Hr or higher,
with static pressures ranging from 40 to 4,000 mm WG.

HEAT GAIN (%
SL. NO. ITEM REMARKS
OF FAN BKW)

1. Fan efficiency 5* * Assumed for the purpose of this

table

2. Belt drive loss to 3 For DIDW fans the belt drive

process air package, i.e. the belts, pulleys etc.,
and the fan motor are located in the air
or gas stream.

3. Motor heat loss 10 Heat loss from motor corresponds to

a motor efficiency of about 90 %

Total heat gain 18 -

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3.5 FAN STATIC PRESSURE

An air circuit diagram shall be prepared in line with the anticipated ducting layout
configuration of the ventilated area, indicating the air pressure at the inlet and outlet of
each of the elements like fans, louvers with bird screen, ducting, supply and exhaust air
grills, volume control dampers, plenums etc., in the air circuit as follows:

(a) Start from the ventilated area for which the room over-pressure is defined as per
the data collected or as per appendix 3 of this guide.

(b) Proceed upstream along the air circuit towards the fan. The pressure will increase
progressively as the pressure drops in the individual elements in the air path.
Indicate the air pressure at the inlet and outlet of each of the elements in the air
path. The procedure shall be continued until the air circuit is completed by either
reaching the starting point or point of air intake from the atmosphere.

The pressure drops to be considered in each of the elements are listed

below. These pressure drops are preliminary and shall be reconfirmed during
further engineering, with firm data from bidders and vendors. The pressure drop
across the plenum being negligible may be ignored for the purpose of preliminary
estimation.

(i) Volume control dampers : 3 mm WG

(ii) Filters in clogged condition

Pre-filters : 12 mm WG
Fine filters : 18 mm WG
HEPA filters : 75 mm WG

(iii) Supply and exhaust air ducting : 0.067 mm WG per metre

of duct length

(iv) Supply air outlets : 3 mm WG

(v) Exhaust air inlets or louvers with : 2 mm WG

bird screen

(vi) Pressure in area to be ventilated

Pressurised ventilation : 1 mm WG
Exhaust ventilation : (-) 1 mm WG

(vii) Pressure in ventilation plant room : (-) 3 mm WG

or at fan inlet

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The differential static pressure across the fan inlet and outlet is the Static Pressure for the
fan.

3.6 TYPES OF VENTILATION SYSTEMS

Various types of ventilation systems are briefly described in the following paragraphs.
Combinations of these systems, or if required by the specific application, variations of the
systems described also may be adopted.

3.6.1 Dry Exhaust Ventilation System

This system essentially comprises of exhaust fans provided for the ventilated area. The
fans may be wall mounted propeller type or roof mounted roof extractors. The location of
wall mounted exhaust fans and air inlets shall be decided so that air flow is not against
wind direction as far as possible. Suitably located wall openings or doors shall be
provided to allow the infiltration of air to replace this exhausted air.

In these systems, the ventilated area is generally at ambient or slightly lower pressure than
the ambient pressure. In areas having large widths (greater than about 15 metres), or
where a specific overall air flow pattern is required, suitably located wall mounted supply
fans may be provided in addition to the wall mounted exhaust fans.

In cases where the dimensions of the ventilated area exceed 15 metres in width and where
roof extractors cannot be installed, it may be necessary to provide exhaust air ducting.
This is to ensure uniform air exhaust over the ventilated area, especially where heat
dissipation loads from equipment are likely to cause local “hot spots”.

For ducted systems tube axial fans may be used for static pressure requirements of up to
40 mmWG. For higher static pressure requirements centrifugal fans shall be used. For
wall mounted fans of air flow capacities exceeding 8,000 M3/Hr, it is recommended that
tube axial fans be used instead of propeller fans so as to limit the size of the fan.

3.6.2 Dry Pressurised Ventilation System

This system is generally provided where the inside design temperature is not critical and
the area is required to be provided with a dust-free environment. A dust-free environment
implies the specification of the type of filtration system. Generally pre-filters with a filtering
efficiency of 80 % down to a particle size of 20 microns as per IS 7613 - test dust G2,
are adequate for ventilation applications like switch-gear rooms or manufacturing areas.

The system essentially comprises of fans, filters and air distribution system.

3.6.3 Evaporative Air Cooling Ventilation System

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In areas with outdoor conditions having a WB depression, i.e. difference between DBT
and WBT, of higher than 80C in summer and ambient DBT above 350C, wet ventilation
system may be considered. This system is also called “evaporative cooling ventilation
system”. A temperature lower than the ambient can be achieved by evaporative cooling
ventilation system.

This system comprises of supply air fan, air intake louvers with bird screen, filters, air
washer, spray water pumps, spray water piping and air distribution system. The fans for
the system are selected as described earlier in this guide. The air washer comprises of a
spray chamber in either masonry construction or sheet metal construction, with necessary
internals i.e. spray headers and standpipes, spray nozzles. Air washers are installed with
one, two or three spray banks (spray header with standpipes and spray nozzles
constitutes a spray bank) having air humidifying efficiencies of up to 90%.

3.7 EXHAUST HOOD REQUIREMENTS

In areas where there is a major equipment load and the temperature rise is to be limited,
or in areas where fumes or dusts are generated, it may be required to provide local
exhaust hood in addition to providing a supply to area. In case exhaust hoods are
provided, a part of the total equipment heat load only is to be considered for the
estimation of the ventilation air flow rates. The ventilation hood design shall be carried out
as per the guidelines given in the Industrial Ventilation – A Manual of Recommended
Practice - 1980 edition.

3.8 HEATING REQUIREMENTS

In case of ventilated areas in locations where winter ambient conditions are lower than the
design lowest temperature it may be necessary to provide heating by use of steam or
electric heating coils. These heaters shall be incorporated into the system so as to provide
the maximum benefit by suitable air distribution.

3.9 NUMBER OF EQUIPMENT / STANDBY ETC.

The local ventilation load distribution may dictate the air distribution requirements, which
in turn will dictate the configuration, i.e. the number and capacities of the ventilation fans,
filters, heaters etc. The configuration of the ventilation system also has to consider the air
movement in the ventilated area to ensure relative comfort conditions in working area. The
economics of providing a standby for the equipment shall be examined while selecting the
system components.

3.10 NOISE AND VIBRATION

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3.10.1 Noise

The noise levels for the equipment e.g. skid-mounted chiller, compressor, fan and base
frame with motor, AHU, pump with base frame and motor etc. may be checked from
vendor catalogues. The allowable noise levels for various areas are given in Table 34,
Chapter 47, ASHRAE Handbook–HVAC Applications, 2003-Edition. Necessary sound
attenuators or acoustic lining of ducting and plant room shall be specified, if necessary, to
meet the above criteria.

3.10.2 Vibration

The acceptable vibration level of all major equipment shall be specified in the respective
enquiry document. Unless specified otherwise by client or the process collaborator, the
vibration level of an equipment shall be specified as “B” as per ISO 10816-1. Vibration
isolators having an isolation efficiency of at least 70% shall be specified for the equipment
wherever required for the system design.

4.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS

As per National Building Code (NBC), a building having height more than 15 metres
above the surrounding ground level is called a High Rise Building. Following requirements
need to be incorporated while designing ventilation system for such a building. While these
requirements are mandatory for High Rise buildings, it is advisable to follow these for any
building.

4.1 Ventilation system fans except propeller type wall mounted exhaust fans shall be
interlocked with fire detection and alarm system such that in case of fire, ventilation fans
shall stop automatically. In case of fire, exhaust fans shall continue to operate, if designed
to exhaust the smoke from fire into the atmosphere.

4.2 Wherever the ventilation system duct pass through fire wall or floor, the opening around
the ducts shall be sealed with fire resisting materials such as asbestos rope, vermiculite
concrete or other suitable materials.

4.3 Wherever the ventilation system duct pass through fire wall or floor, fire damper shall be
provided in the ducting. The fire damper actuators may be fusible link, pneumatically
operated, electric motor or solenoid operated. Solenoid operated dampers being
economical are generally preferred due to their reliability and facility for interlocking with
fire detection and alarm system, so as to shut the damper in case of fire.

4.4 Staircases shall be ventilated to the atmosphere at each landing i.e. at each floor level and
at the topmost level. Minimum free area of 0.5 M2 shall be provided in the external wall at
each landing i.e. at each floor and at the topmost level.
4.5 If the staircase can not be ventilated to the atmosphere, because of the location or other
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reasons like internal staircase within the building, forced ventilation shall be provided.
Positive pressure of 5 mm WG shall be maintained inside the staircase. The mechanism of
pressurising the staircase shall operate automatically with the fire alarm. It shall also be
possible to manually operate the pressurisation.

4.6 Doors for the staircases or stairwells shall be of auto-shut type and shall have 2 hour fire
resistance.

4.7 If the lift shaft and the lift lobby are in the core of the building, a positive pressure of 2.5 to
3 mm WG shall be maintained in the lobby and 5 mmWG in the lift shaft. The mechanism
of pressurising shall operate automatically with the fire alarm. It shall also be possible to
manually operate the pressurisation.

4.8 Each basement floor shall have independent ventilation system. Exhaust from each
basement floor shall be vented to atmosphere and shall not be connected to exhaust of
any other area.

4.9 For multi-storey basements natural fresh air or common fan with ducts may be provided
for supply air. However, exhaust system for each basement floor shall be independent.

4.10 For exhaust ventilation of internal toilets a minimum of 4 M2 shaft shall be provided. This
shaft shall be open to atmosphere at the topmost level.

5.0 OPERATION AND CONTROL SCHEME

Brief description of operation and control scheme of the proposed system shall be
included in the basic study. Project instrument engineer may be consulted, if necessary.

6.0 EQUIPMENT AND ELECTRICAL LOAD LIST

An appendix covering all equipment like fans, filters, air washers, pumps etc., with
equipment tag numbers, name/title/designation, major parameters, materials of
construction and estimated ratings of motor and other electric equipment shall be furnished
in tabular form. Requirements such as fume resistant and anti-corrosive paint for fans,
motors, panels, equipment or structure in battery or chlorination rooms or areas where
corrosive fumes are expected, shall be specifically indicated in the equipment list. Motor
ratings may be calculated as per the relevant design guides.

7.0 UTILITY AND SPACE REQUIREMENTS

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7.1 Requirement of utilities like steam, soft or filtered make-up water and instrument air with
the design parameters like flow rates, pressure, temperature and quality required at the
battery limit of the system shall be indicated in tabular form.

7.2 The space requirements and clear height for ventilation equipment plant rooms, and for
routing of ducting and piping etc. shall be indicated. The space requirements shall
consider the operations and maintenance space for fans e.g. space requirements at fan
inlet as per AMCA, filters, air-washers and pumps etc. Requirements of hoists, cranes
and monorails shall also be included. Preferably, a sketch giving the plant room layout
shall be included.

8.0 PROCUREMENT STRATEGY

Proposed procurement strategy with number of enquiries and the scope for each shall be
clearly indicated.

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APPENDIX 1

LIST OF AREAS NORMALLY VENTILATED

1. Operating areas like main station building, tripper floor, TG area etc.

2. Electrical sub-station building, switch-gear room and cable vault

3. Areas having high equipment load such as fuel oil heater sheds, manufacturing areas,
welding booths, foundries, boiler houses, kitchens, diesel generator room etc.

4. Water treatment plant areas inclusive of DM water plant, chlorination room etc.

5. All control rooms including those for electrostatic precipitator, switchyard, ash
handling, coal yard etc. (These areas are sometimes air-conditioned.)

6. Areas where contaminants like fumes or dust are present or are generated, like
battery rooms, coal conveyor tunnels, machine shops, weld shops, etc.

7. All pump houses

8. All machine or equipment rooms like elevator machine room, compressor room, air-
conditioning plant room, hydrogen generation station, electrostatic precipitator
rectifier room etc.

9. Service building inclusive of office areas, workshop, welding and smithy, instrument
maintenance, stores, warehouses, locker rooms, canteen etc.

10. Toilets

NOTES

1. Some of the areas mentioned above may be located in one building or house.

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX
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VENTILATION SYSTEM

APPENDIX 3

DEFAULT VALUES FOR SOME DESIGN PARAMETERS

1.0 INSIDE DESIGN CONDITIONS

1.1 Dry ventilation systems : 2 to 30C above the ambient DBT

1.2 Wet ventilation systems : 6 to 70C above the ambient WBT

2.0 AIR FLOW RATES

2.1 DRY EXHAUST VENTILATION

2.1.1 Kitchen and pantries 50 air changes per hour or 152 M3/Hr
per M2 whichever is higher
2.1.2 Boiler house, DG rooms, weld shops, foundry 40 air changes per hour or 92 M3/Hr
or furnace rooms, heat treatment shop, per M2 or as dictated by the heat
laundries, refinery hot oil pump houses and dissipation loads whichever is highest
public toilets
2.1.3 Pump houses, compressor houses, welding 25 air changes per hour or 76 M3/Hr
and smithy, canteen and transformer rooms per M2 whichever is higher
2.1.4 Locker rooms, stores, warehouses, private 15 air changes per hour or 54 M3/Hr
toilets, machinery assembly shops, water per M2 whichever is higher
treatment plant, HVAC plant rooms and
battery rooms
2.2 DRY PRESSURISED VENTILATION
MCC rooms and manufacturing areas 25 air changes per hour or 76 M3/Hr
per M2 or as dictated by the heat
dissipation loads whichever is highest

3.0 OVER-PRESSURE

3.1 MANUFACTURING AREAS

3.1.1 Areas requiring dust-free environment and not (+) 1 mmWG
having hazardous fumes or vapours
3.1.2 Areas where hazardous fumes are generated (-) 1 mmWG

3.1.3 Areas where recoverable dust is generated (-) 1 mmWG

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APPENDIX-3 (CONTD.)

3.1.4 Areas where active air is handled e.g. nuclear (-) 1 mmWG
power plants

3.2 MCC AND PCC ROOMS (+) 1 mmWG

3.3 BATTERY ROOMS AND TOILETS (-) 1 mmWG

3.0 FILTRATION

4.1 For MCC rooms, control rooms, manufacturing areas in hazardous areas having
flammable vapour e.g. hydrocarbons as in refinery areas, glycol vapours as in
synthetic fibre plants, chemical filters may have to be provided in case intake of
ventilation air is not possible from a safe area. These filters are required to filter
hydrocarbons or vapour like chlorine, ammonia, oxides of nitrogen, sulphur or its
oxides, compounds etc. Some of this vapour is detrimental to the contacts of
electronic components used in control systems and it is essential to remove them to
ensure the full working life of the components.

4.2 For MCC rooms and manufacturing areas in active areas of nuclear power plant,
carbon filters may have to be provided to remove the radioactive elements in the
ventilation air.

4.3 For MCC rooms and manufacturing areas in safe areas, pre-filters with filtering
efficiency of 80% down to a particle size of 20 microns as per IS 7613 test dust G2
shall be provided.

4.4 For manufacturing areas in pharmaceutical plants handling powder, fine filters having
filtering efficiency of 90 % down to a particle size of 5 microns as per IS 7613 test
dust G2 and HEPA filters having filtering efficiency of 99.99 % down to a particle
size of 0.3 microns as per ISO 14644-1 and ISO 14644-2 shall be provided.

5.0 LIGHTING LOADS

DESCRIPTION OF THE AREA Watts/M2

Pharmaceutical areas 30
Machine, Assembly, Press shops 20
Commercial areas, Show rooms 50

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APPENDIX 3 (CONTD.)
6.0 OCCUPANCY

DESCRIPTION OF THE AREA M2 / PERSON

Office areas 5
Auditorium 2
Conference rooms 2.5
Manufacturing areas 10

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INDUCED DRAFT COOLING TOWERS

DESIGN GUIDE FOR

INDUCED DRAFT COOLING TOWERS

FLOPPY NO. : TCE.00000-ME-FP-136

FILE NAMES : M6ME214R3.DOC AND

REV.NO. R0 R1 R2 R3 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY DP Sd/- KVS/TSR Sd/-/Sd/- SDP Sd/- SDP

CHD.BY AR Sd/- TSR Sd/- TSR Sd/- TSR R3

APD.BY CFC Sd/- KG Sd/- RL Sd/- RL

DATE 86.09.26 94.03.31 99.06.30 01.10.11

TCE FORM NO. 020R2
TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M6-ME-127-214 DESIGN GUIDE FOR SHEET i OF iii

INDUCED DRAFT COOLING TOWERS

M6ME214R3.DWG

REV.NO. R0 R1 R2 R3 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY DP Sd/- KVS/TSR Sd/-/Sd/- SDP Sd/- SDP

CHD.BY AR Sd/- TSR Sd/- TSR Sd/- TSR R3

APD.BY CFC Sd/- KG Sd/- RL Sd/- RL

DATE 86.09.26 94.03.31 99.06.30 01.10.11

TCE FORM NO. 020R2
TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M6-ME-127-214 DESIGN GUIDE FOR SHEET ii OF iii

INDUCED DRAFT COOLING TOWERS

CONTENTS

SL.NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 CLASSIFICATION 1

3.0 DATA TO BE COLLECTED 1

4.0 DESIGN PARAMETERS 2

5.0 DESIGN PROCEDURE 3

6.0 COOLING TOWER COMPONENTS, ACCESSORIES AND 9

BASIN

7.0 EVALUATION AND PENALTY FACTORS 15

8.0 REFERENCES 16

APPENDICES

1. RE-CIRCULATION ALLOWANCE 17

2. ORIENTATION AND SPACING OF INDUCED 18

DRAFT COOLING TOWERS

3. TYPES OF INDUCED DRAFT COOLING TOWERS 19

4. BASIC CONSTRUCTION OF INDUCED DRAFT 20

COOLING TOWERS

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REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 86.09.26 --

R1 94.03.31 Addendum added.

R2 99.06.30 Generally revised.

R3 01.10.11 Paras 6.4 and 6.12

revised.

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1.0 SCOPE

This design guide outlines the data to be collected, analysis of the data and
guidelines to decide the design parameters, design aspects and layout of induced
draft cooling towers. This guide shall form the basis for further detailed engineering
and preparation of enquiry specification.

2.0 CLASSIFICATION

Induced draft cooling towers covered in this design guide are classified under three
(3) categories as follows :
(a) Large size : Total tower capacity above 5,000 M3 /Hr
(b) Medium size : Total tower capacity above 750 M3/Hr and upto
5,000 M3/Hr
(c) Small size : Total tower capacity upto 750 M3/Hr

3.0 DATA TO BE COLLECTED

3.1 Following data shall be collected from sources such as client, meteorological
department, process collaborator, bidders, vendors and past in-house data :

(a) Location

(b) Site meteorological data preferably covering the daily and hourly wet bulb
temperature and wind velocity and direction data. If daily and hourly data is
not available, at least monthly maximum, minimum and mean values shall be
obtained.

(c) Soil conditions

(d) Total cooling water requirements for process plant, power plant, air-
conditioning, chilling plant, diesel generator set, and various other equipment
such as pumps, compressors, turbines, diesel engines etc.

(e) Heat load for each of the equipment mentioned in (d) above.

(f) Maximum hot water outlet temperature and cold water inlet temperature for
each of the equipment mentioned in (d) above.

(g) Make-up water source, quality and availability of water on continuous basis

(h) Disposal point for blowdown

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(i) Space provided for cooling tower in plot plan

(j) Distance of nearby tall buildings from cooling tower

(k) Availability of power supply on continuous basis

(l) Statutory requirements and project specific requirements regarding disposal

of blowdown, restriction on use of certain materials like asbestos, timber
etc.

(m) Plan for any future expansion

(n) Details of existing cooling tower, if any

3.2 Following parameter is not applicable for induced draft cooling towers :

Relative humidity - Since the tower performance is independent of relative humidity

due to presence of fans.

4.0 DESIGN PARAMETERS

Based on the data collected, following design parameters are required to be

established :

(a) Design ambient wet bulb temperature

(b) Re-circulation allowance and design entering wet bulb temperature

(d) Drift loss

(e) Make-up water quantity and cycles of concentration

(f) Siting, orientation and spacing

(g) Types of cooling towers

(h) Number of cells

(i) Materials of construction

Following paras briefly describe the procedure for establishing each of these design
parameters.
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5.0 DESIGN PROCEDURE

5.1 DESIGN AMBIENT WET BULB TEMPERATURE

Data for ambient Wet Bulb Temperature(WBT) throughout the year shall be
reviewed and WBT duration curve prepared. Generally, design ambient WBT is the
temperature where 95% of the ambient WBTs are below that particular
temperature.

5.2 RE-CIRCULATION ALLOWANCE AND DESIGN ENTERING WET BULB

TEMPERATURE

Due to the low height of the tower and the suction head created by the fan there is a
possibility of some of the hot air, discharging from the fan, being sucked in along
with the inlet air thereby causing slight rise in the inlet air WBT. The re-circulation
allowance is the difference between the WBT of air at tower inlet i.e. design entering
WBT and the design ambient WBT. This has to be considered in the design of the
tower, as it reduces the available approach between cold water outlet temperature
and design entering WBT. The re-circulation allowance can be determined from the
curve indicated in appendix 1. The design entering WBT shall be specified after
adding the re-circulation allowance. It may also be added that no further re-
circulation allowance needs to be considered by the bidders.

5.3 COOLING WATER REQUIREMENT, DESIGN HOT WATER INLET

TEMPERATURE AND DESIGN COLD WATER OUTLET TEMPERATURE

The size and cost of cooling tower is proportional to the heat load and approach. It
is of primary importance that a reasonably accurate heat load determination be
made. Hence, it is advisable to determine the heat load of each user equipment as
realistically as possible. From the cooling water inlet and outlet temperatures, flow
rates and heat loads for each user equipment, determine hot water return
temperature assuming mixing of all the return streams. This temperature is nothing
but the “Design Hot Water Inlet Temperature “ for the cooling water. The heat load
imposed on the cooling tower is determined by the amount of water circulated
through the process and by the number of degrees centigrade that the process
elevates the circulating water temperature.

Q = m x Cp x ∆T

Where Q = Heat load in Kcal/Hr

m = Mass flow rate in Kg/Hr

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Cp = Specific heat of water (1 Kcal/Kg/ 0C)

∆T = Design hot water inlet temperature – design cold water
outlet temperature in 0C

It may appear from the above that any combination of flow rate and cooling range
can be selected to give the required heat load. However, in reality, it is not so, since
design cold water outlet temperature is fixed by “Approach”.

Approach = Design cold water outlet temperature – Design Entering WBT

Generally, the approach shall be more than 3 0C as it is not customary in cooling

tower industry to guarantee any approach less than 2.8 0C

As the size of cooling tower is inversely proportional to the approach, it is advisable

to decide on a design cold water outlet temperature which neither results in large
cooling tower nor a very high water circulation rate. Though it is possible to carry
out a theoretical economic analysis resulting in most optimum solution, experience
has shown that an approach of 4 0C to 5 0C results in a near optimal solution.

Hence, decide on a design cold water outlet temperature, design hot water inlet
temperature and circulation water flow rate. Check whether these parameters satisfy
all the user equipment also.

Add 5% to 10% margin on the cooling water requirement based on reliability of

input data indicated at 3.1.d, 3.1.e and 3.1.f.

5.4 DRIFT LOSS

This is loss of water due to water particles carried away by the outgoing air. Due to
the suction created by the fan, the drift loss is high. However, this is minimised by
providing drift eliminators. Depending on the design and effectiveness of drift
eliminators the drift loss varies between 0.005% to 0.1 % of the cooling water flow.

Drift loss shall be specified as 0.1 % maximum for small and medium size cooling
towers.

Drift loss shall be specified as 0.05 to 0.1% maximum for large size cooling towers.

When the electrical substation is nearby, cooling media is sea water and cooling
tower size is large, the drift loss shall be specified as 0.005% maximum.
5.5 MAKE-UP WATER QUANTITY AND CYCLES OF CONCENTRATION

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Refer "Basic Study Guide for Cooling Tower Make-up System" TCE.M1-ME-
127-201.

5.6 SITING, ORIENTATION AND SPACING

5.6.1 Siting

The major disadvantage of induced draft cooling towers is the drift nuisance i.e.
falling of water particles carried away by the discharge air on to the surrounding
structures particularly on electrical equipment such as transformer and switch yard
etc. Normally drift dispersion study is not carried out and towers are located as per
para 5.6.3 below. If required in a particular project due to space constraint, this
study may be carried out for large cooling towers either in-house or from outside
agency . However, this study involves extra cost to the project and shall be carried
out in consultation with the client.

5.6.2 Orientation ( Refer appendix 2)

(a) Towers with air inlets on only one side shall be oriented so that the air inlets
face the prevailing wind.

(b) Towers with air inlets on opposite sides shall be oriented so that the air inlet
sides are either parallel to or at an angle to prevailing wind direction.

5.6.3 Spacing

Towers shall be located so that the clear distance between the tower and any
surrounding structure is at least equal to the height of the tower and distance
between the two parallel cooling towers is at least equal to the length of the longest
tower and the spacing between the towers shall be as shown in appendix 2. It is
also advisable to consult cooling tower vendors in case of space limitations.

5.7 TYPES OF COOLING TOWERS

It is advisable to provide separate cooling towers for process and utility plants, if
there is a possibility of contamination of cooling water in the process plant.

There are two types of induced draft cooling towers

(a) Cross-flow tower

(b) Counter-flow tower

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The arrangements of the above two types are indicated in appendix 3.

In cross-flow tower the air flow is horizontal across the downward fall of water
whereas in counter-flow tower the air and the water flow are opposite in vertical
directions.

The advantages and disadvantages of each of the above types of induced draft
cooling towers are :

5.7.1 Cross-Flow Towers

Advantage

The water distribution system can be attended to without taking tower shut down.

Disadvantages

(a) Prevention of icing during extreme whether conditions demand more care
from the operator. (Applicable only for sub-zero climates.)

(b) The exposure of water distribution basin to sunlight promotes growth of

algae.

5.7.2 Counter-Flow Towers

Advantages

(a) The plan area at basin level and the total power for fans is less than that for
cross-flow towers.

(b) Economical choice for difficult duties (large cooling range combined with
close approach).

(d) The enclosed nature of counter-flow tower restricts exposure of water to

direct sunlight , thus retarding the growth of algae.

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Disadvantage

The water distribution system (generally piping or troughs with spray nozzles) can
not be easily inspected and cleaned unless the tower is shut down.

5.7.3 Choice of Type of Induced Draft Cooling Tower

As explained above since either of the type do not have any overwhelming
advantage over the other type and since different vendors normally specialise in
either one of the two(2) types, the choice of the type of tower is left open to the
bidder. The towers may be single air entry type or double air entry type. If nearby
structures located within a distance of one(1) tower height from the cooling tower
obstruct the free flow of air then single air entry from the unobstructed side may be
considered. Otherwise, it is preferable to adopt double air entry type.

5.8 NUMBER OF CELLS

Large and medium size towers are of multi-cell, each cell having its own fan, water
distribution system, fill, drift eliminators and louvers. This facilitates flexibility of
operation by distribution of water load and control of cooling water temperature
by operation of required number of cells. The maximum fan tip speed shall
be limited to 65 metres per second. On this basis the maximum capacity of each
cell shall be about 3,000 M3/Hr. Depending on the total capacity of tower, number
of cells may be selected. e.g. 30,000 M3/hr capacity tower may have 10 cells.

Normally, standby cells are not provided. Instead standby equipment such as fan,
gearbox, motor and nozzles/orifices shall be provided. However, standby cells may
be provided based on project specific requirement.

5.9 MATERIALS OF CONSTRUCTION

The basic construction features of an induced draft cooling tower are shown in
appendix 4. The major components and their materials of construction are described
in following paras.

5.9.1 Timber

Because of its availability, workability, relative low cost and its durability under the
very severe operating conditions encountered in cooling towers, timber is the
predominant structural material utilized. Normally, timber is not recommended for
hot water inlet temperature above 650C. Above 650C, lower permissible stress

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value of timber with safety margin shall be considered or RCC cooling tower shall
be considered.
Timber shall be as per IS 2372.

The following pressure preservative treatments are used for the treatment of timber
used in industrial water cooling towers :

(a) Chromated Copper Arsenate (CCA)

(b) Acid Copper Chromate (ACC)

CTI Bulletin WMS-112, " Pressure Preservatives Treatment of Lumber for

Industrial Water" governs the treating procedure, the minimum retentions and
penetrations to be obtained, and the physical condition of the timber when pressure
treating industrial water cooling tower timber. Treatment to timber shall conform to
IS 401.

5.9.2 Asbestos Cement Board (ACB)

ACB has excellent resistance to normal industrial atmosphere. It is a non-

combustible material and is not subject to micro-biological decay. The
disadvantages of ACB are as follows :

(a) ACB can hamper manual fire fighters as it explodes in fragments in case of
fire.

(b) It is degraded if exposed to cooling water with relatively high chlorides (>
1000 mg/l).

(c) It is not suitable for water having pH 5.5 or lower.

(d) It is not suitable for food and pharmaceutical industries.

Corrugated asbestos, if used for casing, shall be as per IS 459 and of minimum 6
mm thickness.

5.9.3 Plastics

Plastics used as materials of construction in cooling towers may be grouped into two
classes :

(a) Glass Reinforced Polyesters(GRP) and Fiber Reinforced plastics(FRP)

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GRP or FRP are not suitable when the hot water inlet temperature is above
600C.

(b) Thermoplastics

The non-reinforced thermoplastic resins include polyvinyl chloride(PVC)

and polypropylene. PVC is not suitable for temperature above 55 0C.

5.9.4 Hardware

The choice of materials for cooling tower hardware and fasteners involves the
factors of cost, strength, and corrosion resistance.

Hardware above and below fan deck level shall be normally provided with hot dip
galvanised steel or stainless steel or phosphor bronze or naval brass for fresh water
application.

Hardware above and below fan deck level shall be of silicon bronze or Super
Molybdenum stainless steel for sea water application.

5.9.5 RCC

RCC is most commonly used as basin construction material. Large cooling towers
shall be constructed of RCC to minimise the risk of fire and for larger structure,
higher load carrying capacity.

6. 0 COOLING TOWER COMPONENTS, ACCESSORIES AND BASIN

6.1 CASING

Cooling tower casing acts to contain water within tower, provide an air plenum for
the fan, and transmit wind loads to the tower frame work. It shall be watertight and
shall have corrosion resistant and have fire retardant qualities. It is the enclosure
housing the fill (packing) and drift eliminators. It is normally of RCC or treated
timber with FRP corrugated panel for large towers, timber with FRP corrugated
panel or corrugated asbestos (ACB) for medium size towers and treated timber or
FRP for small towers.

6.2 LOUVERS

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These are provided on the sides of the tower to equalise the air flow into the fill and
to prevent the water drops from falling out. The most utilised louver materials are
FRP or corrugated asbestos sheet or treated timber for all types of towers and pre-
cast, pre-stressed concrete for RCC towers.

6.3 FILL (PACKING)

This is the main component of cooling tower responsible for heat transfer and is of
two types i.e. splash type and film type.

Advantages of splash fill

(a) It reduces air pressure losses.

(b) It is not conducive to clogging.

Disadvantages of splash fill

(a) It is very sensitive to inadequate support.

(b) If proper level is not maintained, there are chances of sagging and
channelling of water and air.

Advantage of film fill

It requires less space for same amount of cooling than the splash type fill.

Disadvantage of film fill

The use of film fill shall be avoided in situations where the circulating water
can become contaminated with debris.

Based on type of application, the type of fill shall be decided.

For splash type - PVC or FRP or treated timber for all towers and sometimes of
RCC for large RCC cooling towers

For film type - PVC

6.4 FILL AND TOWER SUPPORTING STRUCTURE

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INDUCED DRAFT COOLING TOWERS

The fill, casing and fan deck are all supported from the basin and the supporting
structure shall be of RCC or GRP or CS or SS for large towers, treated timber or
GRP or CS or SS for medium and GRP or CS or SS for small towers.

6.5 FAN DECK

This is the deck (floor) at the top ( above the fill ) to provide access to the fan and
water distribution system. The deck shall be of RCC or treated timber or marine
ply timber for large towers and treated timber or marine ply timber for medium and
small towers.

6.6 FANS

Fans create the required air flow through the tower and are driven by electric
motors through gear drives for all towers. The motors shall be suitable for outdoor
location. The fan drive shaft shall be of hollow HDGS or stainless steel. The fan
blades shall be either of cast aluminium alloy or FRP or GRP. In case of corrosive
water, FRP or GRP fan blades shall be used. The gears shall be of enclosed type.
The fan blades shall have manually adjustable pitch.

6.7 FAN CYLINDERS AND RECOVERY STACK

Recovery stack is provided above fan cylinder to recover kinetic energy of air
thereby reducing the power consumption. Suitable air tight access door shall be
provided in the cylinder for approach to the fans and for maintenance of gear box
and fans etc. Suitable removable rail with tripod and handrail shall be provided for
large cooling towers. It is not essential for small towers. Fan cylinder and recovery
stack shall be of RCC or FRP or GRP for large towers and treated timber or FRP
or GRP for small and medium towers.

6.8 DRIFT ELIMINATORS

These are provided at the air outlet from fill, to trap the water particles carried by
the air stream and thereby reduce the drift loss. Most widely used drift eliminators
material is treated timber or PVC.

6.9 WATER DISTRIBUTION SYSTEM

In case of cross-flow tower the hot water is fed to hot water basins or troughs
located on the top of tower by means of hot water inlet pipes. From this basin,
water flows over the fill by gravity through orifices located in hot water basin.

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INDUCED DRAFT COOLING TOWERS

Counter-flow system normally necessitates the use of a pressure-type system of

closed pipe and spray nozzles.

The hot water basin is of RCC or marine plywood for large towers and FRP or
RCC or timber for medium and small towers. The feed pipes are of hot dip
galvanised steel or cast iron. Presently fibre reinforced pipes are used because of
low pressure application, light weight, good resistant to both corrosion and erosion.
Pre-cast and pre-stressed concrete pipes are also used in RCC tower. The nozzles
are of polypropylene or bronze or SS.

6.10 STAIRCASE

This is required for providing approach from ground to the fan deck. For large
towers, one or two staircases one on either side shall be provided and for medium
size tower one staircase is adequate. The staircase is of RCC or treated timber or
HDGS for large tower and of treated timber for medium and small towers.

For small towers only access ladder of HDG steel or treated timber shall be
provided instead of staircase.

6.11 OTHER COMPONENTS AND ACCESSORIES

(a) Fan Deck Illumination

This is required for large towers to provide illumination of deck at night.

(b) Lightning Protection

This is also required only for large cooling towers.

(c) Vibration Limit Switch

This is provided to trip the fan motor in case of excessive vibration of fan.

(d) Vibration Isolators

These are provided if considered necessary, to minimise transfer of vibration

of rotating parts to fan deck and tower structure.

(e) Dual Speed Motors

ISSUE
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INDUCED DRAFT COOLING TOWERS

These are provided only in case where the towers are intended for very
widely varying duty conditions which is achieved by varying the fan speed

(f) Fan Guards

These are provided on top of fan cylinder or recovery stack of medium and
small size towers to prevent birds falling into the stack of standby cell. These
are not essential for large towers in view of large size of fan as the fan noise
keeps the birds away. The guards are normally HDG steel or SS wire mesh.

(g) De-icing System

This is required to be provided only in place having extreme cold climate

which requires passing part of hot water and spraying on to the louvers to
prevent the ice formation.

(h) Hot Water Basin Cover

The hot water distribution basin shall be provided with a suitable cover in
cross-flow cooling towers to avoid direct sun rays falling on the distribution
trough or basin, to minimise algae growth and to prevent choking of
distribution nozzles from external falling objects. In case of dusty
atmosphere, hot water basin cover shall be provided.

(i) Low Oil Level Switch

This is generally provided to trip the fan in case low oil level in gear box.

(j) Mechanical Equipment Removal Devices

These shall be provided in case of large cooling towers. These shall be

provided at fan deck level to remove the mechanical equipment, to lift oil
drums and maintenance tools and tackles. This consists of swivel hoist, track
and dolley arrangement. The removed component can be dollied to the end
of the fan deck, and lowered by means of a properly designed hoisting
structure. This structure shall consist of an endwall derrick or an endwall
davit depending upon magnitude of load.

(k) Screens

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INDUCED DRAFT COOLING TOWERS

Screens shall be provided at the outlet of each basin cell to prevent

suspended particles entering to cooling water pumps. Generally, screens of
12 mm mesh opening shall be provided. The material of construction for
screen shall be carbon steel with epoxy painting or HDGS in case of fresh
water and of SS 316L in case of sea water. Normally, width of screen shall
be 1.2 metres.

(l) Stoplogs

Insertion plate for water-tight stoplogs shall be provided at the outlet of each
basin. Two(2) stoplogs shall be provided to isolate individual basin
compartments during maintenance. Material of construction of stoplogs shall
be FRP with SS316L frame for sea water and carbon steel with epoxy
painting or timber or HDGS for fresh water application. Insertion plate shall
be of SS316L for sea water and carbon steel with epoxy painting for fresh
water.

(m) Monorail with hoist shall be provided for lifting screens and stoplogs.

6.12 COLD WATER BASIN

This holds the re-cooled water falling through the fill and provides an outlet for the
cooled water. The basin is of RCC for large and medium size towers and of steel
with epoxy painting or FRP or steel for smaller towers.

Basin depth may be decided based on following considerations:

(a) Flooded suction and NPSH required for cooling water pumps, if horizontal
pumps are used and submergence and pump dimensions if vertical pumps are
used.

(b) Cooling tower should be able to supply cooling water within acceptable
temperature limits under variable cooling loads during normal operation.

(c) Cooling tower should be able to supply cooling water within acceptable
temperature limits during start-up, shut-down and emergency conditions, if so
specified.

(d) Basin should be able to hold back-flow during pump shut-down and cooling
water shall not overflow into drains. This is particularly important if treated

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INDUCED DRAFT COOLING TOWERS

water is used as cooling water make-up or water is scarce and wastage is to

be minimized.

(e) Basin should have enough reserve capacity during interruption of make-up
water supply.

(f) If basin is to be used as a reservoir for fire water supply, take inputs from
Basic Study for Fire Protection System.
(g) For underground basins, soil conditions and ground water table etc. may be
checked with civil department while deciding the depth of the basin.

The large and medium towers shall be supported on RCC foundation whereas small
cooling tower shall be supported on either concrete pedestals or steel sections.

The basin for large towers may be completely underground whereas the basins for
medium size and small towers may be above ground level, if required, to provide
flooded suction for the pumps.
The cold water outlet from basin shall be through channel for large cooling towers
and through pipes for medium and small towers.

Normally, the cold water basin may be partitioned cell wise to facilitate cleaning
during individual cell maintenance. Outlet of each partition shall be connected to
common sump.

In case of large cooling towers with more than 5 cells, the cold water basin may be
partitioned into two compartments along the length of tower and cleaning of one
compartment of cold water basin may be carried out by shutting down half part of
individual cells of entire cooling tower.

7.0 EVALUATION AND PENALTY FACTORS

7.1 FOR PUMPING HEAD

Increase in cooling tower height i.e. height from basin curb to centre line of riser at
fan deck increases the cooling water pump head

For cooling water circulation pumps

SxQxH
BKW =
367.2 x η

where S = specific gravity of water

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INDUCED DRAFT COOLING TOWERS

Q = Capacity in M3/Hr
H = Differential Head in M
η = Efficiency of pumps

For every metre excess head, there is rise in pump power consumption. For every
rise in excess BKW, the penalty factor (P) shall be calculated as follows:

P = Energy charge in Rs/KwHr x number of operating hours per

year x N x differential power

where N = Capitalisation Factor

( 1 + r/100)n - 1
=
r/100 x (1 + r/100)n

r = Rate of interest in %
n = number of years
P = Penalty in Rs.

7.2 FOR FAN POWER CONSUMPTION

For every KW differential of excess fan power consumption, penalty factor P shall
be calculated as shown in para 7.1

8.0 REFERENCES

References for design and construction features, thermodynamic aspects and testing
requirements of cooling towers are given below :

(a) The Industrial Cooling Tower by Mckelvey and Brooke

(b) BS 4485 Specification for Water Cooling Towers

Part 1 - Glossary of Terms
Part 2 - Methods of Performance Testing
Part 3 - Thermal and Functional Design
Part 4 - Structural Design of Cooling Towers

(c) Cooling tower performance curves published by Cooling Tower Institute

(CTI)

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INDUCED DRAFT COOLING TOWERS

(d) CTI acceptance test procedure as per CTI code ATC 105 for Water
Cooling Towers

(e) Cooling Tower Manual

(f) CTI Bulletin WMS-112, " Pressure Preservatives Treatment of Lumber for
Industrial water"

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TCE FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M6-ME-613-215 DESIGN GUIDE FOR
SHEET i OF iii
HORIZONTAL CIRCULATING WATER PUMPSETS

DESIGN GUIDE FOR

HORIZONTAL CIRCULATING WATER PUMPSETS

FILE NAMES: M6ME215R4.DOC AND

M6ME215R4.DWG

REV. NO. R1 R2 R3 R4
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY DGR Sd/- SCP Sd/- SHN Sd/- VB

CHD. BY RKJ Sd/- MPB Sd/- RKJ Sd/- PDG

R4
APD. BY KG Sd/- SCM/RL Sd/-/Sd/- SCM/RL Sd/-/Sd/- RL

DATE 02.05.1994 06.08.1999 17.08.2002 28.10.2003

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS

TCE.M6-ME-613-215 DESIGN GUIDE FOR

SHEET ii OF iii
HORIZONTAL CIRCULATING WATER PUMPSETS

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 INPUT DATA REQUIRED 1

3.0 APPLICATION 1

4.0 SELECTION OF PARAMETERS 1

5.0 TYPE OF PUMP 3

6.0 CONSTRUCTION FEATURES 3

7.0 MATERIALS OF CONSTRUCTION 4

8.0 PERFORMANCE CHARACTERISTICS 5

9.0 LAYOUT CONSIDERATIONS 5

10.0 MOTORS 5

11.0 PERFORMANCE TEST 5

12.0 NOISE AND VIBRATION 5

13.0 CROSS REFERENCES 6

APPENDICES

1. COOLING WATER REQUIREMENTS 7

2. MATERIALS OF CONSTRUCTION 8

3. PRESSURE ACTING ON A DOUBLE SUCTION 9

IMPELLER

4. DOUBLE FLAT RING TYPE WEARING RING 10

5. CONVENTIONAL STUFFING BOX 11

6. LAYOUT OF SUCTION PIPING 12

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SECTION: REV.
TCE CONSULTING ENGINEERS LIMITED STATUS
TCE.M6-ME-613-
215 DESIGN GUIDE FOR
SHEET iii OF iii
HORIZONTAL CIRCULATING WATER PUMPSETS

REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 24.07.1986 --

R1 02.05.1994 Contents Sheet, Write-up Sheets 3, 4, 9, 11, 12 and Table II

revised.

R2 06.08.1999 Overall Revision

R3 17.08.2002 Clauses 3.0, 4.1, 4.2.1 and 10.0 revised. Clause 4.3.2
added.

R4 28.10.2003 Appendix 2 revised.

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TCE.M6-ME-613-215 DESIGN GUIDE FOR
SHEET 1 OF 12
HORIZONTAL CIRCULATING WATER PUMPSETS

1.0 SCOPE

This design guide deals with selection of parameters, types, construction features,
materials of construction, performance characteristics, tests etc. for horizontal
circulating water pumpsets of cooling system for power plants.

2.0 INPUT DATA REQUIRED

The following data shall be obtained for the selection of the proper pumpset for the
intended service:

(a) Cooling water requirement of the plant, with complete break-up

(b) Normal, maximum and minimum water level in the sump

(c) Minimum and maximum water temperature

(d) Analysis of water

(e) Information regarding screening of water ahead of the pumps by means of

trash racks/screens.

(f) Chlorine dosage and maximum residual chlorine

3.0 APPLICATION

Normally, it is the practice to keep the plant grade level above the highest flood level
to avoid flooding of the power station. Keeping in mind the above, usually it will not
be possible to go in for horizontal pumps for once through cooling system due to the
high suction lift because of variation in water level at the source. Hence, possibility of
using horizontal pumps for once through system is very remote.

In cooling tower installations sometimes it becomes necessary to locate the cooling

tower basin and cold water channels above the grade level due to the soil conditions at
site. It is preferable to go in for horizontal pumps for such installations. It is
recommended to finalise the choice in this case, after cost comparison with the option
of below ground basin with vertical turbine pumps.

4.0 SELECTION OF PARAMETERS

The three important parameters that are to be decided for the pumps are:

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(a) Capacity
(b) Total head

4.1 CAPACITY

4.1.1 The capacity of the pump depends on the total quantity of water required for the
circulating water system and the number of pumps to be provided for the system. The
number of pumps provided could be any of the following alternatives:

(a) Two numbers each of 50% capacity

(b) Three numbers each of 33.3% capacity

(c) Four numbers each of 25% capacity

4.1.2 The approximate cooling water requirements for different sizes of generating units are
given Appendix-1.

4.1.3 The quantity of standby pumps shall be finalised after discussion with client. Typical
guidelines could be:

(a) Nil or minimum standby pumps for fresh water application.

(b) One number standby for (a) and (b) above for sea water application.

(c) For configuration (c) above for seawater application, quantity could be
decided after doing economic analysis of providing standby pump vis-à-vis
loss of generation.

4.2 TOTAL HEAD

Total head comprises static head and friction losses.

4.2.1 Static Head

The static head shall be either the difference in elevation between the water level in the
circulating water sump and the maximum water level or discharge pipe elevation
whichever is higher. For efficient operation of the circulating water pumpsets the
normal water level in the sump shall be considered for computation of the static head.
Minimum water level in sump could be considered in case a prolonged duration of
water level being at minimum level is anticipated.

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HORIZONTAL CIRCULATING WATER PUMPSETS

4.2.2 Friction Head

Friction head is the head necessary to overcome the friction losses in the heat
exchanger, piping, valves and fittings for the system in which the pump operates. The
friction head depends on several factors like velocity of water, type of fittings, inside
surface roughness of the pipeline, length of the pipeline involved in the system etc. The
method of calculation of friction head for a given system is explained in the Design
Guide No. TCE.M6-ME-613-212 “Guide for Calculation of Hydraulic Losses for
Water in Pipes, Fittings and Valves”.

4.3 SPEED

4.3.1 Selection of speed is governed by following considerations:

(a) Type of driver contemplated for the unit

(b) Higher specific speed results in a smaller pump and cheaper drivers.

4.3.2 The pump parameters shall be achievable at a speed corresponding to normally

available frequency.

5.0 TYPE OF PUMP

The pumps could be classified according to the orientation of the suction and discharge
nozzles or could be classified according to the design of the casing. Side suction and
side discharge (horizontal split casing pumps) are generally used. In horizontal split
casing pumps the casing is divided by a horizontal plane through the shaft centre line or
axis. Since both suction and discharge nozzles are in the lower half of the casing the
upper half of the casing could be removed for inspection of the interior without
disturbing the bearings or the piping. The benefit of this type is that the mechanical
design of casing is structurally stable, since the impeller is supported by bearings on
either side of the impeller.

6.0 CONSTRUCTION FEATURES

6.1 ENCLOSED IMPELLER

Only enclosed impellers of double suction type are used for these pumps. The impeller
incorporates shroud that totally encloses the impeller waterways from the suction eye
to the periphery. This design prevents the leakage of water between the impeller and

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HORIZONTAL CIRCULATING WATER PUMPSETS

its side plates. However, a running joint must be provided between the impeller and
the casing to separate the discharge and suction chambers of the pumps. The thrust
developed for a closed impeller is minimum.

6.2 DOUBLE SUCTION IMPELLER

In a double suction impeller theoretically a hydraulic axial balance exists with the
pressure on one side of the impeller equal to and counter balancing the pressure on the
other side of the impeller. However, in practice it may not be possible to achieve this
hydraulic balance. The forces acting on a double suction impeller is shown in
Appendix-3.

6.3 WEARING RINGS

Wearing rings provide an easily and economically renewable leakage joint between
impeller and casing. The material of the wearing ring shall be softer than the impeller
material so that impeller does not get worn out. Some times pumps are provided with
two wearing rings, one on the casing and the other on the impeller. A double flat-ring
construction type of wearing ring is shown in Appendix-4.

6.4 SHAFT COUPLING

The pump shaft is to be connected to the motor shaft by means of flexible/spacer

coupling.

6.5 SHAFT SLEEVE

The shaft sleeve to be provided to protect shaft from direct wear.

6.6 STUFFING BOX

If the pump works with suction lift and the pressure at the interior of stuffing box end is
below atmospheric, stuffing box prevents air leakage into the pump. If the pressure
inside the pump is above atmospheric the stuffing box prevents the liquid being
pumped from leaking out. A conventional stuffing box used in a horizontal pump is
shown in Appendix-5. Mechanical seal instead of gland packing also can be provided
to prevent leakage.

6.7 LUBRICATION AND COOLING OF PUMPS

The stuffing box gland/mechanical seal shall be supplied water for

lubrication/cooling/sealing of the stuffing box packing/mechanical seal. The water for
lubrication/cooling/sealing shall be taken from the pump discharge itself. When pump

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is handling seawater, filtered seawater should be used.

7.0 MATERIALS OF CONSTRUCTION

The materials of construction of the various components of the pump shall be selected
based on the type of water being handled. The materials shall be so selected that
corrosion of the parts is prevented which in turn reduces the maintenance of the pump.
The materials to be adopted for various components of the pump are indicated in the
Appendix-2.

8.0 PEFORMANCE CHARACTERISTICS

The pump at constant speed delivers any capacity from zero to maximum value
depending on the size, design and suction condition of the pump. The pump shall have
stable rising (H Vs Q) characteristic curve from run out flow to no flow condition. The
maximum head developed by the pump shall be at shut off condition. The pumps shall
operate at the best efficiency point. At least 1 MLC difference shall be maintained
between (NPSHa – NPSHr) throughout NPSH curve.

9.0 LAYOUT CONSIDERATIONS

The sump shall be so designed that the velocity of water in the sump is sufficiently low
not to cause any turbulence near the pump. The sump dimensions shall be based on
the recommendations of Hydraulic Institutes Standard. Layout of suction piping with
tentative dimensions is given in Appendix-6 (also refer design guide TCE.M6-ME-
613-213 ”Design Guide for Pump Sump”).

10.0 MOTORS

Normally, circulating water pumps require 6.6 kV or 3.3 kV, 3 phase, 50 Hz, motors.
The selection of the proper motor rating is a very important factor in satisfactory
operation of the pump sets. The motor rating shall be at least 116% of the power
required by the pump at duty point. The enclosure for the motors shall be Totally
Enclosed Fan Cooled (TEFC), Circulating Air Closed Air (CACA) or Circulating Air
Closed Water (CACW). CACA motors though costlier than CACW motors, are
normally preferred as it eliminates the water circulation arrangement for motor.

11.0 PERFORMANCE TEST

Performance test of prototype pump shall be conducted at manufacturer’s works as

per BS: 5316, Part 2/ISO 3555 to find out whether the pumps meet the guaranteed
values of capacity, head, efficiency and power input.

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12.0 NOISE AND VIBRATION

After installation of pumpsets the following parameters are to be checked:

(a) The noise level of the pumpset shall not exceed 85 dBA measured at a
distance of 1.86 m from the outline of the equipment.

(b) The velocity of vibration shall not exceed 4.5 mm/sec (Refer ISO-10816-
1/BS: 7854 Part-I).

13.0 CROSS REFERENCES

This document makes reference to the following standard documents:

DOCUMENT NO. DOCUMENT TITLE

TCE.M6-ME-613-212 Guide for Calculation of Hydraulic losses for Water in

Pipes, Fittings and Valves

TCE.M6-ME-613-213 Design Guide for Pump Sump

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TCE.M6-ME-613-215 DESIGN GUIDE FOR

SHEET 7 OF 12
HORIZONTAL CIRCULATING WATER PUMPSETS

APPENDIX - 1

COOLING WATER REQUIREMENTS

DESIGN GUIDE FOR

TOTAL HEAD AND NPSH CALCULATIONS FOR
CENTRIFUGAL PUMPS

FILE NAME: M6ME217R4.DOC

REV. NO. R1 R2 R3 R4
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY DVL Sd/- MMK Sd/- MMK Sd/- SDP

CHD. BY OKM Sd/- TSR Sd/- TSR Sd/- TSR

R4
APD. BY KG Sd/- RL Sd/- RL Sd/- RL

DATE 29.11.984 17.01.1998 02.01.2001 02.02.2004

TCE FORM NO. 020 R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS

TCE.M6-ME-610-217 DESIGN GUIDE FOR

TOTAL HEAD AND NPSH CALCULATIONS FOR SHEET ii OF iii
CENTRIFUGAL PUMPS

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 TYPICAL PUMP SKETCH 1

3.0 TOTAL HEAD CALCULATIONS 1

4.0 NPSH CALCULATIONS 2

ISSUE
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TCE CONSULTING ENGINEERS LIMITED SECTION: REV. STATUS

TCE.M6-ME-610-217 DESIGN GUIDE FOR

TOTAL HEAD AND NPSH CALCULATIONS FOR SHEET iii OF iii
CENTRIFUGAL PUMPS

REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 10.09.1981 --

R1 29.11.1984 --

R2 17.01.1998 Reformatted in MS Word.

R3 02.01.2001 Generally revised.

R4 02.02.2004 Reformatted.

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TCE FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP

TCE.M6-ME-610-217 DESIGN GUIDE FOR

TOTAL HEAD AND NPSH CALCULATIONS FOR SHEET 1 OF 2
CENTRIFUGAL PUMPS

1.0 SCOPE

This document gives guidelines for calculating total head and Net Positive Suction
Head (NPSH) for centrifugal pumps.

2.0 TYPICAL PUMP SKETCH

EL.Ed Pd

EL.En
EL.Es Ps

PSSSSS
DISCHARGE VESSEL

SUCTION VESSEL

C EL.Ep

PUMP

3.0 TOTAL HEAD CALCULATIONS

SL. NO. ITEM SYMBOL UNIT FORMULA VALUE

3.1 Elevation of water level in Es M
suction vessel
3.2 Elevation of water level in Ed M
discharge vessel
3.3 Elevation of centre-line of En M
nozzle on discharge vessel
3.4 Elevation of centre-line of pump Ep M
3.5 Static suction head hs MLC Es - Ep
3.6 Friction losses in suction piping hfs MLC
and entry losses
3.7 Gauge pressure in suction vessel Ps Kgf/
cm2g
3.8 Specific gravity of the liquid S
handled

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TCE.M6-ME-610-217 DESIGN GUIDE FOR

TOTAL HEAD AND NPSH CALCULATIONS FOR SHEET 2 OF 2
CENTRIFUGAL PUMPS

SL. NO. ITEM SYMBOL UNIT FORMULA VALUE

3.9 Suction head Hs MLC hs - hfs +
(Ps × 10 )/S
3.10 Static discharge head hd MLC (Greater of
Ed or En) -
Ep
3.11 Friction losses in discharge hfd MLC
piping, equipment and the exit
losses
3.12 Gauge pressure in discharge Pd Kgf/
vessel cm2 g
3.13 Delivery head Hd MLC hd + hfd +
(Pd × 10)/S
3.14 Total head H MLC Hd - Hs

4.0 NPSH CALCULATIONS

SL.NO. ITEM SYMBOL UNIT FORMULA VALUE

4.1 Absolute vapour pressure at the Pv Kgf/
temperature at which liquid is cm2
handled
4.2 Absolute atmospheric pressure Pa Kgf/
cm2
4.3 Net Positive Suction Head NPSH MLC (Pa × 10)/S +
Available (NPSH A) Hs -
(Pv × 10 )/S

NOTES

1. All elevations shall be considered from common datum.

2. Elevations mentioned correspond to normal conditions. However, these shall be cross-

checked with the extreme conditions.

3. Ps and Pd are positive if the pressure is above atmospheric pressure and negative if the
pressure is below atmospheric pressure.

4. Hs and hs may either be positive or negative.

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CENTRIFUGAL PUMPS

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TCE.M6-ME-811-301 DESIGN GUIDE FOR SHEET

i OF iii
AIR-CONDITIONING LOAD CALCULATIONS

DESIGN GUIDE FOR

AIR-CONDITIONING LOAD CALCULATIONS

REV. NO. R0 R1 R2 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY PRJ Sd/- HRK Sd/- HRK

CHD. BY DJ Sd/- PRJ Sd/- PRJ R2

APD. BY JSK Sd/- RL Sd/- RL

DATE 22.12.1988 27.12.1999 01.12.2002

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE

TCE.M6-ME-811-301 DESIGN GUIDE FOR SHEET

ii OF iii
AIR-CONDITIONING LOAD CALCULATIONS

FILE NAME: M6ME301R2.DOC

REV. NO. R0 R1 R2 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY PRJ Sd/- HRK Sd/- HRK

CHD. BY DJ Sd/- PRJ Sd/- PRJ R2

APD. BY JSK Sd/- RL Sd/- RL

DATE 22.12.1988 27.12.1999 01.12.2002

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS

TCE.M6-ME-811-301 DESIGN GUIDE FOR SHEET ii OF iii

AIR-CONDITIONING LOAD CALCULATIONS

CONTENTS

SL. NO. TITLE SH.NO.

1.0 SCOPE 1

2.0 INPUT DATA 1

3.0 COMPONENTS AIR-CONDITIONING LOAD 2

4.0 ESTIMATION OF AIR-CONDITIONING LOAD 5

5.0 APPARATUS DEW POINT 27

6.0 DEHUMIDIFIED AIR FLOW RATE 28

7.0 REFERENCES 28

APPENDICES

1. TYPICAL AIR-CONDITIONING PSYCHROMETRIC 29

PROCESS

2. SAMPLE AIR-CONDITIONING LOAD CALCULATIONS 30

3. ASHRAE PSYCHROMETRIC CHART NO. 1 FOR 41

NORMAL TEMPERATURES AT SEA LEVEL

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REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 88.12.22 ----------------

R1 99.12.27 Completely revised.

R2 02.12.01 Generally revised.

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1.0 SCOPE

This document outlines the procedure for performing air-conditioning cooling load,
heating load and dehumidified air flow rate calculations.

2.0 INPUT DATA

Following input data shall be collected from various sources like client, process
collaborator, other groups in the mechanical department, other departments, bidders
and vendors.

2.1 Location of the site and the plot plan

2.2 Latitude and altitude of the site

2.3 Names of areas to be air-conditioned

2.4 Equipment layout drawings of the areas to be air-conditioned

2.5 Architectural drawings and civil Reinforced Cement Concrete (RCC) or

structural steel drawings of the areas to be air-conditioned
2.6 Outside design conditions like Dry Bulb Temperature (DBT), Wet Bulb
Temperature (WBT) and Relative Humidity (RH) for summer, monsoon and
winter and daily temperature range

2.7 Inside design conditions and internal loads for each of the areas to be air-
conditioned
(a) DBT range
(b) RH range

(c) Lighting loads

(d) Sensible and latent equipment heat loads of heat sources within and
adjacent to the air-conditioned areas with specific periodic loading
patterns, if any
(e) Occupancy
(f) Fresh air and exhaust air requirements, if any
(g) Filtration and cleanliness requirements, if any
(h) Pressurisation requirements, if any
(i) Air flow pattern requirements, if any
(j) Hazardous area classification

2.8 Duration of air-conditioning for each of the areas to be air-conditioned

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2.9 Availability of cooling water, make-up water, quality of water, inlet and outlet
pressures and temperatures

2.10 Specific requirements like future expansion plans and provisions required to be
incorporated at present

Some of the input data indicated above may not be readily available at the time of
performing these calculations. Appendices 1 to 4 of TCE.M1-ME-811-301 give
guidelines for assuming such data.

3.0 COMPONENTS OF AIR-CONDITIONING LOAD

3.1 STRUCTURAL HEAT GAIN

3.1.1 Sensible Heat Gain

(a) External Walls

This component of heat gain is by virtue of the Equivalent Temperature

Difference (ETD) across walls, ceiling, exposed roof or floor RCC slabs
and door or window glass. The ETD is the DBT difference across the wall
and the outdoor. Additional corrections in the temperature differential are
due to conduction across the surface, convection and incident radiation on
the surface, month of the year, time of the day, storage effect due to the heat
capacity of the structure, the latitude and the orientation of the building or
structure with respect to the true north. The estimation of this component of
heat gain requires the estimation or establishing of the following parameters
for each of the surfaces of the structure which are exposed to the outside:

(i) Heat transfer area

(ii) Heat transfer coefficient

(iii) ETD

(b) Internal Walls (Partition Walls)

This component of heat gain is by virtue of the temperature difference across

the internal walls of the building, i.e. the areas of the building adjacent to the
area to be air-conditioned. The estimation of this component of heat gain
requires the estimation or establishing of the following parameters for each
of the surfaces of the structure which are not exposed to the outside:

(i) Heat transfer area

(ii) Heat transfer coefficient

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(iii) Temperature difference (∆T)

3.1.2 Latent Heat Gain

The structural heat gain also includes the latent heat load due to the moisture
transmission across the walls, roof or ceiling and floor slabs of the structure or by
ingress with the air that enters the room through door openings, fixed wall openings
for conveyers or open windows. This load component is especially significant for
areas having inside design RH values of 45% and lower. The moisture transmission
load is a function of the differential vapour across the structure.

3.2 FENESTRATION HEAT GAIN

This component of heat gain considers the radiation entering the air-conditioned area
through exposed glass surfaces. The conduction and convection components of
fenestration heat gain have been described in para 3.1.1. This component is not
normally applicable to internal walls. The estimation of this component requires the
estimation or establishing of the following parameters:

(a) Glass area

(b) Glass transmittance factor

(c) Glass Solar Heat Gain Factor (SHGF)

3.3 INFILTRATION HEAT GAIN

This component is due to ambient air leaking into the air-conditioned area through
gaps between door or window frames and their shutters, cracks in the walls etc. The
estimation of this component requires the estimation or establishing of the following
parameters:

(a) Area of gaps between door and window frames, cracks in walls etc.

(b) Air pressure difference across the gap or crack

3.4 INTERNAL HEAT GAIN

This component is due to heat dissipation by the equipment, people and lighting. The
estimation of this component requires the estimation or establishing of the following
parameters:

(a) Sensible and latent heat dissipation loads from equipment, the locations and
quantities of the equipment

(b) Number of people occupying each of the areas and the activities performed
by these people
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(c) Number, type (fluorescent or incandescent) of lighting fixtures in each of the

areas and their rating in watts. In some cases special fixtures are provided
which also serve as return air inlets. Such fixtures (Troufers) do not reduce
the total heat dissipation from the lighting fixture but reduce the lighting heat
dissipation into the room. The reduction in the lighting heat dissipation into
the room is instead transferred to the return air, reducing the room sensible
heat gain and consequently the room dehumidified air flow rate. This heat
dissipation load, within the room and in the return air, shall be furnished by
the electrical department from approved vendor drawings or catalogues.

The diversity factor for the heat dissipation from each of the above shall be
considered.

3.5 FAN AND DUCT HEAT GAIN

This component is due to the supply air fan power consumption and the heat gain to
the supply and return air duct. In addition to the above, a notional heat gain is
considered for the leakage from the supply air and the return air. Heat gain from
return air fan, if provided, shall be added to the return air.

3.6 FRESH AIR HEAT GAIN

This component is due to the fresh air introduced into the air-conditioned area to
maintain indoor air quality or pressurisation. The estimation of this component
requires the estimation or establishing of the following parameters:

(a) Quantity of fresh air

(b) Cooling coil bypass factor

3.7 RETURN AIR HEAT GAIN

The heat gain to the return air, after collection from the area to be air-conditioned
may form a significant proportion of the total cooling load. This cooling load does
not form part of the room cooling load and therefore has no contribution to the
dehumidified air flow rate calculation. The return air heat gain shall be estimated for
the heat gain through the return air duct, which may be sheet metal or masonry.

The heat gain to return air, when collected above the false ceiling, from exposed
roof or ceiling is theoretically not part of the room load and therefore should not be
considered as the room heat gain which is considered for the estimation of the
dehumidified air flow rate. However, to simplify the procedure for the air-
conditioning load calculation, this load is considered as part of the room load. This
will give about 2 to 3% higher dehumidified air flow rate which is more conservative
and acceptable. This return air heat gain above the false ceiling can, if so desired by

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the designer, be estimated by an iterative procedure and considered for the

dehumidified air flow rate estimation.

The parameters which are to be established are :

(a) Overall heat transfer coefficient across the return air duct

(b) Area of the return air duct

(c) ETD for the return air duct

ETD shall be estimated for return air routed through masonry or exposed insulated
sheet metal ducts, which are exposed to the ambient. In case the ducts are located
indoors, the DBT difference shall be the temperature difference across the return air
duct wall.

4.0 ESTIMATION OF AIR-CONDITIONING LOAD

4.1 STRUCTURAL HEAT GAIN

4.1.1 Sensible Heat Gain

(a) Heat Transfer Area

The areas of the heat transfer surfaces of each the air-conditioned areas
shall be estimated from the architectural drawings. The heat transfer areas
include the following:

(i) Wall face areas. These include walls exposed to the ambient
(exposed walls) and walls which are internal to the building.

(ii) Floor, ceiling or exposed roof RCC slab

(iii) Glass areas. These are for doors or windows. These, like walls,
could also be exposed or internal.

The orientation of the respective exposed walls and glass surfaces, above
and below the false ceiling, shall be noted with respect to the true north.

The wall and slab area shall be estimated considering the grouping of the
various areas, for the purpose of combining the areas under one unit or
under multiple units, each being operated separately. For example, in case
two adjacent areas are being air-conditioned simultaneously and the inside
design temperatures are similar, there will be no heat transfer between these
areas. The common glass, wall or RCC slab between these areas shall not
be considered for heat transfer area calculations. In case the areas have
different hours of operation of the air-conditioning systems, the common
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glass, walls and RCC slabs shall be considered for heat transfer for the
duration of time that either of the areas is not air-conditioned.

Normally, it is recommended that for adjacent areas, which are separately

air-conditioned, the common glass, walls and RCC slabs be considered for
heat transfer, for each of the areas. This would give a higher cooling load
estimate than that considering the adjacent rooms being air-conditioned.
However, the designer has to take an overall system design approach while
considering this element of heat gain.

(b) Heat Transfer Coefficient

The overall heat transfer coefficient (U-factor) shall be estimated for each of
the walls, ceiling and floor slabs and glass areas. The U-factor is the
reciprocal of the sum of the total thermal resistance across the slab, wall or
glass. The total thermal resistance shall be estimated for each component of
the thermal resistance as listed below:

(i) Walls

• Outer air film

• Outer cement plaster

• Wall (Ordinary brick, hollow concrete block, concrete,

plywood etc.)

• Inner cement plaster

• Inner air film

(ii) Floor Slabs, Roof or Ceiling

• Outer air film

• Floor finish- tiled finish for floors or water-proofing finish for

exposed roof slabs

• RCC slab

• Thermal insulation

• Inner cement plaster

• Inner air film

Thermal resistances for above shall be referred to in ASHRAE

Handbook, Fundamentals 1993 Edition, Chapter 22, Tables 1, 2, 3
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and 4. The construction materials for the walls, RCC slabs, window
or door glass etc. shall be taken from the architectural drawings. If
necessary, the civil engineer may be consulted. The above
components are listed as guidelines and are generally adequate for
most applications. The components for specific applications or
projects may be established from the respective architectural
drawings.

The insulation thickness required to be provided, shall be calculated

for prevention of condensation on the external surfaces or the
optimised insulation thickness considering the operating and
installation costs for the insulation, whichever is more stringent. For
exposed roofs, thermal insulation is generally provided out of 50
mm thick expanded polystyrene or equivalent insulation material.

In cases where the room temperatures are low enough to cause

condensation on the external surface of the room wall, it may be
necessary to provide thermal insulation. This requirement of thermal
insulation may be verified by the following equation:

Tod < Tr + (Tod – Tr) x (U/U1)

Where,

Tod = Dew point temperature of the area adjacent to the

air-conditioned room

Tr = DBT of air-conditioned room

U = Overall heat transfer coefficient of the common wall

U1 = The reciprocal of the common wall thermal

resistance considered without the wall outer air film
resistance

The outdoor air dew point temperature shall be taken from the
psychrometric chart for the most stringent conditions. Generally, this
will be for the monsoon season. In cases where the adjacent area is
to be maintained at a high RH, the same shall be considered.

Thermal insulation may also be provided for conservation of heat in

case of heating applications. This insulation may serve a dual
purpose. It may serve as a heat conservator to minimise the heating
load during winter and to minimise the heat gain during summer. This
will be applicable to sites located in regions having extreme climates.
In case of dual duty, the thermal insulation thickness for the more
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stringent requirement shall be provided and considered for the air-

conditioning load estimation.

(iii) The heat transfer coefficients in Watts /M2 OC for conduction

through glass shall be taken from the table 1:

TABLE 1
HEAT TRANSFER COEFFICIENTS FOR CONDUCTION THROUGH GLASS

VERTICAL GLASS HORIZONTAL GLASS

SINGLE DOUBLE TRIPLE SINGLE DOUBLE

SUMMER WINTER SUMMER WINTER

AIR SPACE THICKNESS -- 6 12.5 20 6 12.5 20 -- -- 6 6

mm
TO TO
100 100

WITHOUT STORM 6.4 3.5 3.1 3.0 2.3 2.0 1.9 4.9 7.9 2.8 4.0
WINDOWS

WITH STORM WINDOWS 3.1 3.5 3.1 3.0 2.3 2.0 1.9 2.4 3.6 2.8 4.0

SOURCE: ISHRAE 1997, PART I, TABLE 6, PAGE 1.7

Table 2 gives the uncorrected ETD (∆tes for wall in shade and ∆tem for
wall exposed to the design conditions) values for varying weights of wall.

Table 3 gives the uncorrected ETD (∆tes for roof in shade and ∆tem for
roof exposed to the design conditions) values for varying weights of the roof
structure.

Table 4 gives the corrections (∆tc) to be made to the uncorrected ETD

(∆tes and ∆tem) from tables 2 and 3 for a variation in the outdoor to indoor
DBT difference and daily range.

The corrected ETD shall be calculated as per the following equation:

ETD = ∆tesc + {(∆temc - ∆tesc) x c x Rs/Rm}

where,

ETD = Corrected ETD across the wall or roof (OC)

∆tesc = Corrected ETD of the roof or the wall under consideration

in shade (OC).
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= ∆tes + ∆tc

∆temc = Corrected ETD of the roof or the wall under consideration

subjected to the design condition. i.e. load on the exposed
roof or on walls facing the respective directions (0C).

= ∆tem + ∆tc

c = Correction factor for colour shade of wall

= 1 for dark coloured roof or wall

= 0.778 for medium coloured roof or wall

= 0.556 for light coloured roof or wall

Rs = Maximum Solar Heat Gain Factor (SHGF) incident on glass

or wall or horizontal roof for the month and latitude desired.
Rs values shall be taken from ASHRAE Handbook,
Fundamentals, 1993 Edition, Chapter 27, Tables 12 to 18.
(Watts /M2)

Rm = Maximum SHGF incident on glass or wall or horizontal roof

for the month of July and latitude of 400 North. Rm values
shall be taken from ASHRAE Handbook, Fundamentals,
1993 Edition, Chapter 27, Table 15. (Watts /M2)

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TABLE 2
EQUIVALENT TEMPERATURE DIFFERENCE ∆ tes AND ∆ tem ° C
FOR DARK COLOURED, SUNLIT AND SHADED WALLS;
35°C OUTDOOR DBT; 27°C INDOOR DBT; 11°C DAILY RANGE;
24 HOUR OPERATION; JULY AND 40°N LATITUDE
TCE.M6-ME-811-301

EXPOSURE SOUTH SOUTH EAST EAST NORTH EAST

TIME WT.OF WALL 683 488 293 98 683 488 293 98 683 488 293 98 683 488 293 98
Kg/M 2
6 3.9 2.2 -0.6 -0.6 5.0 3.9 0.6 5.6 6.1 2.8 -0.6 0.6 2.8 2.2 -0.6 2.8
7 3.3 2.2 -1.7 -1.1 4.4 3.9 0.6 3.3 5.6 2.8 -0.6 9.4 2.8 1.7 -1.1 8.3
8 3.3 1.1 -2.2 -2.2 4.4 3.3 0.0 7.2 5.6 3.3 0.0 16.7 3.3 2.2 -1.1 12.2
AM 9 2.8 1.1 -1.7 0.6 4.4 3.3 7.2 10.6 5.0 4.4 11.7 18.3 3.3 2.2 2.8 12.8
10 2.2 1.1 -1.1 2.2 4.4 3.3 11.1 14.4 4.4 7.8 16.7 20.0 3.3 2.2 13.3 13.3
11 2.2 1.7 3.9 7.8 3.9 6.1 13.3 15.0 5.0 11.1 17.2 19.4 3.3 5.6 12.2 10.6
12 2.2 2.2 6.7 12.2 3.3 8.9 15.6 15.6 5.6 13.3 17.2 17.8 3.3 8.9 11.1 7.8
1 2.2 4.4 11.1 15.0 6.1 9.4 14.4 14.4 8.3 13.9 10.6 11.1 5.6 8.3 8.3 7.2
2 2.2 6.7 13.3 16.7 7.8 10.0 13.9 13.3 10.0 13.3 7.8 6.7 7.8 7.8 5.6 6.7
3 3.9 8.3 13.9 15.6 8.3 10.6 11.7 10.6 10.6 11.1 7.2 7.2 8.9 6.7 6.1 7.2
4 5.6 8.9 14.4 14.4 8.9 10.0 10.0 8.9 10.0 10.0 6.7 7.8 7.8 5.6 6.7 7.8
5 7.2 10.0 12.8 11.1 10.0 8.9 8.3 8.3 9.4 8.9 7.2 7.8 6.7 6.1 7.2 7.8
DESIGN GUIDE FOR

6 7.8 10.0 11.1 8.9 8.9 7.8 7.8 7.8 8.9 7.8 7.8 7.8 5.6 6.7 7.8 7.8
PM
7 8.3 8.3 8.3 6.7 8.3 7.2 7.2 6.7 7.8 7.8 7.2 6.7 5.6 6.7 7.2 6.7
8 8.9 7.8 6.7 5.6 7.8 6.7 6.7 5.6 6.7 7.8 6.7 5.6 5.6 6.7 6.7 5.6
9 8.9 6.1 5.6 3.9 7.2 6.1 6.1 4.4 7.2 7.2 6.1 4.4 5.6 6.1 6.1 4.4
TCE CONSULTING ENGINEERS LIMITED

10 7.8 5.6 4.4 3.3 6.7 5.6 5.6 3.3 7.8 6.7 5.6 3.3 5.6 5.6 5.6 3.3
AIR-CONDITIONING LOAD CALCULATIONS

11 6.7 5.0 3.3 1.7 6.7 5.6 4.4 2.2 7.8 6.1 4.4 2.2 5.6 5.0 4.4 2.2
12 5.6 4.4 2.2 1.1 6.7 5.6 3.3 1.1 7.8 5.6 2.8 1.1 5.6 4.4 3.3 1.1
1 5.6 4.4 1.1 0.6 6.1 5.0 2.8 0.0 7.2 5.0 2.2 0.0 5.0 3.9 2.2 0.0
2 5.0 3.9 0.6 0.6 6.1 5.0 2.2 -0.6 7.2 4.4 1.7 -0.6 5.0 3.3 1.1 -1.1
AM 3 5.0 3.3 0.6 0.0 5.6 4.4 1.7 -0.6 6.7 3.9 0.6 -1.1 4.4 3.3 0.6 -1.7

120R1
10 OF 41

4 4.4 3.3 0.0 0.0 5.6 4.4 1.7 -1.1 6.7 3.9 0.6 -1.7 3.9 2.8 0.0 -2.2
5 3.9 2.8 -0.6 -0.6 5.0 3.9 1.1 -1.1 6.7 3.3 0.0 -1.7 3.9 2.8 -0.6 -1.1

TCE FORM NO.

SECTION: WRITE-UP
SHEET

SOURCE: ISHRAE 1997, PART I, TABLE 9, PAGE 1.14

R2
ISSUE
TABLE 2 (CONTD.)
EQUIVALENT TEMPERATURE DIFFERENCE ∆ tes AND ∆ tem ° C
FOR DARK COLOURED, SUNLIT AND SHADED WALLS;
35°C OUTDOOR DBT; 27°C INDOOR DBT; 11°C DAILY RANGE;
TCE.M6-ME-811-301

24 HOUR OPERATION; JULY AND 40°N LATITUDE

EXPOSURE NORTH OR SHADED WALL NORTH WEST WEST SOUTH WEST

TIME WT.OF WALL 683 488 293 98 683 488 293 98 683 488 293 98 683 488 293 98
Kg/M 2
6 0.6 0.6 -1.7 -1.7 4.4 2.8 -1.1 -1.7 6.7 3.9 1.1 -1.1 4.4 3.9 1.1 -1.1
7 0.6 0.6 -1.7 -1.7 3.9 2.2 -1.7 -2.2 6.1 3.9 0.6 -1.7 4.4 2.8 0.6 -2.2
8 0.0 0.0 -2.2 -2.2 3.3 2.2 -2.2 -2.2 5.6 3.3 0.0 -2.2 4.4 3.3 0.0 -2.2
AM 9 0.0 0.0 -1.7 -1.7 3.3 2.2 -1.7 -1.1 5.0 3.3 0.0 -1.1 4.4 2.8 0.0 -1.1
10 0.0 0.0 -1.1 -1.1 3.3 2.2 -1.1 0.0 4.4 3.3 0.0 0.0 4.4 2.2 0.0 0.0
11 0.0 0.0 -0.6 0.6 3.3 2.2 0.0 1.7 4.4 3.3 1.1 1.7 3.9 2.8 0.6 2.2
12 0.0 0.0 0.0 2.2 3.3 2.2 1.1 3.3 4.4 3.3 2.2 3.3 3.3 3.3 1.1 3.3
1 0.0 0.6 1.7 4.4 3.3 2.2 3.3 5.6 5.0 3.9 3.9 7.8 3.3 3.9 4.4 10.6
2 0.0 1.1 3.3 5.6 3.3 2.2 4.4 6.7 5.6 4.4 5.6 11.1 3.3 4.4 6.7 14.4
3 0.6 1.7 4.4 6.7 3.3 2.8 5.6 10.6 5.6 5.6 10.6 17.8 3.9 6.7 13.3 18.9
4 1.1 2.2 5.6 7.8 3.3 3.3 6.7 13.3 5.6 6.7 14.4 22.2 4.4 7.8 17.8 22.2
DESIGN GUIDE FOR

5 1.7 2.8 6.1 7.2 3.9 5.0 11.7 18.3 6.1 9.4 18.9 25.0 5.0 10.6 19.4 22.8
6 2.2 2.8 6.7 6.7 4.4 6.7 16.7 22.2 6.7 11.1 22.2 26.7 5.6 12.2 20.0 23.3
PM
7 2.8 2.8 6.7 5.6 5.0 9.4 17.2 20.6 7.8 13.9 22.8 18.9 8.3 12.8 19.4 16.7
8 3.3 4.4 6.7 4.4 5.6 11.1 17.8 18.9 8.9 15.6 20.0 12.2 10.0 13.3 18.9 13.3
9 3.9 3.9 5.6 3.3 7.8 11.7 11.7 10.0 11.7 15.0 15.6 7.8 10.6 12.8 11.1 6.7
TCE CONSULTING ENGINEERS LIMITED

AIR-CONDITIONING LOAD CALCULATIONS

10 4.4 3.3 4.4 2.2 10.0 12.2 6.7 3.3 12.2 14.4 8.9 4.4 11.1 12.2 5.6 3.3
11 3.9 2.8 3.3 1.1 10.6 7.8 4.4 2.2 12.8 10.6 5.6 2.8 7.2 8.3 3.9 2.2
12 3.3 2.2 2.2 0.0 11.1 4.4 3.3 1.1 12.2 7.8 3.3 1.1 4.4 5.6 3.3 1.1
1 2.2 1.7 1.1 0.0 8.9 3.9 2.2 0.0 11.1 6.7 2.8 0.6 4.4 5.6 2.8 0.6
2 1.7 1.7 0.6 -0.6 7.2 3.9 1.7 -0.6 10.0 6.1 2.2 0.0 4.4 5.0 2.2 0.6
AM 3 1.1 1.1 0.0 -0.6 6.1 3.3 0.6 -0.6 8.9 5.6 1.7 0.0 4.4 5.0 2.2 0.0

120R1
11 OF 41

4 1.1 1.1 -0.6 -1.1 5.6 3.3 0.0 -1.1 8.3 5.0 1.7 -0.6 4.4 4.4 1.7 -0.6
5 0.6 0.6 -1.1 -1.1 5.0 2.8 -0.6 -1.1 7.2 4.4 1.1 -0.6 4.4 3.9 1.7 -0.6

TCE FORM NO.

SECTION: WRITE-UP
SHEET

R2
SOURCE: ISHRAE 1997, PART I, TABLE 9, PAGE 1.14

ISSUE
TABLE 3
EQUIVALENT TEMPERATURE DIFFERENCE ∆ tes AND ∆ tem ° C
FOR DARK COLOURED, SUNLIT AND SHADED ROOFS; 35 °C OUTDOOR DBT; 27°C INDOOR DBT;
11°C DAILY RANGE; 24 HOUR OPERATION; JULY AND 40°N LATITUDE
TCE.M6-ME-811-301

CONDITION SHADED SPRAYED COVERED WITH EXPOSED TO SUN

WATER
TIME WT. OF ROOF 293 195 98 293 195 98 293 195 98 391 293 195 98 49
Kg/M2

6 -1.7 -2.8 -2.8 -0.6 -1.1 -2.2 -0.6 -1.7 -2.8 7.2 5.0 2.2 0.0 -2.2
7 -1.7 -2.8 -2.8 -1.1 -1.1 -1.1 -1.1 -1.1 -1.1 6.7 4.4 1.7 -0.6 -3.3
8 -1.1 -2.2 -2.2 -1.1 -0.6 0.0 -1.1 -0.6 0.0 6.1 3.3 1.1 -1.1 -3.9
AM 9 -1.1 -1.7 -1.1 -1.1 -0.6 1.1 -1.1 -0.6 1.1 6.1 3.9 1.7 -0.6 -2.8
10 -1.1 -1.1 0.0 -1.1 0.0 2.2 -1.1 0.0 2.2 6.7 4.4 3.3 1.1 -0.6
11 -0.6 0.0 1.1 0.0 1.1 4.4 1.1 2.8 5.6 7.2 6.1 5.6 5.0 3.9
12 0.0 1.1 3.3 1.1 2.8 6.7 2.8 5.6 8.9 8.9 8.9 8.9 8.9 8.3
1 1.1 2.8 5.0 2.8 5.0 8.3 3.9 7.2 10.6 12.2 12.2 12.8 12.8 13.3
2 2.2 4.4 6.7 4.4 7.2 10.0 5.6 8.3 12.2 14.4 15.0 15.6 16.7 17.8
3 3.3 5.6 7.2 5.6 7.8 9.4 6.7 8.3 11.1 15.6 17.2 18.3 20.0 21.1
4 4.4 6.7 7.8 6.7 7.8 8.9 7.8 8.9 10.0 17.8 19.4 21.1 22.8 23.9
5 5.0 7.2 7.2 7.2 7.8 8.3 8.3 8.3 8.9 19.4 21.1 22.2 23.9 25.6
DESIGN GUIDE FOR

6 5.6 6.7 6.7 7.8 7.8 7.8 8.9 8.3 7.8 20.6 21.7 22.8 23.9 25.0
PM
7 5.6 6.1 5.6 7.2 7.2 6.7 8.3 7.8 6.7 20.6 21.1 21.7 22.2 22.8
8 5.6 5.6 4.4 6.7 6.7 5.6 7.8 6.7 5.6 19.4 20.0 19.4 19.4 19.4
9 5.0 4.4 2.8 6.1 5.0 3.3 6.7 5.6 3.3 18.9 18.9 17.8 16.7 15.6
TCE CONSULTING ENGINEERS LIMITED

10 4.4 3.3 1.1 5.6 3.9 1.1 5.6 3.9 1.1 18.9 17.2 15.6 13.9 12.2
AIR-CONDITIONING LOAD CALCULATIONS

11 3.3 2.2 0.6 4.4 2.8 0.6 4.4 2.8 0.6 17.8 15.6 13.3 11.1 8.9
12 2.2 1.1 0.0 3.3 1.7 0.0 3.3 1.7 0.6 16.7 13.9 11.1 8.3 5.6
1 1.1 0.0 -0.6 2.2 0.6 -0.6 2.2 0.6 -0.6 15.0 12.2 9.4 6.7 3.9
2 0.6 -0.6 -1.7 1.1 0.0 -1.1 1.7 -0.6 -1.1 12.8 10.0 7.2 4.4 1.7

120R1
AM 3 0.0 -1.7 -2.2 0.6 0.0 -1.1 1.1 -1.1 -1.7 11.1 8.9 6.1 3.3 0.6
12 OF 41

4 -0.6 -2.2 -2.8 0.0 -0.6 -1.7 0.6 -1.7 -2.2 10.0 7.2 5.0 2.2 -0.6
5 -1.1 -2.8 -2.8 -0.6 -0.6 -1.7 0.0 -1.7 -2.8 7.8 6.1 3.3 1.1 -1.7

TCE FORM NO.

SECTION: WRITE-UP
SHEET

SOURCE: ISHRAE 1997, PART I, TABLE 10, PAGE

R2
ISSUE
TCE CONSULTING ENGINEERS LIMITED
SECTION: WRITE-UP
TCE.M6-ME-811-301 DESIGN GUIDE FOR SHEET
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AIR-CONDITIONING LOAD CALCULATIONS

TABLE 4
CORRECTIONS TO ETD ∆ tc ° C

OUTDOOR
DAILY RANGE °C
TO INDOOR
DBT
DIFFERENCE 4.4 5.6 6.7 7.8 8.9 10.0 11.1 12.2 13.3 14.4 15.6 16.7 17.8 18.9 20.0 21.1 22.2
°C
-16.7 -21.7 -22.2 -22.8 -23.3 -23.9 -24.4 -25.0 -25.6 -26.1 -26.7 -27.2 -27.8 -28.3 -28.9 -29.4 -30.0 -30.6
-11.1 -16.1 -16.7 -17.2 -17.8 -18.3 -18.9 -19.4 -20.0 -20.6 -21.1 -21.7 -22.2 -22.8 -23.3 -23.9 -24.4 -25.0
-5.6 -10.6 -11.1 -11.7 -12.2 -12.8 -13.3 -13.9 -14.4 -15.0 -15.6 -16.1 -16.7 -17.2 -17.8 -18.3 -18.9 -19.4
0.0 -5.0 -5.6 -6.1 -6.7 -7.2 -7.8 -8.3 -8.9 -9.4 -10.0 -10.6 -11.1 -11.7 -12.2 -12.8 -13.3 -13.9
2.8 -2.2 -2.8 -3.3 -3.9 -4.4 -5.0 -5.6 -6.1 -6.7 -7.2 -7.8 -8.3 -8.9 -9.4 -10.0 -10.6 -11.1
5.6 0.6 0.0 -0.6 -1.1 -1.7 -2.2 -2.8 -3.3 -3.9 -4.4 -5.0 -5.6 -6.1 -6.7 -7.2 -7.8 -8.3
8.3 3.3 2.8 2.2 1.7 1.1 0.6 0.0 -0.6 -1.1 -1.7 -2.2 -2.8 -3.3 -3.9 -4.4 -5.0 -5.6
11.1 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0.0 -0.6 -1.1 -1.7 -2.2 -2.8
13.9 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0.0
16.7 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8
19.4 14.4 13.9 13.3 12.8 12.2 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6
22.2 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 11.7 11.1 10.6 10.0 9.4 8.9 8.3
SOURCE: ISHRAE 1997, PART I, TABLE 11, PAGE 1.15

The temperature difference for internal surfaces like walls, ceiling, roof or
floor slab or glass, shall be the temperature difference between the area to
be air-conditioned and the respective adjoining areas. In case the
temperature in the adjoining area is not available from the input data, the
room shall be assumed to be non-air-conditioned. The temperature
difference (∆T) for such cases shall be taken as:

∆T = DBT(ambient) - DBT(air-conditioned area) - 2.8OC

For external glass, the temperature difference shall be taken as:

∆T = DBT(ambient) - DBT(air-conditioned area)

For heating coil calculations, the ambient DBT will be lower than the DBT
for the air-conditioned area. The temperature difference for all glass area,
exposed and internal walls, for heating load calculations shall be the
difference between room and ambient DBT.

∆T = DBT(air-conditioned area) - DBT(ambient)

4.1.2 Latent Heat Gain

This component of heat gain is to be calculated for room design RH values of 45%
or lower as the contribution for higher indoor RH values is not significant. The latent
heat gain due to moisture ingress shall be estimated by the following equations:

ISSUE
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AIR-CONDITIONING LOAD CALCULATIONS

(a) Moisture Load Through the Fabric of the Structure

HLS = 2.225 x ∆H x V x ∆G x F1 x F2 x F3 x F4

Where,

HLS = Latent load due to vapour permeance through structure

(watts)
∆H = Enthalpy differential between humidity ratios Gi for room
and Go for the adjacent area, at the room DBT from
psychrometric chart at altitude of the site (KJ/Kg).
V = Room volume (M3)
∆G = Differential humidity ratio across the room i.e. difference
between outside humidity ratio Go and room humidity ratio
Gi (gms of moisture per Kg of dry air)
F1 = Factor for differential humidity ratio (Refer table 5)

F2 = Factor for space permeance (Refer table 6)

F3 = Factor for wall or slab construction (Refer table 7)

F4 = Factor for vapour treatment (vapour barrier) of walls (Refer

table 8)

(b) Moisture Load Due to Door Openings

HLD = 1.357 x ∆H x N x A x ∆G x F1

Where,

HLD = Latent load due to vapour permeance through door

openings (watts)

∆H = Enthalpy differential between humidity ratios Gi for room

and Go for the adjacent area, at the room DBT from
psychrometric chart at altitude of the site KJ/Kg.

N = Number of door openings per hour

A = Area of door opening (M2)

∆G = Differential humidity ratio across the door (gms of moisture

per Kg of dry air)

F1 = Factor for differential humidity ratio (Refer table 5)

ISSUE
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AIR-CONDITIONING LOAD CALCULATIONS

HLO = 62.039 x ∆H x (A x ∆G x F1) / D

Where,

HLO = Latent load due to vapour permeance through fixed

openings (Watts)

∆H = Enthalpy differential between humidity ratios Gi for room

and Go for the adjacent area, at the room DBT from
psychrometric chart at altitude of the site KJ/Kg

A = Area of fixed opening (M2)

∆G = Differential humidity ratio across the fixed opening (gms of

moisture per Kg of dry air)

F1 = Factor for differential humidity ratio (Refer table 5)

D = Depth of the opening (M)

(d) Total Latent Heat Gain

HL = HLS + HLD + HLO

TABLE 5
FACTOR F1 FOR DIFFERENTIAL HUMIDITY RATIO
DIFFERENTIAL HUMIDITY
RATIO (gms per Kg of dry air) 5.00 5.71 7.14 8.57 10.00
FACTOR F1 1.00 1.11 1.35 1.58 1.82

DIFFERENTIAL HUMIDITY
RATIO (gms per Kg of dry air) 11.43 12.86 14.29 15.71 17.14

FACTOR F1 2.05 2.29 2.59 2.76 2.99

SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS, TABLE II, PAGE 8.

TABLE 6
FACTOR F2 FOR SPACE PERMEATION
VOLUME OF ROOM
(IN 1000 M3) 0.28 0.57 0.85 1.13 1.42 1.70 1.98 2.27 2.55 2.83

FACTOR F2 0.64 0.57 0.53 0.50 0.47 0.44 0.42 0.40 0.38 0.37

ISSUE
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AIR-CONDITIONING LOAD CALCULATIONS

TABLE 6 (CONTD.)
VOLUME OF ROOM 3.40 3.96 4.53 5.10 5.66 6.23 6.80 7.36 7.93 8.50
(IN 1000 M3)
FACTOR F2 0.36 0.34 0.33 0.32 0.29 0.28 0.27 0.27 0.26 0.25
SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS,TABLE III, PAGE 8.

TABLE 7
FACTOR F3 FOR WALL OR SLAB CONSTRUCTION

DETAILS OF CONSTRUCTION FACTOR F3

Masonry or frame construction 1.0
Sheet metal, steel welded 0.2
Module panel, caulked and sealed 0.5
SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS, TABLE IV, PAGE
8.

TABLE 8
FACTOR F4 FOR VAPOUR BARRIER

DETAILS OF VAPOUR BARRIER FACTOR F4

Laminated mylar – metallic or polyethylene film 0.50
Two layers edge sealed moisture paper 0.67
Two coats vapour proof paint 0.75
SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS, TABLE IV, PAGE 8.

NOTES:

1. If product of F3 and F4 is less than 0.5, use 0.5.

2. If room is completely vapour proofed with continuous vapour barrier under

the floor (or of all-metal welded construction) the factor (F3 x F4) may be
reduced to 0.2

4.2 FENESTRATION HEAT GAIN

(a) Glass Transmittance Factor (G)

This factor considers the type of glass whether single, double etc., the type
of shading for the glass whether provided with shading, tints, curtains or
blinds etc. This factor shall be referred to in tables 9, 10 and 11.

ISSUE
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(b) Glass Solar Heat Gain Factor (SHGF)

SHGF shall be selected from ASHRAE Handbook, Fundamentals 1993

edition, Chapter 27, Tables 12 to 18. This component takes into
consideration the orientation of the glass with respect to the true north,
latitude, time of the day and month of the year.

The fenestration heat gain shall be calculated as follows:

Qf = G x SHGF x A

Where,

Qf = Fenestration heat gain for the glass (Watts)

G = Glass transmittance factor (dimensionless)

SHGF = Solar Heat Gain Factor (watts / M2)

A = Area of the glass (M2)

The glass transmittance factor shall be referred from tables 9, 10 and 11.

TABLE 9
GLASS TRANSMITTANCE FACTOR (G) FOR SOLAR HEAT
GAIN THROUGH GLASS WITH AND WITHOUT SHADING
GLASS INSIDE VENETIAN BLIND OUTSIDE OUTSIDE SHADING OUTSIDE AWNING
TYPE OF
FACTOR 45 o HORIZ. OR VERTICAL OR VENETIAN BLIND SCREEN VENT. SIDES &
GLASS
NO ROLLER SHADE 45 o HORIZ. SLATS 17 o HORIZ. SLATS TOP
SHADE
LIGHT MEDIU DARK LIGHT LIGHT ON MEDIU DARK LIGHT MEDIU
COLOUR M COLOUR COLOUR OUTSIDE M COLOUR COLOUR M OR
COLOUR DARK ON COLOUR DARK
INSIDE

ORDINARY 1.00 0.56 0.65 0.75 0.15 0.13 0.22 0.15 0.20 0.25
GLASS

REGULAR 0.94 0.56 0.65 0.74 0.14 0.12 0.21 0.14 0.19 0.24
PLATE
6 mm

HEAT ABSORBING GLASS

40 TO 48% 0.80 0.56 0.62 0.72 0.12 0.11 0.18 0.12 0.16 0.20

48 TO 56% 0.73 0.53 0.59 0.62 0.11 0.10 0.16 0.11 0.15 0.18

56 TO 70% 0.62 0.51 0.54 0.56 0.10 0.10 0.14 0.10 0.12 0.16

ISSUE
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TABLE 9 (CONTD.)

DOUBLE PANE

ORDINARY 0.90 0.54 0.61 0.67 0.14 0.12 0.20 0.14 0.18 0.22
GLASS

REGULAR 0.80 0.52 0.59 0.65 0.12 0.11 0.18 0.12 0.16 0.20
PLATE

48 TO 56% 0.52 0.36 0.39 0.43 0.10 0.10 0.11 0.10 0.10 0.13
ABSORBING
OUTSIDE,
ORDINARY
GLASS INSIDE

48 TO 56% 0.50 0.36 0.39 0.43 0.10 0.10 0.11 0.10 0.10 0.12
ABSORBING
OUTSIDE,
REGULAR
PLATE INSIDE

TRIPLE PANE

ORDINARY 0.83 0.48 0.56 0.64 0.12 0.11 0.18 0.12 0.16 0.20
GLASS

REGULAR 0.69 0.47 0.52 0.57 0.10 0.10 0.15 0.10 0.14 0.17
PLATE

SOURCE: ISHRAE 1997, PART I, TABLE 5, PAGE 1.7

TABLE 10
OVERALL FACTOR (G) FOR SOLAR
HEAT GAIN THROUGH PAINTED
GLASS
PAINTED GLASS LIGHT COLOUR MEDIUM COLOUR DARK COLOUR

GLASS FACTOR NO SHADE 0.28 0.39 0.50

SOURCE: ISHRAE 1997, PART I, TABLE 5, PAGE 1.7

TABLE 11
OVERALL FACTOR (G) FOR SOLAR HEAT GAIN THROUGH STAINED GLASS

STAINED GLASS AMBER DARK DARK DARK GREYED LIGHT DARK

COLOUR RED BLUE GREEN GREEN OPALESCEN OPALESCEN
T T

GLASS FACTOR NO SHADE 0.70 0.56 0.60 0.32 0.46 0.43 0.37
SOURCE: ISHRAE 1997, PART I, TABLE 5, PAGE 1.7

4.3 INFILTRATION HEAT GAIN

ISSUE
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The infiltration air flow rate is approximately proportional to the square root of the
pressure differential across the gaps. The air conditions vary as the air moves
through the various areas or stages of the air-conditioning system. To enable the
estimation of the cooling or heating load the air properties are taken at standard air
conditions, i.e. at sea level with air pressure of 101.323 KPa and temperature of
21.11 0C. The RH of air is taken as 50%. The major parameters of the air used for
the calculation with the values at the standard air conditions are as follows:

Specific heat of air = 1000 J/Kg0C

Density of air = 1.187 Kg/M3

Latent heat of moisture = 2502.5 KJ/Kg

The cooling load may be calculated from the following formula:

F = Cd x A x √( 2∆p/ ç)
Where,
F = Air flow rate (M3 /sec)
A = Area of the gap between door or window and its frame or the crack
in the structure (M2)
∆p = Pressure drop across the gap (N / M2 )
ç = Density of air (Kg/M3)
Cd = Discharge coefficient (normally taken as 1.0)
The infiltration air adds latent and sensible load to the total cooling load. Generally,
the room pressures are higher than the adjacent areas and will indicate a leakage of
conditioned air from the room to the outside. Only the air ingress is to be considered
for the cooling load estimation.

4.3.1 The sensible heat gain from the infiltration air ingress into the room shall be
calculated from the following formula:

QFs = F x Cp x ç x (To – Ti)

Where,

QFs = Sensible heat gain due to the infiltrated air ingress (Watts)

F = Infiltrated air flow rate (M3 / sec)

Cp = Specific heat of air (Joules/Kg0C)

ç = Air density (Kg / M3 )

ISSUE
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AIR-CONDITIONING LOAD CALCULATIONS

To = Outside air DBT (oC)

Ti = Inside air DBT (oC)

4.3.2 The latent heat gain from infiltration air ingress into the room shall be calculated from
the formula:
QFl = F x ç x ∆H x 1000
Where,
QFl = Latent heat gain due to the infiltrated air ingress (Watts)

F = Infiltrated air flow rate (M3 / sec)

ç = Air density (Kg / M3 )

∆H = Enthalpy differential between humidity ratios Gi for room and Go for

the adjacent area, at the room DBT from psychrometric chart for
the altitude of the site (KJ/Kg).

4.4 INTERNAL HEAT GAIN

The internal heat gain includes the following components:

(a) Heat dissipation loads from equipment located within the room. This load
includes the sensible and latent loads that may be dissipated by the
equipment located within the room. The actual heat dissipated into the room
shall be considered for the cooling load estimation. Considering that motor
ratings are selected with a margin of about 15 to 20% above the equipment
BKW, this load will generally be lower than the connected electrical rating
or rated capacity of a driver of a rotating equipment like pump, compressor,
spindle or shaft of a machine etc.
(b) Heat dissipation from the occupancy in the room. This heat dissipation has
latent and sensible component. The total heat dissipation is a function of the
activity. The proportion of the sensible and the latent components of this
total heat dissipation is a function of the temperature in the room. These
loads shall be taken from TCE.M1-ME-811-301 - “Basic Study Guide For
Air-conditioning Systems”.
(c) Lighting loads from the lighting system for the room. In some cases special
fixtures are provided which also serve as return air inlets. Such fixtures
(Troufers) do not reduce the total heat dissipation from the lighting fixture
but reduce the lighting heat dissipation into the room. The reduction in the
lighting heat dissipation to the room is instead transferred to the return air,
reducing the room sensible heat gain and consequently the room
dehumidified air flow rate.

ISSUE
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AIR-CONDITIONING LOAD CALCULATIONS

(d) For heating load calculations the internal heat dissipation loads such as the
equipment heat dissipation, lighting loads and occupancy shall not be
considered. This will give a higher heating load requirement.

4.5 FAN AND DUCT HEAT GAIN

The heat gain to the supply air due to supply air fan, duct heat gain shall be
estimated as follows:

(a) Fan Heat Gain

Qfan = Fbkw + B + M

where,

Qfan = Fan heat gain (watts)

Fbkw = Fan shaft power consumption (watts)

B = Fan belt drive losses (normally considered as 3% of

fan shaft power consumption) (Watts)

= 0.03 x Fbkw

M = Heat gain due to motor efficiency (η) (Watts)

= {(1 - η) x Fbkw }/η

The above calculation cannot be made for the first estimation of the cooling
load. This component therefore shall be taken as a percentage of the
estimated total room heat gains (Sum of heat gains as per paras 4.1, 4.2,
4.3 and 4.4) as follows:

(i) Upto fan static pressure of 50 mmWG = 7.5%

(ii) Add 3% for every 25 mmWG increase in fan

static pressure

(b) Duct Heat Gain

Qduct = Uduct x Aduct x ∆T

where,

Qduct = Duct heat gain due to the temperature difference

across the duct wall (Watts)

ISSUE
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Uduct = Overall heat transfer coefficient across the duct wall

estimated as indicated in para 4.1.1 (b) (watts / M2
0
C)

Aduct = Surface area of the duct (M2)

∆T = Temperature difference across the duct wall (0C)

The total duct area will not be available for the first estimate of the cooling
load calculation. The duct heat gain shall therefore be taken as a percentage
of the estimated total room heat gains (Sum of heat gains as per paras 4.1,
4.2, 4.3 and 4.4) as follows:

(i) Duct heat gain = 2.5%

(ii) Air leakage from supply or return air duct = 2.5%

(iii) Safety and contingencies = 2.5%

Hence total fan and duct heat gain = 15.0%

(Fan static pressure upto 50 mmWG)

4.6 FRESH AIR HEAT GAIN

The fresh air taken into the air-conditioning system adds to the room heat gain due
to the “bypass” of the air over the cooling coil of the air handling unit. This “bypass”
of the air over the cooling coil is characterised by the “Bypass Factor” (BF). It is a
measure of the efficiency of the heat exchange over the cooling coil. The higher the
BF the lower is the efficiency of the cooling coil.

This factor is dictated by the cooling coil size i.e. the number of rows of the cooling
coil and the air velocity across the coil face. The higher the velocity of air across the
cooling coil the higher is the BF. On the other hand the higher the number of rows of
tubes of the cooling coil across the air flow or the lower the fin spacing, the lower is
the BF.

The component of the fresh air load to be considered as part of the room load is
given by equations listed in paras 4.6.1 and 4.6.2.

The balance fresh air load does not constitute a part of the room load. However,
this load shall be taken in the total cooling load estimate as indicated in paras 4.6.3
and 4.6.4.

4.6.1 The fresh air sensible heat gain due to the bypass of the fresh air over the cooling
coil in the room is given by the following equation:
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FASH = F x Cp x ç x (To - Ti) x BF

Where,

FASH = Fresh Air Sensible Heat (watts)

F = Fresh air flow rate (M3 / sec)

Cp = Specific heat of air (Joules/Kg 0C)

ç = Air density (Kg / M3 )

To = Outdoor air DBT (0C)

Ti = Room air DBT (0C)

4.6.2 The fresh air latent heat gain due to the bypass of the fresh air over the cooling coil
in the room is given by the following equation:

FALH = F x ç x ∆H x BF x 1000

Where,

FALH = Fresh Air Latent Heat (watts)

F = Fresh air flow rate (M3 / sec)

ç = Air density (Kg / M3 )

∆H = Enthalpy differential between humidity ratios Gi for room and Go for

the adjacent area, at the room DBT from psychrometric chart at
altitude of the site (KJ/Kg).

4.6.3 The balance fresh air sensible heat gain on the cooling coil is given by the following
equation:

BFASH = F x Cp x ç x (To - Ti) x (1 - BF)

Where,

BFASH = Fresh Air Sensible Heat (watts)

F = Fresh air flow rate (M3 / sec)

Cp = Specific heat of air (Joules/Kg 0C)

ç = Air density (Kg / M3 )

To = Outdoor air DBT (0C)

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Ti = Room air DBT (0C)

4.6.4 The balance fresh air latent heat gain on the cooling coil is given by the following
equation:

BFALH = F x ç x ∆H x (1- BF) x 1000

Where,

BFALH = Fresh Air Latent Heat (watts)

F = Infiltrated air flow rate (M3 / sec)

ç = Air density (Kg / M3 )

∆H = Enthalpy differential between humidity ratios Gi for room

and Go for the adjacent area, at the room DBT from
psychrometric chart at altitude of the site (KJ/Kg).

The values of the BF to be considered for the purpose of cooling load estimation for
various applications are as given in table 12.

The BF ranges given in table 12 are indicative. For the purpose of the estimation of
the cooling load for preparation of specification a conservative value i.e. the highest
value given in the range for the particular application may be taken. The correct
value of the BF will be available on selection of the cooling coil by the vendor.

The fresh air load into the room is a part of the total cooling load due to fresh air,
proportional to the BF. The balance of the fresh air cooling load does not constitute
a part of the room load. However, this load shall be part of the cooling load
imposed on the cooling coil. In case a preliminary cooling coil selection has been
done, the values of the BF for finned cooling coil may be taken from table 13.

TABLE 12
COOLING COIL BYPASS FACTORS FOR VARIOUS APPLICATIONS

COOLING COIL BY- TYPE OF APPLICATION EXAMPLE

PASS FACTOR (BF)

0.30 to 0.50 A small total load or a load that has a low sensible load Residence
factor (i.e. high latent load)

0.20 to 0.30 Typical comfort application with a relatively small total Residence, Small retail
load or a low sensible heat factor with a somewhat shop, Factory
larger load

0.10 to 0.20 Typical comfort application Department store, Bank,

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Factory

0.05 to 0.10 Applications with high internal sensible loads or requiring a Department store,
large amount of outdoor air for ventilation Restaurant, Factory

0.00 to 0.10 100% outdoor air applications Hospital operation

theatres, Clean room, etc.
SOURCE: ISHRAE 1997, PART I, TABLE 14, PAGE 1.16

TABLE 13
COOLING COIL BYPASS FACTORS WITH AND WITHOUT SPRAYS,
VARIOUS AIR VELOCITIES AND FIN SPACING

DEPTH OF WITHOUT SPRAYS WITH SPRAYS (NOTE 1)

COOLING COIL
3.1 FINS PER cm 5.5 FINS PER cm 3.1 FINS PER cm 5.5 FINS PER cm
NUMBER OF ROWS
AIR VELOCITY M / sec

1.5 to 3.5 1.5 to 3.5 1.5 to 3.5 1.5 to 3.5

BYPASS FACTOR (BF)

2 0.42 to 0.55 0.22 to 0.38 - -

3 0.27 to 0.40 0.10 to 0.23 - -

4 0.19 to 0.30 0.05 to 0.14 0.12 to 0.22 0.03 to 0.10

5 0.12 to 0.23 0.02 to 0.09 0.08 to 0.14 0.01 to 0.08

6 0.08 to 0.18 0.01 to 0.06 0.06 to 0.11 0.01 to 0.05

8 0.03 to 0.08 - 0.02 to 0.05 -

SOURCE: ISHRAE 1997, PART I, TABLE 13, PAGE 1.16

NOTES:

1. Sprayed coils have a lower BF because the spray provides more heat
transfer surface for contacting air.

2. The BFs are to be taken in proportion with the air velocity across the
cooling coil.

3. The number of rows for residences and comfort applications may be taken
as 4 rows, whereas those for high latent load applications i.e. for room
sensible heat factor values lower than 0.75 may be taken as 6 rows.

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4. The fin spacing for cooling coils may be taken as 36 fins per cm of cooling
coil finned tube length.

5. The air velocity may be taken as 2.5 M/sec across the cooling coil.

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4.7 RETURN AIR DUCT HEAT GAIN

The return air heat gain shall be estimated using the following equation:

RAHG = U x A x ∆T

where,

RAHG = Return Air Heat Gain (Watts)

U = Overall heat transfer coefficient across the duct wall. U is to

be estimated as per para 4.1.1(b) (Watts / M2 0C)

A = Area of the duct wall (M2)

∆T = Temperature difference across the duct wall (0C)

4.8 SUMMARY

Various heat gains calculated as per paras 4.1 to 4.7 are summarised in the table
14.
TABLE 14
SUMMARY OF HEAT GAIN CALCULATION
SL.NO. ITEM SENSIBLE LATENT TOTAL
HEAT GAIN HEAT GAIN
(Calculated as (Calculated as
per para) per para)

1. Structural heat gain 4.1.1 4.1.2

2. Fenestration heat gain 4.2 -

3. Infiltration heat gain 4.3.1 4.3.2

4. Internal heat gain 4.4 a, b, c 4.4 a, b

5. Total room heat Sl.Nos. Sl.Nos.

1+2+3+4 = 1+2+3+4 =
(RSH) (RLH)
RSH
6. Room Sensible Heat Factor
RSH+RLH
(RSHF)
7. Fan and duct heat gain 4.5 a, b -

8. Fresh air bypass heat gain 4.6.1 4.6.2

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TABLE 14 (CONTD.)

9. Effective room heat Sl.Nos. Sl.Nos.

5+7+8 = 5+7+8 =
ERSH ERLH

10. Effective Room Sensible Heat ERSH

Factor (ESHF) ERSH+ERLH

11. Balance fresh air heat gain 4.6.3 4.6.4

12. Return air heat gain 4.7 -

Sl.Nos. Sl.Nos. 9+11+12
13. Grand Total Heat (GTH)
9+11+12 =GSH =GLH
= GSH + GLH
GSH
14. Grand Sensible Heat Factor
GSH+GLH
(GSHF)
In cases where the air-conditioning cooling load is to be met by a chilled water or
brine system the total refrigeration capacity (Qch) of the chilled water or brine units
shall be calculated as follows:

Qch = GTH x 1.1

The additional 10% load is to account for the pumping and piping heat gain.

5.0 APPARATUS DEW POINT

The ESHF is utilised to calculate the Apparatus Dew Point (ADP). This is the
temperature that the air would achieve at the outlet of an ideal cooling coil. This
temperature is represented by the intersection of the ESHF line and the saturation
curve on the psychrometric chart.

The ADP is not a temperature that can be physically measured, but is a parameter
which is used to estimate the dehumidified air flow rate. The ADP is also used to
select the evaporating temperature in case of Direct Expansion (DX) cooling coils or
the chilled water supply temperature in case of chilled water cooling coils.

The evaporating temperature for DX systems shall be at least 4 to 5 0C lower than

the ADP. Whereas, the chilled water cooling coil entering temperature should be at
least 3.5 to 4.5 0C lower than the air leaving temperature.

Appendix 1 indicates a typical plot of the various sensible heat factors listed in table
14. The ESHF, GSHF, RSHF and ADP are indicated on this representation. In the
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process of calculating the cooling loads the air-conditioning process shall be

represented on a psychrometric chart for the altitude of the area being air-
conditioned.

6.0 DEHUMIDIFIED AIR FLOW RATE

The dehumidified air flow rate is given by the equation:

DHF = ERSH .
(1-BF) x (Room DBT – ADP) x Cp x ç
Where,

DHF = Dehumidified air flow rate (M3/sec)

Cp = Specific heat of air (Joules/Kg 0C)

ç = Air density (Kg / M3 )

7.0 REFERENCES

7.1 ASHRAE Handbook, Fundamentals, 1993 Edition

7.2 Indian Society of Heating Refrigerating and Air-Conditioning Engineers – HVAC

Handbook, 1997 Edition, Part I – Air-Conditioning

7.3 Engineering Data Manual – BRY-AIR, Dehumidifiers

7.4 Basic Study Guide for Air-conditioning System – TCE.M1-ME-811-301

7.5 Handbook of Air-conditioning System Design – Carrier Air-Conditioning Company,

1965 edition

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APPENDIX 1
TYPICAL AIR-CONDITIONING PSYCHROMETRIC PROCESS

SPECIFIC HUMIDITY GMS PER KG OF DRY AIR

MIXTURE AIR
CONDITION
OUTDOOR DESIGN
CONDITION

CONDITION
ROOM AIR
ROOM
GSHF

DRY BULB TEMPERATURE

RSHF LINE

ESHF LINE
SATURATION

0
C
CURVE

ROOM ENTERING AIR

CONDITION

APPARATUS
DEW POINT
(ADP)

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APPENDIX 2
SAMPLE AIR-CONDITIONING LOAD CALCULATIONS
1.0 INPUT DATA

SL. ITEM PARAMETER

NO.

1. Location of site New Delhi

2. Latitude 28.35 0N

3. Altitude 216 M above MSL

4. Name of area Office premises

5. General arrangement / Arch. drawing Refer sketch below

6. Outside design conditions DBT WBT Specific Humidity

0 0
C C gms/Kg of dry air

6.1 Summer 43.3 23.9 10.70

6.2 Monsoon 35.0 28.3 21.74

6.3 Winter 7.2 5.0 4.60

6.4 Daily range 13.89

7. Inside design conditions

7.1 Temperature 24 ± 10C DB

7.2 RH 55 + 5 % - No lower limit on RH

7.3 Specific humidity 10.25 gms / Kg of dry air

8. Lighting loads 15 Watts/M2 of floor area

9. Equipment loads Sensible load 1.5 KW, Latent load 0 KW

10. Occupancy 15 persons - Office activity

11. Fresh air requirements 1 air change per hour

12. Exhaust air requirements Nil

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APPENDIX 2 (CONTD.)

13. Filtration Pre-filters to be provided

14. Pressurisation Nil

15. Air flow pattern No specific requirements

16. Hazardous area classification Safe area

17. Duration of air-conditioning system From 0800 Hrs to 1800 Hrs continously

18. Availability of cooling water / make-up water No water available

19. Future expansion plans No specific plans. Roof is exposed and floor
below is not air-conditioned.

PLAN AND SECTION – OFFICE AREA

EXPOSED
ROOF

FALSE CEILING

4,500
3,000

SECTION AA

18,000 6,00

3,00
A A

WINDOW W1 (TYP)
(SIZE 4000 X 1200) GENTS AND
12,000

LADIES TOILET
OFFICE AREA

NORTH
3,000

DOOR (TYP)
3,000

AIR-CONDITIONING PLANT
ROOM
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APPENDIX 2 (CONTD.)
2.0 AREA CALCULATIONS
The area calculations are based on the layout sketch above

SL. SURFACE WALL WALL HEIGHT M SURFACE FACE AREA M 2 GLASS WALL AREA
NO. LENGTH AREA M 2 M2
M
TOTAL UPTO IN ROOM ABOVE FALSE
FALSE CEILING
CEILING

a b c d = a-c

1. North wall 18.0 4.5 3.0 54.0 27.0 14.4 39.6

2. West wall 12.0 4.5 3.0 36.0 18.0 4.8 31.2

3. Part. wall 30.0 4.5 3.0 90.0 45.0 - 90.0

4. Plant room

4.1 East
3.0 4.5 - 13.5 - - 13.5
wall

4.2 Part.
9.0 4.5 - 40.5 - - 40.5
wall

5. Exposed roof

5.1 Office
- - - 216.0 - - -
area

5.2 Plant
- - - 9.0 - - -
room

6. Floor area

6.1 Office
- - - 216.0 - - -
area

6.2 Plant
- - - 9.0 - - -
room

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APPENDIX 2 (CONTD.)

3.0 OVERALL HEAT TRANSFER COEFFICIENT

3.1 External Wall

(a) Outer air film 0.030 Table 1*

(b) Outer cement plaster 20 mm thick 0.028 Table 4*

(c) Wall 230 mm thick brick 0.299 Table 4*

(Density 1760 Kg/M3 as per IS 875 Part 1)

(d) Inner cement plaster 15 mm thick 0.021 Table 4*

(e) Inner air film 0.120 Table 1*

Total thermal resistance (R) of external wall 0.498

Overall heat transfer coefficient (U= 1/R) 2.008 W/M2 °C

3.2 Internal Wall

(a) Outer air film 0.120 Table 1*

(b) Outer cement plaster 15 mm thick 0.021 Table 4*

(c) Wall 115 mm thick brick

(Density 1760 Kg/M3 as per IS 875 Part 1) 0.150 Table 4*

(d) Inner cement plaster 15 mm thick 0.021 Table 4*

(e) Inner air film 0.120 Table 1*

(f) Total thermal resistance (R) of internal wall 0.432

(g) Overall heat transfer coefficient (U = 1/R) 2.315 W/M2 °C

3.3 Exposed Roof

(a) Outer air film 0.030 Table1*

(b) Water proofing 0.026 Table 4*

(c) RCC slab 100 mm thick = 0.1 x 0.69 0.069 Table 4*

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APPENDIX 2 (CONTD.)

(d) Thermal insulation (t/k) = 0.05/0.034 1.471

(Para 6.4 of TCE.M1-ME-811-301 R2)

(e) Inner cement plaster 15 mm thick 0.021 Table 4*

(f) Inner air film 0.160 Table 1*

(g) Total thermal resistance (R) of roof 1.777

(h) Overall heat transfer coefficient (U = 1/R) 0.563 W/M2 °C

3.4 Floor

(a) Inner air film 0.110 Table 1*

(b) Floor tile plaster 25 mm thick 0.035 Table 4*

(c) RCC slab 100 mm thick = 0.1 x 0.69 0.069 Table 4*

(d) Cement plaster 15 mm thick 0.021 Table 4*

(e) Tile terrazo 25 mm thick 0.014 Table 4*

(f) Outer air film 0.110 Table 1*

(g) Total thermal resistance (R) of floor 0.359

(h) Overall heat transfer coefficient (U = 1/R) 2.786 W/M2 °C

3.5 Glass

(a) Conduction (single glass without storm windows) 6.4 W/M2 °C

(Table 1 of this guide)

(b) Glass transmittance factor (G) 0.56

(Table 9 of this guide Ordinary glass with light coloured inside venetian
blinds)
* Table numbers referred are as per ASHRAE Handbook, Fundamentals 1993
Edition, Chapter 22. The outer air film resistance is assumed for wind velocity of
24 KM/Hr and inner film resistance for still air.

3.6 Equivalent Temperature Difference (ETD)

3.6.1 Outdoor and indoor temperature difference (∆T)

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APPENDIX 2 (CONTD.)

∆T = 43.3 – 24 = 19.3°C

For daily range of 13.89°C, the correction to ∆T is interpolated from table 4 of this
design guide as follows:

∆T °C DAILY RANGE °C

13.3 13.89 14.4

16.7 7.2 6.93 6.7

19.3 9.58

19.4 10.0 9.68 9.4

Correction to ∆T = 9.58 Say 9.6°C.

3.6.2 Factor c for colour shade assumed to be for dark walls = 1

3.6.3 Exposed Walls

(a) North Wall

ETD = ∆tesc + {(∆temc - ∆tesc ) x c x Rs/Rm}

∆tes = 2.2 °C (From table 2 for wall weight of 488 Kg/M2)

∆tem = 2.2°C (From table 2 for wall weight of 488 Kg/M2)

Substituting in equation for ETD above:

ETD = 16.29°C say 16.3°C

(c) East Wall

ETD = ∆tesc + {(∆temc - ∆tesc ) x c x Rs/Rm}

∆tes = 2.2°C (From table 2 for wall weight of 488 Kg/M2)

∆tem = 10.0°C (From table 2 for wall weight of 488 Kg/M2)

∆T = (43.3-24) - 2.8°C

= 16.5 °C

(f) Floor

∆T = (43.3-24) - 2.8°C

= 16.5 °C

3.6.4 Solar Heat Gain

(a) Glass transmission factor G = 0.56 (table 9 of this guide)

(b) SHGF North glass = 98 W/M2 *

(c) SHGF West Glass = 679 W/M2*

(d) SHGF East Glass = 82 W/M2*

(*From Table 14 of ASHRAE Fundamentals, 1993 Edition, Chapter 27.)

3.6.4 Infiltration Heat Gain

NIL - as room is to be kept under slight positive pressure.

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3.6.6 Internal Heat Gain

(a) For office worker at 24°C room DBT for office activity the sensible and
latent heat dissipation loads from appendix 2 of TCE.M1-ME-811-301

APPENDIX 2 (CONTD.)

(i) Sensible heat load = 75 Watts/person

(ii) Latent heat load = 60 Watts/person

(b) Equipment heat dissipation load = 1.5 KW

3.6.7 Fresh Air Heat Gain

Fresh air flow rate = 1 air change per hour

= 12M width x 18M length x 3M height

= 648 M3/Hr

= 0.18 M3/sec

For a coil bypass factor of 0.165, from table 13 of this design guide, considering a 3
row deep cooling coil, 5.5 fins per cm and an air face velocity on the cooling coil of
2.5 M/sec, the fresh air bypass sensible and latent loads as per paras 4.6.1 and
4.6.2 of this guide will be as follows:

FASH = 0.18 x 1000 x 1.187 x (43.3 - 24) x 0.165

= 680.4 Watts

FALH = 0.18 x 1.187 x (10.7 - 10.25) x 1000 x 0.165

= 15.9 Watts

The fresh air balance load on the cooling coil given as per paras 4.6.3 and 4.6.4 of
this guide will be as follows:

BFASH = 0.18 x 1000 x 1.187 x (43.3 - 24) x (1 - 0.165)

= 3443.2 Watts

BFALH = 0.18 x 1.187 x (10.7 - 10.25) x 1000 x (1 - 0.165)

= 80.3 Watts

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APPENDIX 2 (CONTD.)

TATA CONSULTING ENGINEERS

AIR-CONDITIONING LOAD ESTIMATION
BY : CLIENT : TCE PROJECT:
DATE : JOB NO. : 971 DOC. NO. : TCE.971-ME-811-01
CHD. : OFFICE : DW SUBJECT : HVAC CALCULATION
DATE: DEPT. : ME SH : 1 OF 1 REV. NO. : 0
DESIGNCONDITIONS SUMMER / MONSOON / WINTER LOCATION : NEW LATITUDE:28.35 ° ALTITUDE: 216M
DELHI N
DBT WBT RH SP.HUM. ENTHALPY NAME OF THE AREA : OFFICE
( 0 C) ( 0 C) (%) (gm/kg) (J/KG)
OUTSIDE 43.3 23.9 10.70 72 FLOOR : FIRST
INSIDE 24.0 55 10.25 50 ROOF : EXPOSED UNEXPOSED
DIFF. 19.3 0.45 ROOF INSULATION : 50 mm THK EPS or PUF
DAILY RANGE (0 C) DESIGN TIME (AM / 4 PM
13.89 PM)
ROOM AREA (M2 ) 216 ROOM VOLUME (M3 ) 648
ASSUMED BYPASS FACTOR (BF) 0.165 SELECTED FRESH AIR (M3 /sec) 0.18
GLASS FENESTRATION GAIN TRANSMISSION GAIN - GLASS
AREA (M2 ) SOL HEAT G. FACT WATTS AREA (M2 ) TEMP. U. FACT WATTS
N GLASS 14.4 98 0.56 790.3 N GLASS 14.4 19.3 6.4 1778.7
S GLASS S GLASS
E GLASS E GLASS
W GLASS 4.8 679 0.56 1825.2 W GLASS 4.8 19.3 6.4 592.9
NW GLASS NW GLASS
NE GLASS NE GLASS
SW GLASS SW GLASS
SE GLASS SE GLASS
SKYLIGHT SKYLIGHT
SOLAR & TRANS. GAIN - WALLS AND TRANSMISSION GAIN
ROOF
N WALL 39.6 11.8 2.008 938.3 PART. 1 90 16.5 2.315 3437.8
S WALL PART. 2
E WALL PART. 3
W WALL 31.2 16.3 2.008 1021.2 PRT.GLASS
NW WALL CEILING
NE WALL FLOOR 216 16.5 2.786 9929.3
SW WALL FLOOR
SE WALL ROOF 216 28.9 0.563 3514.5
INTERNAL HEAT GAIN INFILTRATION HEAT GAIN
OCCUP. -- 15 75 1125.0
LIGHTING -- 15 X 216 3240.0
EQUIPT. -- 1.5 1000 1500.0
SUBTOTAL1 10440.0 SUBTOTAL2 19253.2
SUBTOTAL 1 + SUBTOTAL 2 29693.2
SAFETY FACTOR % -- APPARATUS DEW POINT TEMPERATURE (0 C )

ROOM SENSIBLE HEAT ( RSH ) ESHF = ERSH/ERTH 34827.6 / 35833.5 0.97

SUPPLY DUCT HEAT GAIN IN % INDICATED ADP (0 C) SELECTED ADP 14.5
0
C
SUPPLY DUCT LEAK LOSS 15 % OF ST1 & 2 4454.0 ENTHALPY AT ADP (KJ/Kg) 41.0

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FAN HEAT GAIN IN % COIL ENTERING AIR TEMPERATURE 24.9 / 51.1

/ENTHALPY
FRESH AIR SENSIBLE LOAD 680.4 COIL LEAVING AIR TEMPERATURE 16.2 / 42.7
/ENTHALPY
EFFECTIVE ROOM SENSIBLE HEAT (ERSH) 34827.6 DEHUMIDIFIED AIR
QUANTITY M3 /sec 3.7

APPENDIX 2 (CONTD.)

RETURN DUCT HEAT GAIN IN % PLANT ROOM 2635.7

LATENT HEAT
OCCUPANCY 15 x 60 900 RETURN DUCT LEAK LOSS IN 2% OF 787.1
SUBTOTAL 3
EQUIPMENT ------ GRAND TOTAL HEAT ( GTH ) 42779.8
SAFETY FACTOR (%) 10 90 AC LOAD IN TR = GTH /3520 12.2
ROOM LATENT HEAT ( RLH ) 990 CHECK FIGURES :
SUPPLY DUCT LEAK LOSS IN % ------ COOLING LOAD / UNIT FLOOR AREA 198.05
(WATTS/M2 )
FRESH AIR LATENT LOAD 15.9 DEHUMIDIFIED AIR QUANTITY / UNIT FLOOR 0.0171
AREA (M3 /sec.M2 )
EFFECTIVE ROOM LATENT HEAT (ERLH) 1005.9 NOTES :
EFFECTIVE ROOM TOTAL HEAT (ERTH) 35833.5 PLANT ROOM GAIN:
FRESH AIR HEAT EWALL = 13.5 x 19.5 x 2.008 = 528.6
SENSIBLE 3443.2 PART. = 40.5 x 16.5 x 2.315 = 1547.0
LATENT 80.3 ROOF = 9 x 28.9 x 0.563 = 146.4
FRESH AIR HEAT SUBTOTAL 3523.5 3523.5 FLOOR = 9 x 16.5 x 2.786 = 413.7
SUBTOTAL 3 39357.0 Total load 2635.7 WATTS

SUMMARY

The summer load for the room is 12.2 TR with a dehumidified air flow requirement of 3.7
M3/sec and an ADP of 14.5 0C

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AIR-CONDITIONING LOAD CALCULATIONS
APPENDIX 3
ASHRAE PSYCHROMETRIC CHART NO. 1 FOR NORMAL TEMPERATURES AT SEA LEVEL

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COOLING AND HEATING COILS

GUIDE FOR SELECTION OF

COOLING AND HEATING COILS

FILE NAMES: M6ME304R2.DOC AND

M6ME304R2.DWG

REV. NO. R0 R1 R2
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY RRC Sd/- TPR Sd/- TPR

CHD. BY SCM Sd/- PRJ Sd/- HRK

R2
APD. BY SJB Sd/- RL Sd/- RL

DATE 27.12.1989 27.03.2000 20.03.2003

TCE FORM NO. 020 R2

020R2
TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M6-ME-811-304 GUIDE FOR SELECTION OF
SHEET ii OF iv
COOLING AND HEATING COILS

CONTENTS

SL.NO. TITLE SH.NO.

1.0 SCOPE 1
2.0 USES OF COILS 1
3.0 DESIGN AND CONSTRUCTION FEATURES 2
4.0 APPLICATION RANGE 8
5.0 INPUT AND OUTPUT DATA FOR COIL SELECTION OR 8
SIZING
6.0 PROCEDURE FOR SELECTION OR SIZING 9
7.0 REFERENCES 10
APPENDICES
1. EXAMPLES OF COOLING COIL SELECTION PROCEDURE 11
2. EXAMPLES OF HEATING COIL SELECTION PROCEDURE 20
FIGURES
1. TYPES OF FIN-COIL ARRANGEMENTS 28
2. WATER CIRCUIT ARRANGEMENTS 29
FOR COOLING COILS
3. CHILLED WATER FLOW ARRANGEMENTS 30
4. TYPICAL REFRIGERANT DISTRIBUTORS 31
5. COIL CONTROL ARRANGEMENTS FOR MULTIPLE 32
THERMOSTATIC EXPANSION VALVE FED COILS
6. WATER CIRCUIT ARRANGEMENTS FOR 33
HEATING COILS
7. TYPICAL BYPASS FACTORS FOR COILS 34
8. CHILLED WATER COIL PERFORMANCE CURVES 35
9. TYPICAL PERFORMANCE CURVES FOR 36
DIRECT EXPANSION COIL
10. WATE PRESSURE DROP 37
11. WATER VELOCITY FACTOR F2 37
12. FACTOR F3 38
13. AIR PRESSURE DROP 38
TABLES
1. RANGES OF STANDARD RATING CONDITIONS 39
2. PHYSICAL DATA – AIR HANDLING UNITS 40
3. AIR SIDE RESISTANCE OF COOLING AND HEATING COILS 41
4. PHYSICAL PARAMETERS OF COIL 42

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CONTENTS (CONTD.)
TABLES
(CONTD.) TITLE SH.NO.

5. K FACTORS FOR CHILLED WATER COILS 43

6. MULTIPLIERS WS FOR WETTED CHILLED WATER COOLING 44
COIL SURFACES
7. COIL FACE AREAS (FA) 45
8. WATER VELOCITY CONSTANT ‘R’ 46
9. HOT WATER BTU CONSTANTS 47
10. 2 ROW HOT WATER COIL CAPACITIES 48
11. STEAM HEATING COIL CAPACITIES 49

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REVISION STATUS

REV.NO. DATE DESCRIPTION

R0 27.12.1989 ---

R1 27.03.2000 Generally revised. Heating

coils added.

R2 20.03.2003 Generally revised.

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1.0 SCOPE

Cooling coils for air-conditioning applications are generally used in Air Handling
Units (AHUs), fan coil units, packaged air-conditioners, split air-conditioners and
window air-conditioners. Steam or hot water heating coils are generally used in
AHUs to heat, pre-heat or re-heat air whereas for smaller capacity heating
applications such as in window air-conditioners, electric resistance heating coils are
used.

This document describes various types, design and construction features of cooling
and heating coils for air-conditioning applications and provides guidelines for
selection and sizing of these coils.

2.0 USES OF COILS

2.1 COOLING COILS

2.1.1 Cooling coils are generally used for air cooling with or without accompanying
dehumidification. Examples of cooling applications without dehumidification are
pre-cooling coils, sensible cooling coils or coils that use ordinary or cooling tower
water at relatively high temperatures to reduce refrigeration capacity. However, a
sizeable portion of coil applications involves simultaneous air sensible cooling and
dehumidification.

2.1.2 The usual cooling media used in extended surface coils are chilled water or volatile
refrigerants. Brines are seldom used for air-conditioning applications but could be
used for some process air cooling or low humidity and low temperature applications
or sometimes when brine from industrial system already installed is the only source
of refrigeration.

2.1.3 Generally, for air-conditioning applications the temperature of cooling medium

such as chilled water or brine or volatile refrigerants like R22, R134a, R123,
ammonia etc. are sufficiently above 0 0 C and no frosting is expected in normal
operation. For coils operating with cooling medium temperature below 0 0 C, a
defrosting mechanism has to be provided. The method of defrosting may be hot gas,
electric heaters, water sprays or air.

2.2 HEATING COILS

2.2.1 Heating coils are generally used for temperature and humidity control. Normally,
the heating media used in coils is steam or hot water.

2.2.2 Heating coils may be used in AHUs as pre-heating or re-heating coils in

conjunction with cooling and dehumidifying coils. These may also be installed in
supply air ducts to air-conditioned areas for re-heating. Sometimes these coils are
used in fresh air supply system as pre-heating coils.

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2.2.3 Direct electric resistance air heating coils, also known as blast coils or duct heaters
may be used for the same applications as steam or hot water coils. These may be
used in smaller sizes and where flow connections or maintenance of pitch in piping
would be troublesome. Electric coils are sometimes installed in branch ducts of
central fan system and hot water systems to provide the final temperature and
relative humidities required for comfort or process air-conditioning. Electric coils
installed for use primarily in the heating cycle can also be utilised for re-heat in the
cooling cycle if located downstream of the cooling coil. When using electric coils
safety aspects like fire hazards should be considered.

3.0 DESIGN AND CONSTRUCTION FEATURES

Coils are basically of two types, those consisting of bare tubes and those having
extended or finned surfaces. The former is seldom times used where conditions can
cause frost accumulation or for cooling within sprayed coil dehumidifiers. The
design and arrangement of a coil, constructed with extended surface on the air side,
involves consideration of various parameters such as :

(a) Air face velocity

(b) Material of fins and tubes

(c) Types and spacing of fins

(d) Tube diameters and nesting centre dimensions

(e) Surface ratio

(f) Provisions to increase air turbulence

(g) Chilled water flow or refrigerant distribution for cooling coils and hot water
flow or steam distribution for heating coils.

3.1 AIR FACE VELOCITY

Air flow rate, M3 /Hr
Air face velocity, M/sec =
Coil face area, M2 x 3,600

3.1.1 Cooling Coil

The extended surface coils may be designed with air face velocity of 1.5 to 4 M/sec.
Higher air face velocities give better heat transfer characteristics with higher
pressure drop and higher coil bypass. Higher velocities used with dehumidifying
coils may also lead to condensed moisture carry-over in ducting system downstream
of the coil. As a good compromise between various factors dehumidifying coils are
normally designed for an air face velocity of around 2.5 M/sec. However, sensible
cooling coils may be designed for air face velocity as high as 4 M/sec.

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3.1.2 Heating Coil

The extended surface coils may be designed with air face velocity of 1 to 4 M/sec.
Higher air face velocities give better heat transfer characteristics with higher
pressure drop. When heating coils are used in conjunction with cooling and
dehumidifying coils in AHUs, the air face velocity is kept same as for cooling and
dehumidifying coil. For duct mounted or independent heating coils higher air face
velocities may be used.

3.2 MATERIAL OF FINS AND TUBES

3.2.1 Cooling Coil

Cooling coils for water or volatile refrigerants usually have aluminium fins and
copper tubes. Copper tubes and copper fins are also used quite frequently in
corrosive atmosphere like marine applications. Copper tubes and fins also minimise
galvanic corrosion and loss of fins bonding to the tube, extending the life of the
coil. Aluminium tubes with aluminium fins are also finding usage. Although copper
tubes with copper fins are expected to give best heat transfer characteristics most
commonly available indigenous designs are with copper tubes and flat or
configurated plate aluminium fins.

For ammonia refrigeration system normally carbon steel tubes are used since
ammonia reacts with copper.

3.2.2 Heating Coil

Copper and aluminium are the materials most commonly used in the fabrication of
extended surface heating coils. Tubing made of steel or various copper alloys is
used in applications where corrosive forces might attack the coils from either inside
or outside. The most common combination for low-pressure applications is
aluminium fins on copper tubes. Low-pressure steam coils are usually designed to
operate upto 10 to 13 Kg/cm2 (g). Above this pressure, tube materials such as red
brass, admiralty brass or cupronickel is selected. It is preferable to operate steam
heating coil below 3.5 Kg/cm2 (g), as otherwise IBR approval is required.

3.3 TYPES AND SPACING OF FINS

3.3.1 Numerous types of fin arrangements are used such as smooth spiral, flat plate and
configurated plate fins as shown in Figure 1. The spiral fins surround each tube
individually in all cases, while the plate type may be either continuous including
several rows of tubes or individual fin for each tube in round or square shape. Most
common designs available in India are flat plate or configurated plate continuous
fins.
3.3.2 A major factor in performance of extended surface coils is the bond between the fin
and the tube. An intimate contact must be permanently maintained to assure
unimpeded heat transfer.

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3.3.3 In individually finned tubes, fins are generally wound on the tube under pressure, to
upset the metal slightly at the fin root and are then given a coating of solder while
still revolving to assure a uniform coat. In some designs the spiral fins are knurled
into a shallow groove on the tube exterior. In very common flat or configurated
continuous plate fin designs, the tubes are usually mechanically expanded after the
fins are assembled or tube hole collars of a fin are made to override those in the
preceding fin thus compressing the fins on the tubes. Most designs available
indigenously are of the two types described last.

3.3.4 Various coil designs are made with fins spaced from 3 to 14 per 25 mm. However,
most coils used in air-conditioning applications are with 8 to 14 fins per 25 mm.
Although the coils with densely packed fins are expected to give better heat
transfer, fin spacing should be selected according to job to be performed with
special attention given to practical considerations such as condensate drainage,
possibility of lint and dust product accumulation and especially at lower
temperatures, frost accumulation. Based on above, for normal comfort air-
conditioning, one may select the coils with 14 fins per 25 mm, while applications
such as textile processing industry, pharmaceutical formulation plants (granulating
and tabling sections) may require wide spaced fins say 8 fins per 25 mm.
Applications involving possibility of frost formation such as cold diffusers may call
for still wider fin spacing, say 3 to 5 fins per 25 mm.

3.4 TUBE DIAMETERS AND NESTING CENTRE DIMENSIONS

3.4.1 The cooling and heating coils are built with tubes of commonly 6.4 mm(1/4”), 9.5
mm(3/8”), 12.7 mm(1/2”), 15.9 mm(5/8”), 19.1 mm(3/4”) and 25.4 mm(1”) outside
diameter. However, most commonly available designs are with 12.7 and 15.9 mm
outside diameter tubes. The tube nesting centres generally vary from 15.9 to 63.5
mm for cooling coils and 25 mm to 75 mm for heating coils. Spacing for 15.9 mm
outside diameter tubes is usually 38 to 50 mm vertical and 27 to 38 mm horizontal.
Coils with closely spaced tubes are expected to result in better-finned surface
effectiveness.

3.4.2 Due to high temperature difference between the heating medium (i.e. hot water or
steam) and air, one or two tube rows are normally sufficient for heating
applications.

For Direct Expansion (DX) coils, a three or four row deep coil is the most common
coil used for comfort air-conditioning applications. A five row DX coil may be
required for applications having a large percentage of latent load.

For chilled water coils, three, four or five rows are used for normal air-conditioning
applications. Six row coils are generally used for very large percentage latent load
applications.

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3.5 SURFACE RATIO

The surface ratio is defined as ratio of total external heat transfer surface of coil to
that of internal surface of tubes. Most common designs of extended surface coils
usually have surface ratios ranging from 18 to 34.

3.6 PROVISIONS TO INCREASE AIR TURBULENCE

Air turbulence and hence outer surface heat transfer could be improved in extended
coils by using configurated fins rather than flat fins and staggered tube arrangement
as against in-line tube arrangements. However, these features also add to air side
friction resistance, though slightly.

3.7 CHILLED AND HOT WATER FLOW & REFRIGERANT AND STEAM
DISTRIBUTION

3.7.1 Chilled Water Flow Distribution

To ensure sufficient water velocities inside tube for adequate heat transfer and at the
same time to avoid excessive pumping head, water coils can be provided with
various water circuit arrangements. For instance a typical 12 tubes high and six
tubes deep coils can be arranged in 3 circuits (quarter-circuited), 6 circuits (half-
circuited), 12 circuits (full-circuited) or 24 circuits (double- circuited) parallel water
circuits as shown in Figure 2. The circuits could be arranged to get water velocities
usually ranging between 0.3 and 2.4 M/sec and pressure drop across coils varying
between 1.5 and 15 MWC. Common designs are usually with 1 to 2 M/sec and
pressure drop of around 7 MWC. The normal air-conditioning system designs
usually employ full circuited coils while half or quarter circuited coils may find
application for sensible cooling coils operating with large Log Mean Temperature
Difference (LMTD). Double-circuited coils may have application in all fresh air
cooling coils handling relatively smaller volumes of air with large tonnages.

The chilled water flow through coil can be in parallel or counter flow arrangement
as shown in Figure 3. Counter flow is most preferred arrangement for normal coils
to secure advantage of highest possible mean temperature difference between air
and chilled water. However, parallel flow arrangement may find usage while sizing
coil with large terminal temperature difference between leaving air and leaving
chilled water.
3.7.2 Refrigerant Distribution (DX Coils)

Coils using volatile refrigerants present more complex cooling fluid distribution
problems than water or brine coil. DX coils are used on two types

of refrigeration systems i.e. flooded and dry expansion.

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The flooded system is used mainly for low temperature applications where a small
temperature difference between the air and refrigerant is required. However, this
system needs large volume of refrigerant.

For dry expansion coils two of the most commonly used refrigerant liquid metering
devices are the capillary tube and the thermostatic expansion valve. Capillary tube
is frequently used with factory built self-contained air-conditioning units upto
maximum capacity of 35.2 KW (10 TR) while it is extensively used in India for
small capacity models such as window air-conditioners and split units.

The thermostatic expansion valve is commonly used for all larger factory assembled
units as well as all field assembled central AHUs.

Internally equalised thermostatic expansion valves are used for capacity upto about
5 TR. Beyond this capacity, it is recommended that externally equalised
thermostatic expansion valves be used. Thermostatic expansion valve maintains a
constant superheat for the leaving refrigerant gas. For details of thermostatic
expansion valves, refer ASHRAE Handbook, Refrigeration.

To ensure reasonably uniform refrigerant distribution in multi-circuit coils,

distributing means are provided between expansion valve and the coil to divide
refrigerant equally among all coil circuits. Such a refrigerant distributor must be
effective in distributing both liquid and vapour, because the entering refrigerant is a
mixture of the two. Figure 4 shows five typical types of refrigerant distributors.

(a) In refrigerant distributor 'A', the liquid vapour mixture from the thermostatic
expansion valve is led tangentially into a chamber. The coil circuit
connections extend outward radially at the top of this chamber.

(b) In distributor 'B', the refrigerant is discharged at a high velocity through an

orifice against the end plate, forming a uniform mixture of vapour and liquid
within the refrigerant distributor, from which individual connections are led.

(c) In distributor 'C' the refrigerant enters at high velocity from the thermostatic
expansion valve and is discharged against sidewall to operate a liquid
vapour mixture, which is led to the end plug in which the individual circuit
connections are closely arranged.

(d) 'D' and 'E' are typical pressure type distributors. The venturi throat in 'D'
minimises pressure loss. The liquid vapour mixture flows into the orifice,
which is selected to match the load so that adequate mixing of the two
phases is maintained to feed equal portions of the mixture to individual
circuits. Beyond the orifice, a conical part deflects the refrigerant stream
towards the individual circuits. The distributors can be used in either vertical
or horizontal position. However, operation in vertical position leads to best
distribution.

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Large coils fed with multiple thermostatic expansion valves can be provided with
two arrangements for partial load control i.e. face control and depth control as
shown in Figure 5. Face control is used in most cases and provides substantially
equal loading on various refrigerant circuits. However, this has the disadvantage of
permitting re-evaporation of condensate on the coil and bypassing air into
conditioned space during partial load operation. Depth control, seldom available as
standard equipment, is usually supplied on special orders. Depth control usually
produces unequal loading on the thermostatic expansion valve. Hence, care shall be
taken to properly design and size the thermostatic expansion valves to overcome
this unbalance. Normally, depth control would be required for deep row coils
having six or more rows used for high latent load applications. Depth control
eliminates air bypassing during partial load operation and minimises condensate re-
evaporation.

3.7.3 Hot Water Flow Distribution

To obtain proper water velocity in tubes for most efficient heat transfer capacity,
without excessive pressure drop through the coil, various circuit arrangements are
used as shown in Figure 6.

The most common circuiting arrangement is full circuiting, which is considered as

standard circuiting. In this arrangement, all tubes in each coil row are supplied with
an equal amount of water through a manifold commonly called coil header. A
single tube serpentine circuit arrangement can be used on small size booster heater
requiring small water quantities upto a maximum of approximately 0.25 to 0.32
lit/sec. With this arrangement a single tube handles the entire water quantity.

3.7.4 Steam Distribution

For proper performance of steam heating coils, condensate must be rapidly
eliminated and steam must be uniformly distributed to the individual tubes.
Condensates are removed by providing proper steam traps and condensate drain
lines. Uniform steam distribution is accomplished by different methods such as :
(a) Individual orifices in the tubes
(b) Distributing plates in the steam headers and
(c) Special perforated small diameter inner steam distributing tubes extending
into the larger diameter tubes of the primary surface.
Coils of the perforated inner tube type are constructed with different arrangements
such as :
(a) Supply and return on one end, with the incoming steam used to heat the
leaving condensate ( non-freeze type)
(b) Supply and return on opposite ends and
(c) Supply and return on one end and a supply on the opposite end( non-freeze
type).

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Properly designed and selected steam distribution tube coils distribute the steam
throughout the entire length of all primary tubes, even when the leaving air
temperature is controlled by modulating the steam supply through a steam metering
valve.
As steam is condensing, the steam temperature is constant. The LMTD is not
dependent on direction of steam flow. Steam and air in steam heating coils are in
cross flow only.
4.0 APPLICATION RANGE

As per ARI 410-2001, cooling coil and heating coil standard rating shall be shown
within the range of operating conditions in Table-1. For special applications the
range in above design variables could be exceeded.

5.0 INPUT AND OUTPUT DATA FOR COIL SELECTION OR SIZING

5.1 INPUT DATA

Following input data is required for selection and sizing of coils :

5.1.1 Cooling Coil

(a) Air flow rate

(b) Entering air DBT and WBT

(c) Leaving air DBT and WBT

(d) Total cooling load

(e) Sensible cooling load

(f) Entering chilled water temperature

(g) Maximum leaving chilled water temperature

(h) Maximum allowable water side and air side pressure drop

(i) Assumed bypass factor in arriving at the air flow rate

5.1.2 Heating Coil

(a) Air flow rate

(b) Entering air DBT

(c) Leaving air DBT

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(d) Total heating load

(e) Entering hot water pressure, temperature and available water flow rate or
desired temperature drop (for hot water coils)

(f) Steam pressure and temperature (for steam coils)

(g) Maximum allowable water side and air side pressure drop

5.2 OUTPUT DATA

The following are the output data from a cooling or heating coil selection :

(a) Coil face area and overall dimensions

(b) Coil cooling or heating medium flow rate

(c) Coil cooling or heating medium temperature rise or drop

(d) Coil cooling or heating medium pressure drop

(e) Coil air side pressure drop

(f) Coil air outlet DBT and WBT

(g) Coil spin spacing, tube size, number of rows.

6.0 PROCEDURE FOR SELECTION OR SIZING

6.1 COOLING COILS

6.1.1 Unit Rating Method

Coils can be sized or selected from manufacturers’ data furnished for specific unit
size of given face area and rows depth. Typical examples of sizing coils by this
method are illustrated for chilled water coil and DX coil in examples 1 and 3
respectively of Appendix-1.
6.1.2 Basic Data Method
Certain manufacturers furnish derived heat transfer parameters in the form of tables
or charts from which by taking certain physical dimensions of coil face area the coil
rows depth is determined. In this procedure it is frequently necessary to re-check
and re-select the various parameters to more closely match the required air and
cooling fluid conditions with integral rows depth. Typical example of sizing coil by
this method is illustrated in example 2 of Appendix-1.

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6.2 HEATING COILS

The selection of heating coils is relatively simple, because it involves DBT and
sensible heat only. Heating coils are usually selected from manufacturers’
performance charts or tables giving final air temperature at various air face
velocities, entering air temperatures and steam or water temperatures. Most coil
manufacturers have their own methods of producing performance rating charts or
tables from a suitable number of coil performance tests. Typical example of
selecting coil from manufacturer’s charts, table or curves is given in Appendix-2.

6.3 COIL SIZING FROM FUNDAMENTAL PRINCIPLES

By this method coil can be sized by estimating fundamental heat transfer resistances.
This method helps in sizing coils without much relying on manufacturers’ data or
establishing the performance of already installed coil with varying parameters. This
method also needs few iterations to finalise the exact parameters. This method is
normally not used in jobs executed by TCE.

6.4 COMPUTER SELECTION

Some manufacturers use computer programmes to select the cooling and heating
coils. Input requirements are the same as given in para 5.1. Computer output gives
the various parameters of the selected coils.

7.0 REFERENCES

7.1 ASHRAE Handbook, Equipment, 1979 Edition

7.2 ASHRAE Handbook, Refrigeration, 2002 Edition

7.3 ARI 410-2001 Standard for Forced-Circulation Air-Cooling and Air-Heating Coils

7.4 Engineering Bulletin - Hot water heating coils - Blue Star Limited

7.5 Engineering Bulletin - Air Handling Units - Frick India Limited

7.6 Air-Conditioning & Refrigeration Engineer’s Handbook - Voltas Limited,
1977 Edition

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APPENDIX-1

EXAMPLES OF COOLING COIL SELECTION PROCEDURE

The following abbreviations and suffixes are used in Appendix-1 and Appendix-2.
Units are indicated at appropriate places.

ABBREVIATIONS

Q = Flow rate ∆h = Difference in enthalpy

V = Velocity ∆t = Difference in temperature
t = Temperature BF = Bypass Factor
h = Enthalpy FA = Face Area
∆p = Pressure drop GTH = Grand Total Heat

SUFFIXES
1 = entering af = air face
2 = leaving adb = air dry bulb
o = outside awb = air wet bulb
i = inside cw = cold water
a = air hw = hot water

EXAMPLE-1: CHILLED WATER COIL - BASED ON RATING CHARTS

FURNISHED BY VOLTAS LIMITED

1.0 INPUT DATA

(a) Air flow rate, Qa = 14,000 CFM

(b) Entering air DBT, tadb1 = 79 0 F

(c) Entering air WBT, tawb1 = 68 0 F

(d) Leaving air DBT, tadb2 = 59 0 F

(e) Leaving air WBT, tawb2 = 58 0 F

(f) Entering chilled water temperature , t cw1 = 46 0 F

(g) Allowable chilled water pressure drop, ∆pcw = 7 MWC

(h) BF (Assumed during estimation of air flow = 0.10

rate)

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 12 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

2.0 SELECT COIL FACE AREA

Minimum coil face area to keep the air face velocity around 500 FPM (2.5
M/sec)

Coil face area, FA = Qa / 500 = 14,000 / 500

= 28 FT2

From Table-2 select AH-11 having nearest face area to meet the requirement
i.e. 34 FT2 (3.16 M2 )

Air face velocity, Vaf = 14,000 / 34

= 411.76 FPM

Say = 410 FPM (Acceptable)

3.0 CHECK BYPASS FACTOR

From Figure-7, select 4 rows depth coil as it has bypass factor of about 0.08 at
410 FPM, which is reasonably close to assumed bypass factor of 0.1.

4.0 ESTIMATE CHILLED WATER FLOW RATE

Enthalpy of entering air, ha1 = 32.50 BTU/lb (*)

Enthalpy of leaving air, ha2 = 25.25 BTU/lb (*)

---------------
ha1-ha2 = ∆h = 7.25 BTU/lb
(*) From psychrometric chart

Grand Total Heat (GTH) = 4.5 x Qa x ∆h

= 4.5 x 14,000 x 7.25

= 4,56,750 BTU/Hr

Say = 4,57,000 BTU/Hr

(tadb1 - tadb2 )
Apparatus Dew Point (ADP) = tadb1 -
(1 - BF)
ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 13 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

(79 - 59)
= 79 -
(1 - 0.08)
0
= 57.26 F

Say = 57 0 F

GTH
Coil loading rate (q) =
(ADP – tcw1 )

4,57,000
=
(57-46)

= 41,545 BTU/Hr 0 F

As indicated in Figure-8, Chart q = Actual q / Factor. Factor for Unit AH-11 is 3.

41,545
Chart q = = 13,848 BTU/Hr0 F
3

Say = 13,900 BTU/Hr0 F

From Figure-8, read chilled water flow rate at

q = 13,900 BTU/Hr 0 F and air face velocity = 410 FPM

Chart chilled water flow rate = 23 USGPM

Actual GPM = Chart GPM x 3. Factor for Unit AH-11 is 3

Actual flow rate, Qcw = 23 x 3 = 69 USGPM

= 15.68 M3 /Hr

Say = 16 M3 /Hr

5.0 ESTIMATE WATER SIDE PRESSURE DROP

From Figure-8 top curve read water side pressure drop for unit flow of 23
USGPM as 2 psi

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 14 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

Actual psi = Chart psi x Factor. Factor for Unit AH-11 is 0.92
Pressure drop referred to actual coil size

= 2 x 0.92

= 1.84 psi

= 1.84 x 0.7 MWC

Chilled water pressure drop, ∆pcw = 1.29 MWC Say 1.3 MWC

6.0 ESTIMATE AIR SIDE PRESSURE DROP

From Table-3 read air side pressure drop for 4 row wet coil corresponding to
410 FPM air face velocity and wet surface coil (interpolated value) as

Pressure drop = ∆pa = 0.384 inches of WC

= 9.75 mmWC

7.0 ESTIMATE CHILLED WATER TEMPERATURE RISE

GTH
Chilled water temperature rise , ∆tcw =
Qcw (GPM) x 500

= 4,57,000 / (69 x 500)

= 13.25 0 F = 7.36 0C

This temperature is higher than the maximum temperature rise of about 6 0 C

generally specified. If the temperature rise is higher than that specified, another
coil has to be selected meeting other requirements and temperature rise brought
within the specified limit.

8.0 SUMMARY OF PARAMETERS

Coil face area ,FA = 3.16 M2 (34 FT2 )

Total cooling capacity = 38 TR (4,57,000 BTU/Hr)

Chilled water flow rate, Qcw = 16 M3 /Hr

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 15 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

Number of rows deep = 4

Fin spacing = 5 fins/cm (13 fins/inch)

Water side pressure drop, ∆pcw = 1.3 MWC

Air side pressure drop, ∆pa = 9.75 mmWC

Based on the layout constraints and meeting the coil face area requirements,
manufacturer shall furnish coil dimensions.

EXAMPLE-2: CHILLED WATER COIL - BASED ON BASIC DATA

FURNISHED BY FRICK INDIA LIMITED

1.0 INPUT DATA

Same as for example 1.

2.0 SELECT COIL FACE AREA

Minimum coil face area to keep air face velocity around 500 FPM (2.5 M/sec)

Coil face area, FA = Qa / 500 = 14,000 / 500

= 28 FT2

From Table-4 select model FAH-145 having face area of 29 FT2 and 28 tubes
in face.

Actual air face velocity, Va = 14,000/29

= 482.76 FPM

Say = 480 FPM

3.0 ESTIMATE CHILLED WATER FLOW RATE

Assume temperature rise through coil (∆tcw) = 10 0 F

GTH
Chilled water flow rate, Qcw =
500 x ∆tcw
ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 16 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

4,57,000
=
500 x 10

= 91.4 USGPM

Say = 90 USGPM

91.4 x 10
Actual temperature rise, ∆tcw =
90

= 10.16 0 F

Leaving chilled water temperature,

tcw2 = tcw1 + ∆tcw = 46 + 10.16 = 56.16 0 F

4.0 ESTIMATE WATER VELOCITY THROUGH TUBES

Assuming full circuited coil

Qcw(USGPM) x 1.235
Water velocity Vcw =
Number of tubes in face
where 1.235 is the factor for 5/8”diameter coil

90 x 1.235
=
28

= 3.97 FPS(Acceptable as within applicable range)

Say = 4 FPS

5.0 ESTIMATE SENSIBLE HEAT TRANSFER FACTOR (K) AND

MULTIPLYING FACTOR FOR WETTED SURFACE COIL (Ws)

From Table-5 read value of K for water velocity of 4 FPS and air face velocity
of 480 FPM (interpolated) as

K = 173.20 BTU/(Hr row FT2 of coil face area 0 F LMTD)

Coil Sensible Load = 1.08 x Qa (tadb1 - tadb2 )

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 17 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

= 1.08 x 14,000 x (79-59)

= 3,02,400 BTU/Hr

Coil Sensible Load 3,02,400

Sensible Heat Factor (SHF) = =
GTH 4,57,000

= 0.6617

Say = 0.66

From Table-6 read value of Ws for SHF = 0.66 and water velocity = 4 FPS

Ws = 0.891

(tadb1 - tcw2 ) - (tadb2 - tcw1 )

LMTD =
(tadb1 - tcw2 )
ln
(tadb2 - tcw1 )

(79 - 56.16) - (59 - 46)

=
(79 - 56.16)
ln
(59 - 46)

= 17.46 0 F

Say = 17.5 0 F

6.0 ESTIMATE NUMBER OF ROWS

GTH x SHF
Number of rows =
K x LMTD x Ws x FA

4,57,000 x 0.66
=
173.20 x 17.5 x 0.891 x 29
= 3.85 rows

Say = 4 rows

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 18 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

7.0 Water side pressure drop and air side pressure drop can be estimated from the
water pressure drop and air pressure drop tables or charts.

8.0 SUMMARY OF PARAMETERS

Coil face area, FA = 2.7 M2 (29 FT2 )

Total cooling capacity = 38 TR (4,57,000 BTU/Hr)

Chilled water flow rate, Qcw = 20.5 M3 /Hr

Number of rows deep = 4

Fin spacing = 3.15 fins/cm (8 fins/inch)

EXAMPLE-3: DIRECT EXPANSION VOLATILE REFRIGERANT COILS

1.0 INPUT DATA

Same as for example 1.

2.0 SELECT COIL FACE AREA

From Table-2 select AH-9 with 22.6 FT2 (2.10 M2 ) coil face area .

Air face velocity = 14000 / 22.6

= 619.47 FPM

Say = 625 FPM

This air face velocity is on a higher side of the recommended velocity of

around 2.5 M/sec. However, the refrigerant evaporating temperature selection
method is explained below.
Grand Total Heat (GTH) = 4,57,000 BTU/Hr

3.0 ESTIMATE REFRIGERANT EVAPORATING TEMPERATURE

In Figure-9, enter at upper right hand side with GTH = 4,57,000 BTU/Hr and
move upto intersection with 625 FPM curve. From this point project down to
intersect with air entering wet bulb temperature curve of 68 o F, reading
refrigerant evaporating temperature of approximately 50 o F.
ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 19 OF 49

COOLING AND HEATING COILS

APPENDIX-1 (CONTD.)

4.0 SUMMARY OF PARAMETERS

Coil face area, FA = 2.10 M2 (22.6 FT2 )

Total cooling load, GTH = 38 TR (4,57,000 BTU/Hr)

Refrigerant (R - 22)
Refrigerant evaporating temperature = 10 o C (50 o F)

Number of rows deep =5 (from Figure-9)

Fin spacing = 5 fins/cm (13 fins/inch)(from Figure-9)

Air side pressure drop = 0.89 INCHES WC ( 23mmWC)

(from Table-3)

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 20 OF 49

COOLING AND HEATING COILS

APPENDIX-2

EXAMPLES OF HEATING COIL SELECTION PROCEDURE

For abbreviations and suffixes, refer Appendix-1.

EXAMPLE-1: HOT WATER COIL - BASED ON RATING CHARTS AND

TABLES FURNISHED BY BLUE STAR LIMITED

1.0 INPUT DATA

(a) Heating load = 1,02,000 BTU/Hr

(b) Air flow rate, Qa = 2,500 CFM

(c) Entering air DBT , tadb1 = 60 0 F

(d) Air face velocity, Vaf = 600 FPM

(e) Water pressure drop, ∆phw = 10 feet of water

(f) Entering water temperature , thw1 = 150 0 F

(g) Leaving water temperature, thw2 = 138 0 F

2.0 DETERMINE COIL FACE AREA

Qa 2,500
Coil face area = = = 4.17 FT2
Vaf 600

3.0 TUBES HIGH (TH) AND FINNED LENGTH (FL)

From Table-7 select TH =10 and FL =48 INCHES

Coil face area ,FA = 4.2 FT2

Several combinations of TH and FL are possible to obtain same area. Select

TH and FL based on layout consideration.

4.0 KBH / FT2 , where KBH = 1,000 BTU/Hr

102
= 24.5 KBH/ FT2
4.17

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 21 OF 49

COOLING AND HEATING COILS

APPENDIX-2 (CONTD.)
5.0 CALCULATE QB

QB = (Average water temp – tadb1 ) x 0.308 (constant)

= (144-60) x 0.308 = 25.9 KBH/ FT2

6.0 For heating, F1 (water temperature rise factor) = 1.0

7.0 ESTIMATE HOT WATER FLOW RATE

KBH x 2 102 x 2
Hot water flow rate, Qhw = = = 17 USGPM
∆thw 12

= 17/4.4 = 3.9 M3 /Hr

8.0 ESTIMATE HOT WATER PRESSURE DROP

In Figure-10 choose a water circuit, taking into consideration any limitation on

Water Pressure Drop (WPD)

Accordingly choose circuit B, WPD = 6 FT

Qhw (USGPM)x R
Calculate water velocity, Vhw =
TH x RD
Where R= water velocity constant to be obtained from Table-8 = 6.84

TH= Tubes High =10 (from para 3.0)

RD= Rows Deep = 2 (assumed)

17 x 6.84
Vhw = = 5.81 FPS
10 x 2
Vhw of 5.81 FPS is within acceptable limit.

Now correct the 6 FT WPD for Vhw of 5.81

From Figure-10 multiplication factor = 1.95

6 FT x 1.95 = 11.7 FT

Now correct for thw1 of 150 0 F

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 22 OF 49

COOLING AND HEATING COILS

APPENDIX-2 (CONTD.)

From formula given in Figure-10

Heating WPD = WPD[0.75 +0.0012 (180-thw1 )]

= 11.7 x [ 0.75 + 0.0012 (180-150)] = 9.2 FT

WPD of 9.2 FT is within specified limit.

9.0 OBTAIN WATER VELOCITY FACTOR , F2

From Figure-11 read F2 = 1.0

10.0 CALCULATE F3

KBH / FT2 required = QB x F1 x F2 x F3

Where, KBH / FT2 = 24.5 (from para 4.0) ; F1 = 1.0 (from para 6.0)

F2 = 1.0 (from para 9.0)

24.5 = 25.9 x 1 x 1 x F3

which gives F3 = 0.95

11.0 SELECT FINS PER INCH (FPI)

In Figure-12, for 2 rows deep, F3 = 0.95 and air face velocity = 600 FPM,
select a FPI that provides a value of F3 greater than required. Choose 10 FPI.
Then F3 = 1.0

12.0 ESTIMATE ACTUAL KBH

Actual KBH / FT2 = QB x F1 x F2 xF3

= 25.9 x 1 x 1 x 1 = 25.9

Actual KBH = 25.9 x 4.17 = 108 KBH

or 1,08,000 BTU/Hr

13.0 CALCULATE LEAVING AIR DRY BULB TEMPERATURE (tadb2 )

KBH x 1000 108.0 x 1,000

tadb2 = tadb1 + = 60 + = 100 0 F
1.08 x Qa 1.08 x 2,500

ISSUE
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TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX

TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 23 OF 49

COOLING AND HEATING COILS

APPENDIX-2 (CONTD.)
14.0 CALCULATE AIR PRESSURE DROP (∆pa)

From Figure-13 , Y = 0.082

Air pressure drop, ∆pa = Y x Rows deep = 0.082 x 2

= 0.164 INCHES WC = 4.17 mmWC

15.0 SUMMARY OF PARAMETERS

Coil face area, FA = 0.39M2 ( 4.17 FT2 )

Total heating capacity = 25,760 Kcals/Hr (1,02,000 BTU/Hr)

Hot water flow rate, Qhw = 3.9 M3 /Hr

Number of rows deep = 2

Fins spacing = 4 fins /cm (10 fin/inch)

Water side pressure drop, ∆pw= 2.8MWC

Air side pressure drop, ∆pa = 4.17 mmWC

EXAMPLE-2: HOT WATER COIL - BASED ON RATING CHARTS AND

TABLES FURNISHED BY VOLTAS LIMITED
1.0 INPUT DATA

(a) Outside design temperature, to = 0 0F

(b) Inside design temperature, ti = 70 0 F

(c) Heating load = 2,00,000 BTU/Hr

(d) Total air flow rate, Qa = 4,000 CFM

(e) Outside air flow rate, Qo = 800 CFM

(f) Entering water temperature, thw1 = 180 0 F

(g) Unit size(Selected based on
total cooling load, dehumid- = AH-5
ified CFM and air face velocity)
(h) Air face velocity, Va = 500 FPM

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 24 OF 49

COOLING AND HEATING COILS

APPENDIX-2 (CONTD.)
2.0 Calculate the temperature of the air mixture entering the coil
Qo x to + Qi x ti
tmixture =
Qa

(800 x 0 ) + (3,200 x 70)

= = 56 0 F
4,000
3.0 DETERMINE BTU CONSTANT

From Table-9

for water temperature drop = 20 0 F,

entering water temperature = 180 0 F and

entering air temperature = 56 0 F,

interpolating between 50 0 F and 60 0 F ,

the hot water BTU constant = 0.87

4.0 CALCULATE TABLE BTU/HR

Dividing the given heating load = 2,00,000 BTU/Hr by the BTU constant =
0.87,

Table BTU/Hr = 2,30,000 BTU/Hr

This value is to be used in Table-10 which is based on entering water

temperature = 200 0 F, entering air temperature =60 0 F and hot water
temperature drop =20 0 F.

5.0 DETERMINE HOT WATER FLOW RATE AND PRESSURE DROP

From Table-10 for 2 row coil, unit size = AH-5 and face velocity = 500 FPM

the BTU/Hr is 2,48,000,

Qhw = 25 USGPM = 25 x 0.227 M3 /Hr = 5.7 M3 /Hr

∆phw = 0.98 psi =0.98 x 0.69 MWC = 0.68 MWC

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 25 OF 49

COOLING AND HEATING COILS

APPENDIX-2 (CONTD.)

6.0 FIND THE LEAVING AIR TEMPERATURE

BTU / Hr required
Tadb2 = tadb1 +
1.08 x CFM

2,00,000
= 56 + = 102.3 0 F
1.08 x 4,000

7.0 DETERMINE ACTUAL TEMPERATURE DROP

BTU/Hr required
Water temperature drop, ∆thw =
500 x Water Flow Rate (USGPM)

2,00,000
= = 16 0 F
500 x 25
8.0 SUMMARY OF PARAMETERS

Coil face area, FA = 0.767 M2 (from Table-2)

Total heating capacity = 50,500 Kcal/Hr (2,00,000 BTU/Hr)

Hot water flow rate, Qhw = 5.7 M3 /Hr.

Number of rows deep = 2

Water side pressure drop,∆phw= 0.68 MWC

Air side pressure drop , ∆pa = 3 mmWC (0.12 INCHES WC) (from Table-3)

EXAMPLE-3: STEAM HEATING COIL : BASED ON RATING CHARTS

AND TABLES FURNISHED BY VOLTAS LIMITED

1.0 INPUT DATA

(a) Outside design condition, to = 0 0 F

(b) Inside design condition, ti = 70 0 F

(c) Heating Load = 2,80,000 BTU/Hr

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 26 OF 49

COOLING AND HEATING COILS

APPENDIX-2 (CONTD.)

(d) Total air flow rate, Qa = 4,000 CFM

(e) Outside air flow rate,Qo = 800 CFM

(f) Unit size ( selected based on total cooling load,

dehumidified CFM and air face velocity) = AH-5

(g) Air face velocity ,Va = 500 FPM

(h) Steam pressure available = 10 psig

2.0 Calculate the temperature of the mixed air entering the coil using the formula
Qo x to + Qi x ti
tmixture =
Qa

(800 x 0) + (3,200 x70)

= = 56 0 F
4,000
3.0 ESTIMATE EQUIVALENT HEATING COIL CAPACITY

As 10 psig steam is available, calculate the equivalent capacity of a heating

coil when operating at 2 psig steam and 70 0 F entering air

10 psig saturated steam temperature = 240 0 F

BTU/Hr required x 149
Equivalent capacity = (Voltas Handbook)
Steam temp. - entering air temp.

2,80,000x 149
= = 2,26,740 BTU/Hr
240 - 56
Say = 2,27,000 BTU/Hr

4.0 SELECT THE COIL

From Table-11 for AH-5 heating coil, for 2 psig steam and entering air
temperature = 70 0 F and coil air face velocity = 500 FPM, select a 1 row high
rise coil. Capacity = 2,33,000 BTU/Hr. This capacity will work satisfactorily.
ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 27 OF 49

COOLING AND HEATING COILS

APPENDIX-2 (CONTD.)

The actual capacity of the coil = 2,33,000 x (240 - 56) / 149

= 2,88,000 BTU/Hr

5.0 DETERMINE LEAVING AIR TEMPERATURE

The leaving air temperature is found from the formula :

BTU/Hr required
tadb2 = tadb1 +
1.08 x Qa

2,80,000
= 56 + = 120.8 0 F
1.08 x 4,000
6.0 SUMMARY OF PARAMETERS

Coil face area = 0.767 M2 (from Table-2)

Total heating capacity = 70,700 Kcal/Hr (2,80,000 BTU/Hr)

Number of rows deep = 1

Air side pressure drop , ∆pa = 2 mmWC (0.08 INCHES WC) (from Table-3)

ISSUE
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TCE CONSULTING ENGINEERS LIMITED SECTION: TABLE

TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 39 OF 49

COOLING AND HEATING COILS

TABLE - 1 RANGES OF STANDARD RATING CONDITIONS

SL. ITEM UNIT COOLING COILS HEATING COILS

NO. VOLATILE COLD COLD STEAM HOT HOT
REFRIGE- WATER ETHYLENE WATER ETHYLENE
RANT GLYCOL GLYCOL
SOLUTION SOLUTION
1. Standard air face M/ 1 to 4 1 to 4 1 to 4 1 to 8 1 to 8 1 to 8
velocity sec
2. Entering air dry- 18 to 38 18 to 38 18 to 38 (-) 29 (-) 18 (-) 29 to
0
bulb temperature C to 38 to 38 38
3. Entering air wet- 16 to 29 16 to 29 16 to 29 -- -- --
0
bulb temperature C
4. Tube-side fluid M/ 0.3 to 0.3 to 1.8 0.1 to 0.1 to 1.8
velocity Sec -- 2.4 (N1) (N2) -- 2.4 (N2)
(N1)
5. Entering fluid -- 1.7 to 18 (-) 18 to 32 -- 49 to (-) 18 to
0
temperature C 121 93
6. Saturated suction
0
refrigerant C (-) 1.1 to -- -- -- -- --
temperature 13
at coil outlet
7. Minimum suction
0
vapour superheat at C 3.3 -- -- -- -- --
coil outlet
8. Steam pressure at KPa -- -- -- 14 to -- --
coil inlet (g) 1723
9. Maximum superheat -- -- -- 28 -- --
0
in steam at coil inlet C
10. Concentration by -- -- 10 to 60 -- -- 10 to 60
mass %
11. Minimum fin > 0.0 > 0.0 > 0.0 > 0.0 > 0.0 > 0.0
0
surface temperature C
12. Minimum tube wall > ethylene > ethylene
0
surface temperature C > 0.0 > 0.0 glycol > 0.0 > 0.0 glycol
solution solution
freeze freeze
point point
NOTES
1. On lower limit, Reynolds Number shall exceed 3,100 at mean water temperature.
2. On lower limit, Reynolds Number shall exceed 700 at mean glycol temperature.

SOURCE: ARI 410-2001

ISSUE
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TABLE-2 PHYSICAL DATA - AIR HANDLING UNITS

UNIT SIZE AH-0 AH-1 AH-2 AH-3 AH-5 AH-6 AH-7 AH-9 AH-11 AH-12
3
CAPACITY IN M /HR BASED ON COIL FACE VELOCITIES
TCE.M6-ME-811-304

AIR FACE VELOCITY, M/sec 3.5 4420 7260 9820 13330 20825 26900 40460 53790
3 3790 6220 8415 11425 17850 23050 34680 46100
2.5 3160 5185 7015 9520 14875 19200 28900 38420
2 1140 1715 2515 4150 5610 7615 11900 15370 23120 30735

1.5 850 1290 1890 3110 4210 5715 8925 11525 17350 23050
1 570 865
COOLING AND HEATING COILS
2
COIL FACE AREA , M 0.155 0.236 0.344 0.567 0.767 1.041 1.626 2.100 3.160 4.201
NUMBER OF TUBES IN FACE 8 10 10 16 20 20 20 20 30 40

OUTSIDE SURFACE AREA, M2 2 ROW 7.342 10.409 18.587 27.881 40.892 55.298 82.714 111.06 166.82 222.12

3 ROW 11.060 17.100 28.067 42.286 61.803 83.178 124.07 166.82 250.00 333.64
4 ROW 14.684 22.700 37.639 56.227 82.249 110.595 165.43 222.12 333.64 444.24
5 ROW 18.401 28.439 46.933 70.167 102.695 138.011 206.32 277.89 416.36 555.76
1
6 ROW 22.119 34.108 56.227 84.572 123.606 166.357 333.64 248.14 500.00 667.29
NUMBER OF FANS AND OUTLETS 1 1 1 1 1 1 2 2 3 3

WHEEL SIZE - DIAMETER , mm 190 240 325 325 380 457 380 457 457 457
2
GUIDE FOR SELECTION OF

OUTLET AREA, M 0.048 0.079 0.117 0.165 0.242 0.325 0.483 0.651 0.976 0.976
COOLING AND HEATING COILS

MAXIMUM OPERATING SPEED RPM 1800 1500 1100 1100 1100 900 1100 900 900 900
FILTERS 625 x 400 x 25 1
TCE CONSULTING ENGINEERS LIMITED

625 x 375 x 25 1
625 x 500 x 50 2 6 4 12 18 24
625 x 400 x 50 2 6 6
500 x 500 x 50
MINIMUM LOAD FOR DX
2 ROWS 3.03 4.55 9.10 9.10 18.20 18.20 27.3 36.4
COILS (1000 Kcals/Hr) MINIMUM LOAD
3,4 5 ROWS
FOR&DX COILS 6.06 9.10 18.20 18.20 36.40 36.40 54.6 72.8
SOURCE : VOLTAS HANDBOOK-1977

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SHEET 40 OF 49

ISSUE
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TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 41 OF 49

COOLING AND HEATING COILS

TABLE-3 AIR SIDE RESISTANCE OF COOLING AND HEATING COILS

(INCHES OF WATER COLUMN)

SL. AIR COOLING COIL (NOTE 2) HEATING COIL

NO. FACE 2 3 4 5 6 1 ROW 2
VELO- ROW ROW ROW ROW ROW LOW HIGH ROW
CITY RISE RISE
FPM
(NOTE 1)
1. 300 0.12 0.18 0.24 0.30 0.36 0.01 0.03 0.05
2. 350 0.15 0.23 0.30 0.38 0.45 0.01 0.04 0.07
3. 400 0.18 0.28 0.37 0.47 0.55 0.02 0.06 0.08
4. 450 0.22 0.33 0.44 0.55 0.66 0.02 0.07 0.10
5. 500 0.26 0.39 0.52 0.65 0.78 0.03 0.08 0.12
6. 550 0.30 0.45 0.60 0.76 0.90 0.03 0.10 0.14
7. 600 0.34 0.51 0.68 0.85 1.00 0.04 0.11 0.17
8. 650 0.37 0.55 0.74 0.93 1.10 0.04 0.13 0.19
9. 700 0.40 0.66 0.81 1.01 1.21 0.05 0.15 0.22

NOTES

1. Air quantity for each unit size corresponding to the air face velocity is
shown in the physical data in Table-2.

2. Cooling coil resistance is based on wet surface.

ISSUE
SOURCE : VOLTAS HANDBOOK-1977
R2
TCE CONSULTING ENGINEERS LIMITED SECTION: TABLE

NO. HEAT 1 1.5 2 2.5 3 3.5 4 5 6
FACTOR
1. 0.40 0.605 0.638 0.688 0.690 0.707 0.722 0.736 0.750 0.765
2. 0.42 0.624 0.657 0.687 0.705 0.723 0.737 0.750 0.763 0.770
3. 0.44 0.643 0.676 0.706 0.720 0.739 0.750 0.764 0.777 0.787
4. 0.46 0.662 0.695 0.724 0.735 0.755 0.767 0.780 0.790 0.803
5. 0.48 0.680 0.714 0.739 0.752 0.772 0.784 0.795 0.803 0.818
6. 0.50 0.698 0.728 0.754 0.766 0.785 0.798 0.807 0.816 0.829
7. 0.52 0.713 0.740 0.769 0.782 0.800 0.811 0.820 0.829 0.841
8. 0.54 0.728 0.757 0.783 0.796 0.813 0.822 0.831 0.842 0.852
9. 0.56 0.743 0.770 0.796 0.810 0.824 0.833 0.841 0.853 0.860
10. 0.58 0.759 0.782 0.810 0.822 0.837 0.844 0.851 0.861 0.868
11. 0.60 0.772 0.796 0.823 0.835 0.849 0.855 0.862 0.872 0.880
12. 0.62 0.785 0.808 0.832 0.847 0.859 0.866 0.871 0.880 0.888
13. 0.64 0.800 0.822 0.846 0.857 0.868 0.876 0.881 0.889 0.896
14. 0.66 0.813 0.835 0.855 0.867 0.877 0.885 0.891 0.898 0.905
15. 0.68 0.826 0.848 0.867 0.876 0.887 0.893 0.900 0.907 0.913
16. 0.70 0.839 0.860 0.878 0.886 0.897 0.902 0.908 0.915 0.921
17. 0.72 0.850 0.871 0.888 0.896 0.906 0.911 0.916 0.923 0.928
18. 0.74 0.864 0.880 0.899 0.905 0.913 0.919 0.924 0.929 0.935
19. 0.76 0.875 0.890 0.907 0.914 0.922 0.926 0.931 0.936 0.941
20. 0.78 0.888 0.901 0.916 0.923 0.930 0.933 0.938 0.942 0.947
21. 0.80 0.899 0.911 0.925 0.932 0.938 0.940 0.944 0.948 0.952
22. 0.82 0.910 0.921 0.933 0.939 0.942 0.946 0.951 0.954 0.957
23. 0.84 0.921 0.931 0.942 0.945 0.950 0.952 0.957 0.960 0.962
24. 0.86 0.933 0.941 0.950 0.952 0.957 0.960 0.963 0.965 0.967
25. 0.88 0.944 0.951 0.956 0.959 0.963 0.964 0.970 0.971 0.972
26. 0.90 0.955 0.960 0.966 0.967 0.970 0.968 0.975 0.976 0.977

SOURCE : FRICK INDIA LIMITED – ENGINEERING BULLETIN ISSUE

R2
TABLE-7 COIL FACE AREAS (FA)
(SQUARE FEET)
TUBES HIGH (TH) 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
FINNED HEIGHT 7.5 10.0 12.5 15 17.5 20.0 22.5 25.0 27.5 30.0 32.5 35.0 37.5 40.0 42.5 45.0
(FH) - INCHES
TCE.M6-ME-811-304

12 0.6 0.8 1.0

18 0.9 1.3 1.6 1.9 2.2
24 1.3 1.7 2.1 2.5 2.9 3.3 3.8
30 1.6 2.1 2.6 3.1 3.7 4.2 4.7 5.2 5.7
36 1.9 2.5 3.1 3.8 4.4 5.0 5.6 6.3 5.9 7.5 8.1
42 2.9 3.7 4.4 5.1 5.8 6.6 7.3 8.0 8.8 9.5 10.2 10.9
48 3.3 4.2 5.0 5.8 6.7 7.5 8.3 9.2 10.0 10.8 11.7 12.5 13.3 14.2
54 4.7 5.6 6.6 7.5 8.4 9.4 10.3 11.3 12.2 13.1 14.1 15.5 15.9 16.9
60 5.2 6.3 7.3 8.3 9.4 10.4 11.5 12.5 13.5 14.6 15.6 16.7 17.7 18.8
66 6.9 8.0 9.2 10.3 11.5 12.6 13.8 14.9 16.0 17.2 18.3 19.5 20.6
72 7.5 8.8 10.0 11.3 12.5 13.8 15.0 16.9 17.5 18.8 20.0 21.3 22.5
78 9.5 10.8 12.2 13.5 14.9 16.3 17.6 19.0 20.3 21.7 23.0 24.4
84 10.2 11.7 13.1 14.6 16.0 17.5 19.0 20.4 21.9 23.3 24.8 26.3
90 12.5 14.1 15.6 17.2 18.8 20.3 21.9 23.4 25.0 26.6 28.1
96 13.3 15.0 16.7 18.3 20.0 21.7 23.3 25.0 26.7 28.3 30.0
102 15.9 17.7 19.5 21.3 23.0 24.8 26.6 28.3 30.1 31.9
108 16.9 18.8 20.6 22.5 24.4 26.3 28.1 30.0 31.9 33.8

FINNED LENGTH (FL) - INCHES

114 19.8 21.8 23.8 25.7 27.7 29.7 31.7 33.7 35.6
GUIDE FOR SELECTION OF

120 20.8 22.9 25.0 27.1 29.2 31.3 33.3 35.4 37.5
COOLING AND HEATING COILS

126 21.9 24.1 26.3 28.4 30.6 32.8 35.0 37.2 39.4
TCE CONSULTING ENGINEERS LIMITED

132 22.9 25.2 27.5 29.7 32.0 34.4 36.7 38.9 41.3
140 24.0 26.3 28.8 31.0 33.5 35.9 38.4 40.7 43.2

FINNED LENGTH AVAILABLE IN 2 INCH INCREMENTS FROM 12 TO 140 INCHES

SOURCE: BLUE STAR LIMITED – ENGINEERING BULLETIN

R2
SECTION: TABLE

SHEET 45 OF 49

ISSUE
TCE CONSULTING ENGINEERS LIMITED SECTION: TABLE

TCE.M6-ME-811-304 GUIDE FOR SELECTION OF SHEET 46 OF 49

COOLING AND HEATING COILS

TABLE-8 WATER VELOCITY CONSTANT ‘R’

COIL CIRCUIT COOLING HEATING TUBE WALL CONSTANT

BTU/Hr
Temperature Rise =
1.08 x CFM

SOURCE: VOLTAS HANDBOOK-1977 ISSUE

R2
TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET i OF iii

DESIGN GUIDE FOR DUCT SIZING

FILE NAME: M6ME307R2.DOC

REV. NO. R0 R1 R2
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN

PPD. BY DSJ/BM/DJ Sd/-/Sd/-/Sd/- HRK Sd/- TPR

CHD. BY SJB Sd/- PRJ Sd/- HRK

R2
APD. BY RRG Sd/- RL Sd/- RL

DATE 21.01.1986 15.02.2000 20.03.2003

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET ii OF iii

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 INPUT DATA 1

3.0 METHODS OF DUCT SIZING 1

4.0 DUCT SIZING BY EQUAL FRICTION METHOD 2

5.0 REFERENCES 8

ISSUE
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TCE CONSULTING ENGINEERS LIMITED SECTION: REV. STATUS
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET iii OF iii

REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 21.01.1986 ---

R1 15.02.2000 Completely revised.

R2 20.03.2003 Generally revised.

ISSUE
R2

TCE FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET 1 OF 8

1.0 SCOPE

This document gives guidelines for duct sizing for air-conditioning, ventilation
and dust extraction systems.

2.0 INPUT DATA

The following data shall be obtained from the preliminary single-line duct
layout drawings:

(a) Proposed duct routing with air flow rates in each individual duct branch

(b) Type, sizes and locations of air outlets and inlets. Orientation of grilles
to be indicated, i.e. location on side or bottom of duct.

(c) Maximum allowable friction drop in the ducting system

(d) Dust or powder loading on the duct. This item is required only for the
dust extraction systems

3.0 METHODS OF DUCT SIZING

The duct sizing is carried out by the following methods:

3.1 EQUAL FRICTION METHOD

In this method the duct sizing is done for a constant pressure loss per unit
length. This implies that the longest air flow path will dictate the maximum
pressure drop in the system. This method is simple to use and made even easier
by the use of ductulators.

3.2 STATIC REGAIN METHOD

In this method the ducts for succeeding duct branches are sized so as to reduce
the duct velocity and effect an increase in the air static pressure. This causes the
duct sizes to be larger increasing the ducting system cost. This method is
therefore, generally not used. For a more detailed description of this method of
ducting system design, ASHRAE Handbook, Fundamentals, 2001 edition may
be referred.

3.3 T-METHOD

This is a computerised method, developed for optimisation of the ducting

system design minimising the total costs considering the plant operation and
installation costs. If required, ASHRAE Handbook, Fundamentals, 2001 edition
may be referred.

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4.0 DUCT SIZING BY EQUAL FRICTION METHOD

4.1 The equal friction method is generally used in TCE for duct sizing. In this
method the length of the longest branch governs the total static pressure drop in
the system. In case the allowable pressure drop in the system is specified, the
friction drop per unit length of the duct is given by the following expression:
n
∆p = [∆P - Σ x ]] / L
i
i=1
Where,

∆p = Friction drop per unit length of duct (mmWG / M)

∆P = Allowable friction drop in the system (mmWG)

xi = Friction drop across elements in the system like cooling and

heating coils, filters, dampers, supply and return grilles, etc.
(mmWG)

n = Number of elements

L = Equivalent length of the duct (M).

The equivalent length of the duct shall be estimated for each of the fittings
envisaged, from tables and chart listed below. These tables and charts are given
in Part 2, Chapter 2, Handbook of Air-Conditioning System Design, Carrier
Air-Conditioning Company, 1965 edition:

(a) Table 9 Friction of Round Duct System Elements

(b) Table 10 Friction of Rectangular Duct System Elements

(c) Table 11 Friction of Round Elbows

(d) Table 12 Friction of Rectangular Elbows

(e) Table 13 Percent Section Area in Branches for Maintaining Equal

Friction

Losses for round fittings given in Chart 9 and the additional equivalent length of
straight duct given in Table 11 and Table 12 listed above, are in FPS units and
shall be converted to MKS units in the course of the calculations.

The spacing and number of vanes for elbows shall be selected from Chart 6 -
Vane Location for Rectangular Elbows, Part 2, Chapter 2, Handbook of Air-
Conditioning System Design, Carrier Air-Conditioning Company, 1965 edition.

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4.2 DUCT SIZING CRITERIA

4.2.1 The equal friction method is normally used for duct sizing. As per Figure 9,
Chapter 34, ASHRAE Handbook, Fundamentals, 2001 edition, for equal friction
method, the friction drop is selected in the range of 0.06 to 0.5 mmWG per M of
duct length or air velocity in duct between 9.0 to 20.0 M/sec, whichever is more
stringent.

4.2.2 It is recommended that the ducts be sized for a pressure drop of 0.067 mmWG
per M of duct length. The lower of the friction drop per unit length as calculated
from equation given in para 4.1 or 0.067 mmWG per M of duct length as given
above, shall be considered for the duct sizing.

4.2.3 The recommended air velocities for air-conditioning applications may be lower
than the lower limit of 9.0 M/sec indicated in para 4.2.1 from criteria of noise
reduction and application. Refer table 1 for recommendations on air velocity
selection for various applications. In addition to the recommendations given in
table 1, the recommended velocity for installations of indigenous packaged air-
conditioners considering the static pressures achievable is 7.5 M/sec. For
ventilation systems the air velocity may be selected between 7.5 to 9.15 M/sec.
TABLE 1
RECOMMENDED MAXIMUM DUCT VELOCITIES FOR AIR-CONDITIONING AND VENTILATION SYSTEMS

SL. APPLICATION DUCT VELOCITY (M/sec)

NO.
CONTROLLING FACTOR

NOISE MAIN DUCTS BRANCH DUCTS

SUPPLY RETURN SUPPLY RETURN

1. RESIDENCES 3.0 5.0 4.0 3.0 3.0

2. APARTMENTS, HOTEL 5.0 7.5 6.5 6.0 5.0

BEDROOMS, HOSPITAL
BEDROOMS

3. PRIVATE OFFICES, 6.0 10.0 7.5 8.0 6.0

DIRECTORS ROOMS,
LIBRARIES

4. THEATRES, AUDITORIUMS 4.0 6.5 5.5 5.0 4.0

5. GENERAL OFFICES, HIGH 7.5 10.0 7.5 8.0 6.0

CLASS RESTAURANTS, HIGH
CLASS STORES, BANKS

6. AVERAGE STORES, CAFETERIAS 9.0 10.0 7.5 8.0 6.0

7. INDUSTRIAL 12.5 15.0 9.0 11.0 7.5

SOURCE: CARRIER, PART 2, CHAPTER 2., TABLE 7

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TABLE 2

TRANSPORT VELOCITIES FOR DIFFERENT MATERIALS

SL. MATERIAL VELOCITY SL. MATERIAL VELOCITY

NO. NO.
M/sec FPM M/sec FPM

1. Abrasive blasting 17.8 - 20.3 3500 - 4000 15. Coal (powdered) dust 20.3 4000

2. Aluminium coarse dust 20.3 4000 16. Cocoa dust 15.2 3000

3. Asbestos carding 15.2 3000 17. Cork (ground) dust 12.7 2500

4. Bakelite moulding 12.7 2500 18. Cotton dust 15.2 3000

powder dust

5. Barrel filling or 17.8-20.3 3500-4000 19. Crushers 15.2 or 3000 or

dumping higher higher
6. Belt conveyors 17.8 3500 20. Flour dust 12.7 2500

7. Bins and hoppers 17.8 3500 21. Foundry, general 17.8 3500

8. Brass turnings 20.3 4000 Sand mixer 17.8-20.3 3500-4000

9. Bucket elevators 17.8 3500 Shakeout 17.8-20.3 3500-4000

10. Buffing and 15.2-17.8 3000-3500 Swing grinding 15.2 3000

polishing, Dry booth exhaust

11. Buffing and 17.8-22.9 3500-4500 Tumbling mills 20.3-25.4 4000-5000

polishing, Sticky

12. Cast iron boring dust 22.9 4000 22. Grain dust 12.7-15.2 2500-3000

13. Ceramics, general 23. Grinding general 17.8-22.9 3500-4500

Glaze spraying 12.7 2500 24. Portable hand 17.8 3500

grinding

Brushing 17.8 3500 25. Jute Dust 12.7-15.2 2500-3000

Fettling 17.8 3500 26. Jute Lint 15.2 3000

Dry pan mixing 17.8 3500 27. Jute dust shaker waste 16.3 3200

Dry press 17.8 3500 28. Jute pickerstock 15.2 3000

Sagger filling 17.8 3500 29. Lead dust 20.3 4000

14. Clay dust 17.8 3500 30. Lead dust with 25.4 5000
small chips

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TABLE 2 (CONTD.)

31. Leather dust 17.8 3500 48 Soldering and tinning 12.7 2500

32. Limestone dust 17.8 3500 49. Spray painting 10.2 2000

33. Lint 10.2 2000 50. Starch dust 15.2 3000

34. Magnesium dust, 20.3 4000 51. Stone cutting and 17.8 3500
coarse finishing

35. Metal turnings 20.3-25.4 4000-5000 52. Tobacco dust 17.8 3500

36. Packaging, 15.2 3000 53. Woodworking

weighing, etc

37. Downdraft grille 17.8 3500 Wood flour, light dry 12.7 2500
sawdust and shaving

38. Pharmaceutical 15.2 3000 Heavy shaving, damp 17.8 3500

coating pans sawdust

39. Plastic dust (buffing) 19.3 3800 Heavy wood chips 20.3 4000
waste, green shavings

40. Plating 10.2 2000 Hog waste 15.2 3000

41. Rubber dust, Fine 12.7 2500 54. Wool 15.2 3000

42. Rubber dust, Coarse 22.9 4000 55. Zinc oxide fume 10.2 2000

43. Screens, Cylindrical 17.8 3500 56. Very fine light dusts 10.2 2000

44. Screens, Flat deck 17.8 3500 57. Fine ,dry dusts and 15.2 3000
powders

45. Silica dust 17.8-22.9 3500-4500 58. Average industrial 17.8 3500
dusts

46. Soap dust 15.2 3000 59. Coarse dusts 20.3 - 22.9 4000 - 5000

47. Soapstone dust 17.8 3500 60. Heavy or moist 22.9 or 4500 or
dust loading higher higher

SOURCE: ADVANCED DESIGN OF VENTILATION SYSTEMS FOR CONTAMINANT CONTROL BY HOWARD D.

GOODFELLOW, ELSEVIER SCIENCE PUBLISHERS, B. V. 1985, TABLE 4.11, PAGE 320.

4.2.4 The duct velocities for dust extraction systems, however, may be much higher
than the velocity range indicated in table 1, depending on the application. The
recommended duct velocities for dust extraction systems are as given in table 2.
However, for more details of dust or fume extraction system design, the
designer may refer reference number 5.3 indicated at the end of this write-up.

ISSUE
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DESIGN GUIDE FOR DUCT SIZING SHEET 6 OF 8

4.2.5 The duct sizing may be carried out using ductulators of Trane, Carrier or
SMACNA make, or Chart 7 and Table 6, Part 2, Chapter 2, Friction Loss for
Round Duct, Handbook of Air-Conditioning System Design, Carrier Air-
Conditioning Company, 1965 edition. The chart may be used for systems
handling air from (-)1 to 490 C (30 to 120 0 F) and for altitudes upto 600 M
(2000 ft) without correcting for density. Air density correction factors for other
conditions are given in Chart 15, Part 2, Chapter 2, of Handbook of Air-
Conditioning System Design, Carrier Air-Conditioning Company, 1965 edition.
However, correction factors for altitude and temperature for air density other
than 0.075 lb/ft3 can be read directly using SMACNA make ductulators.

4.3 In case the duct sizing calculations are done manually, the friction drop in the
ducting shall be calculated from following equation:

f x (100 x L x ρ x V2 )
∆p =
2 x Dh
Where,

∆p = Friction drop in unit length of duct (mmWG/ M)

f = Friction factor (Dimensionless)

L = Duct length (M)

ρ = Air density (Kg / M3 )

pa
=
2.871 x 105 x T
pa = partial pressure of dry air (kPa)

T = Absolute temperature of air (0 K)

V = Air velocity (M/sec)

Dh = Hydraulic diameter of duct (mm)

= [4 x Duct cross section area ( mm2 )] ÷ Duct perimeter (mm)

The values for air partial pressure shall be taken from Table 2, Chapter 6,
ASHRAE Handbook, Fundamentals, 2001 edition.

4.4 The friction factor for the manual duct friction drop calculation shall be
calculated from the following equation:

∈
f0.5
1.
= (-)2 x log [ 3.7Dh
+ 2.51
Re x f0.5
]
Where,

f = Friction factor (Dimensionless)

ISSUE
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DESIGN GUIDE FOR DUCT SIZING SHEET 7 OF 8

∈ = Material absolute roughness factor (mm). Refer Table 1, Chapter

34, ASHRAE Handbook, Fundamentals, 2001 edition, for duct
roughness factors of various materials of construction.

Dh = Hydraulic diameter of duct (mm)

Re = Reynolds number

= (Dh x V) ÷ (1000 x ν)

= 66.4 x Dh x V (For standard air)

V = Air velocity (M/sec)

ν = Kinematic viscosity of air (M2 /sec)

The values for air viscosity shall be taken from Figure 12, Chapter 6, ASHRAE
Handbook, Fundamentals, 2001 edition.

4.5 The equivalent rectangular duct diameter is given by the following equation:
0.625
De = 1.3 x (ab) 0.250
(a+b)
Where,

De = Circular equivalent of rectangular duct for equal length, fluid

resistance and air flow (mm)

a = Length of one side of duct (mm)

b = Length of adjacent side of duct (mm)

Normally, the value of the recommended maximum aspect ratio i.e. (a/b) or
(b/a) is 4.0. However, this limitation may be ignored if the layout requires a
flatter duct having an aspect ratio greater than 4.0.

4.6 For flat oval ducts the formula is modified as follows:

A 0.625
De = 1.55 x
P0.250
Where,

A = Cross sectional area of flat oval duct (mm2 )

= (πb2 / 4) + b(a – b)

P = Perimeter (mm)

= πb + 2(a - b)

a = Major dimension of oval duct (mm)

ISSUE
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DESIGN GUIDE FOR DUCT SIZING SHEET 8 OF 8

b = Minor dimension of oval duct (mm)

4.7 For the criteria given above the round duct diameter shall be obtained from the
equation given in para 4.3. The sizes for the equivalent rectangular ducts shall
be calculated from equation given in para 4.5. Equivalent duct sizes can also be
directly read from Table 6, Part 2, Chapter 2, Handbook of Air-Conditioning
System Design, Carrier Air-Conditioning Company, 1965 edition, or Table 2,
Chapter 34, ASHRAE Handbook, Fundamentals, 2001 edition or from
ductulators. These dimensions shall be decided considering the major criteria
listed below. Refer TCE.M6-ME-811-318 “Design Guide for Duct Layout
Drawings” for details.

4.7.1 Clear height requirements in the room

4.7.2 Clearances from structures, piping, cable trays or ducts

4.7.3 Access to other facilities

4.7.4 Sizes of equipment to which ducts are connected

4.7.5 Requirements of duct internal lining. The duct size to be enhanced to the extent
of the thickness of the lining and the roughness of the surface in contact with the
air.

5.0 REFERENCES

5.1 ASHRAE Handbook, Fundamentals, 2001 Edition

5.2 Handbook of Air-Conditioning System Design, Carrier Air-Conditioning

Company, 1965 edition.

5.3 Advanced Design of Ventilation Systems for Contaminant Control by Howard

D. Goodfellow, Elsevier Science Publishers, B. V. 1985.

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DESIGN GUIDE FOR AIR WASHERS SHEET i OF iii

DESIGN GUIDE FOR AIR WASHERS

FILE NAMES: M6ME311R2.DOC AND

M6ME311R2.DWG

REV. NO. R0 R1 R2
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY SM/GSJ Sd/-/Sd/- IYM/HRK Sd/-/Sd/- IYM

CHD. BY SJB/SCM Sd/-/Sd/- PRJ Sd/- TPR

R2
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DATE 19.12.1980 24.03.2000 20.03.2003

TCE FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M6-ME-811-311
DESIGN GUIDE FOR AIR WASHERS SHEET ii OF iii

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 APPLICATIONS 1

3.0 TYPES OF AIR WASHERS 7

4.0 PROCEDURE FOR SIZING 9

5.0 REFERENCES 11

FIGURES

1. RECIRCULATED WATER SPRAY OR EVAPORATIVE AIR 2

COOLING

2. PRE-HEATED AIR WITH RECIRCULATED WATER SPRAY 3

3. HEATED WATER SPRAY 4

4. COOLING AND DEHUMIDIFICATION 6

5. TYPICAL SPRAY TYPE AIR WASHER 12

6 TYPICAL RIGID MEDIA PAD TYPE AIR WASHER 12

TABLE 1. SATURATION EFFICIENCIES AND LENGTHS OF AIR 8

WASHERS

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REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 19.12.1980 ----------------

R1 24.03.2000 Generally revised.

R2 20.03.2003 Generally revised.

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1.0 SCOPE

Air washer is a chamber or enclosed casing where water and air come in direct
contact for applications like humidification, cooling & dehumidification and
air cleaning. This design guide briefly describes these applications, describes
various types of air washers available and gives procedure for sizing of most
commonly used air washers.

2.0 APPLICATIONS

2.1 HUMIDIFICATION

Humidification process increases the specific humidity of the air. Figures 1, 2

and 3 illustrate thermodynamic changes that occur between the air and water
that are in direct contact. Humidification can be achieved in three ways :
(a) Using recirculated water spray
(b) Pre-heating the air and
(c) Using heated water spray

2.1.1 Recirculated Water Spray

Recirculated water spray (also called evaporative air cooling) reduces the air
Dry Bulb Temperature (DBT) by evaporation of water into an air stream.
Figure 1 illustrates thermodynamic changes that occur between the air and
water that are in direct contact. The continuously recirculated water reaches an
equilibrium temperature equal to the Wet Bulb Temperature (WBT) of the
entering air. The heat and mass transfer between the air and water lowers the
air DBT and increases the specific humidity at a constant WBT.

Evaporative air cooling or saturation efficiency (Ec) is given by the relation:

T1 – T2
Ec = 100 x T1 – T3
Where,

Ec = Saturation efficiency

T1 = DBT of the entering air

T2 = DBT of the leaving air

T3 = WBT of entering air

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Evaporative air cooling system is normally provided in areas where wet bulb
depression is more than 11OC. In cases where inside heat gain is very high,
irrespective of the wet bulb depression, evaporative cooling is provided as this
will reduce the required air flow rate. Figure 1 represents this schematically on
a psychrometric diagram. Figure 1 also indicates the thermodynamic process
showing the air temperature variation and constant water temperature.

AIR WASHER
AIR OUTLET
CONDITION

WET BULB
TEMPERATURE
AIR WASHER
AIR INLET
CONDITION

SATURATION
CURVE

(gm / KG OF DRY AIR)

SPECIFIC HUMIDITY
T3 T2 T1

DRT BULB TEMPERATURE (0 C)

FINAL AIR
INLET AIR TEMPERATURE
TEMPERATURE T1 DIFFERENCE
(T2 – T3)
TEMPERATURE

OUTLET AIR
DIFFERENCE
INITIAL AIR

TEMPERATURE T2
(T1 – T3)

WATER TEMPERATURE T3 (CONSTANT)

FIGURE 1
RECIRCULATED WATER SPRAY OR EVAPORATIVE AIR COOLING

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2.1.2 Pre-heating the Air

Air is pre-heated before it enters the air washer. Pre-heating the air increases
both DBT and WBT and lowers Relative Humidity (RH), but does not alter
the specific humidity. At a higher WBT and with the same specific humidity,
more water can be absorbed per unit mass of dry air passing through the air
washer. Process that occurs in the air washer is the same as that for
recirculated water spray. The final preferred conditions are achieved by
adjusting the amount of pre-heating to give the required WBT at the entrance
of air washer. Figure 2 represents this process schematically on a
psychrometric diagram.

AIR WASHER
AIR OUTLET
CONDITION
WET BULB
TEMPERATURE
AIR WASHER
AIR INLET
CONDITION

EVAPORATIVE
SATURATION COOLING
CURVE

(gm / KG OF DRY AIR)

SPECIFIC HUMIDITY
HEATER ENTRY
AIR CONDITION

T0 T3 T2 T1 AIR HEATING

DRT BULB TEMPERATURE (0 C)

FIGURE 2
PRE-HEATED AIR WITH RECIRCULATED WATER SPRAY

2.1.3 Heated Water Spray

Spray water is heated before it is sprayed in the air washer. It is possible to

raise both DBT and WBT above the DBT of the entering air. The leaving air
condition may be controlled by

(a) Bypassing some of the air around the air washer and re-mixing the two
air streams downstream or
(b) Automatically reducing the number of operating spray nozzles.

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Figure 3 represents this process schematically on a psychrometric diagram.

Also indicated is the relative variation of the air and water temperature in the
process.

SATURATION
CURVE
AIR WASHER
AIR OUTLET
CONDITION

WET BULB
TEMPERATURE

(gm / KG OF DRY AIR)

SPECIFIC HUMIDITY
AIR WASHER
AIR INLET
CONDITION

T3 T1 T2

DRT BULB TEMPERATURE (0 C)

FINAL
INLET WATER TEMPERATURE
TEMPERATURE T3 DIFFERENCE
(T4 – T2)
INITIAL AIR TEMPERATURE DIFFERENCE

OUTLET WATER
TEMPERATURE T4
(T3 – T1)

CONTACT TIME

OUTLET AIR
TEMPERATURE T2
INLET AIR
TEMPERATURE T1

FIGURE 3
HEATED WATER SPRAY

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2.2 COOLING AND DEHUMIDIFICATION

Cooling and Dehumidification reduces the DBT and specific humidity. Figure
4 represents this process schematically on a psychrometric diagram. Also
indicated is the relative variation of the air and water temperature in the
process. Heat and moisture removed from the entering air raises the water
leaving temperature. Dehumidification results if the leaving water temperature
is below the entering dew-point temperature. Moreover, the final water
temperature is determined by the sensible and latent heat pick-up and the
quantity of water circulated.

Air leaving the air washer is substantially saturated. The difference between
DBT and WBT is less than 0.5°C. The difference between leaving air and
leaving water temperatures depends on the difference between entering DBT
and WBT and the construction features of the air washer. The rise in water
temperature is usually between 3 to 7OC.

The most common air washer arrangement for cooling and dehumidifying air
has two spray banks and is 2,500 to 3,500 mm long. If the air washer can cool
and dehumidify the entering air to a WBT equal to the leaving water
temperature, the performance factor of such an air washer is said to be 1.0.
The actual performance of any air washer is the actual enthalpy change
divided by the enthalpy change in washer having a performance factor of 1.0.

The required performance factor may be calculated by:

h1 – h2
Fp = h1 – h3
Where,

Fp = Performance factor

h1 = Enthalpy at entering air WBT

h2 = Enthalpy at leaving air WBT at actual condition

h3 = Enthalpy at WBT leaving the air washer with Fp = 1.0 i.e. at

WBT equal to leaving water temperature

This type of system was used extensively for applications having large air
flow capacities, e.g. synthetic fibre plants. This is an open system and ingress
of dust and particulate contaminants from the process, which may be absorbed
by the water, may cause clogging of chiller tubes and also the piping system.
This could lead to major maintenance problems, breakdown and loss of
production. Hence this type of system is normally not preferred.

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WET BULB
TEMPERATURE

(gm / KG OF DRY AIR)

SPECIFIC HUMIDITY
SATURATION
CURVE

AIR WASHER
AIR OUTLET
CONDITION

AIR WASHER
AIR INLET
CONDITION

T2 T3 T1

DRT BULB TEMPERATURE (0 C)

FINAL
INLET AIR TEMPERATURE
TEMPERATURE T1 DIFFERENCE
(T2 – T4)
INITIAL TEMPERATURE DIFFERENCE

OUTLET AIR
TEMPERATURE T2
(T1 – T3)

CONTACT TIME

OUTLET WATER
TEMPERATURE T4
INLET WATER
TEMPERATURE T3

FIGURE 4
COOLING AND DEHUMIDIFICATION

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2.3 AIR CLEANING

Air washers are also used for removing dust particles etc. before it enters the
process or discharged to atmosphere. The dust removal efficiency of air
washer depends largely on the size, density, wettability and solubility of the
dust particle. Efficiency is higher for the larger and the more wettable
particles, separation being accomplished entirely by impingement on the
wetted surfaces of the eliminator plates. Experience has shown that the spray
itself is relatively ineffective in removing most atmospheric dusts. Air washers
are of little use in removing soot particles because of the absence of an
adhesive effect from the greasy surface. They are also ineffective in
removing smoke because of inadequate inertia of the small particles (less than
1 micron). Rigid media pad type washers, however are efficient air cleaners.
In practice they remove from 70 to 90 % percent by weight of air borne solid
particles which include most of the particles exceeding 5 microns and many
down to size 1 micron. The actual size and arrangement should be verified
based on manufacturer’s data.

3.0 TYPES OF AIR WASHERS

3.1 SPRAY TYPE AIR WASHERS

Spray type air washer consists of an air-tight chamber or casing containing air
distribution plates, spray nozzle system arranged in a single bank or multiple
banks, a tank for collecting the spray water, eliminators for removing
entrained drops of water from the air, flooding nozzles for cleaning
eliminators and a pump with piping, valves and specialities for recirculating
water at higher rate than the evaporation rate. The tank is provided with drain,
overflow, make-up water and quick-fill connections. Drain sump with suction
screens are provided in tank. Spray type air washers are usually available from
3,500 to 4,25,000 M3 /Hr capacity. However, there is practically no limit for
specially constructed air washers.

There is no standardisation in air washer sizes. Normally, recirculated water

flow rate is 0.53 M3 /Hr for a single bank and 1.34 M3 /Hr for double or
multiple banks per 1,000 M3 /Hr of air flow rate. Air resistance varies from 6
mmWC to as high as 25 mmWC. Spray nozzle pressure varies from 1.4 to 2.8
Kg/cm2 g, whereas flooding nozzle operates at 0.2 to 0.3 Kg/cm2 g pressure.
Generally, specified air face velocity through the air washer internals i.e.
distribution plate, spray nozzles and the eliminators is 2.5 M/sec. Typical
spray type air washer is shown in Figure 5.

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Tank has a minimum depth of 600 mm with 450 mm water level. The distance
between air distribution plates and spray bank as well as spray bank and
eliminator plates is 400 to 600 mm. The distance between the two spray banks
is 800 to 1,400 mm. Normally, air washer tank is extended beyond eliminators
by 500 mm. An air-tight inspection door is provided on the chamber or casing
along with a marine light and catwalk inside the spray section, to facilitate
cleaning of spray and flooding nozzles during maintenance.

It is recommended that a level switch be provided to safeguard the pump.

However, this is left to the discretion of the designer as the air washer
operation is normally manual and the operator verifies and monitors the
adequacy of the water level in the basin to ensure proper pump operation.

For details and selection of air washers for humidification or cooling and
dehumidification applications, refer Handbook of Air-conditioning System
Design, Carrier Air-Conditioning Company, 1965 edition, Part 6, Chapter 2.

Air washers are available in metallic or Fibre Reinforced Plastic (FRP)

construction for smaller capacities upto about 25,000 M3 /Hr. For higher
capacity these are normally in masonary construction.

The saturation efficiencies and lengths of air washers are given in table 1
below:

TABLE 1
SATURATION EFFICIENCIES AND LENGTHS OF AIR WASHERS

SL. NO. SPRAY BANK SATURATION LENGTH OF AIR

ARRANGEMENT EFFICIENCY % WASHER M

1. Single bank facing downstream 50 to 60 1.2

side of air washer
2. Single bank facing upstream 65 to 80 1.8
side of air washer
3. Double bank both facing 80 to 90 2.4 to 3
downstream side of air washer
4. Double bank with one facing 85 to 95 2.4 to 3
downstream side and other facing
upstream side of air washer

5. Double bank both facing 90 to 98 2.4 to 3

upstream side of air washer
6. Multiple bank 90 to 98 3.5
SOURCE : ASHRAE HANDBOOK, HVAC SYSTEMS AND EQUIPMENT, 2000 EDITION, CHAPTER 19, PAGE 19.7

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3.2 HIGH VELOCITY SPRAY TYPE AIR WASHER

High velocity spray type air washers generally operate at air face velocities in
the range of 6 to 9 M/sec. However, velocity as high as 12 M/sec may also be
used. The reduced cross-sectional area allows air washers to be installed in a
less space.

High velocity spray type air washers are rectangular in cross-section and
except for eliminators are similar in appearance and construction to spray type
air washers. Eliminator blades come in varying shapes, but most are a series of
aerodynamically clean, sinusoidal shapes. Air resistance varies from 15
mmWC to as high as 40 mmWC.

3.3 RIGID MEDIA PAD TYPE AIR WASHER

Rigid media pad type air washer consists of an air-tight chamber or casing of
Galvanised Steel Sheet (GSS) or FRP containing corrugated rigid media pad, a
tank for collecting water and a pump with piping, valves and specialities for
recirculating water.Rigid media pad shall be of cellulose and fibre glass that
have been treated chemically with antirot and rigidifying resins. Details for
these media and fill configurations may be referred from vendor catalogues.
Pad shall be cross-corrugated to maximise mixing of air and water in the
direction of air flow. Depth of pad shall be 300 to 600 mm.

The pad shall be arranged in tiers over which water is distributed. No

atomisation of water is required. Only good distribution of water over the face
of the pad is essential. Nozzles operate under comparatively low pressure as
compared to those in spray type air washer.

It is recommended that fine filters, with a filtering efficiency of 99% down to

a particle size of 5 microns with test dust 2 as per IS 7613, in conjunction with
pre-filters, with a filtering efficiency of 90% with test dust 3 as per IS 7613, be
provided with rigid media type air washers. This is to minimise the clogging
of the media with dust carried by the incoming air flow. However, this aspect
may be examined by the designer with the site conditions in the respective
applications.

Saturation efficiency of this type of air washer is 70 to 95 %. Figure 6 shows a

typical rigid media pad type air washer.

4.0 PROCEDURE FOR SIZING

Procedure for evaporative air cooling application is given below :

4.1 INPUT DATA

DBT of the entering air in OC = T1

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WBT of the entering air in OC = T3

Heat load in KCal/Hr (calculated as per = Q

TCE.M6-ME-811-309)

DBT to be maintained inside the space = Ta

4.2 LEAVING AIR TEMPERATURE

T1 – T2
Saturation efficiency Ec =
T1 – T3

The value of saturation efficiency Ec may be referred to from para 3.1.

Knowing the saturation efficiency, T2 can be calculated. Where, T2 is the
DBT of the air leaving the air washer.

4.3 TEMPERATURE RISE DUE TO FAN HEAT GAIN

The temperature rise due to fan heat gain is calculated by:

P x 9.81 x 1.15
∆T =
η x 10 x ρa
Where,

P = Static pressure of fan in mmWC (calculated as per TCE.M1-

ME- 811-302)
η = Fan static efficiency (normally assumed @ 60%)
ρa = Air density in Kg/M3

4.4 AIR FLOW RATE

4.4.1 For draw-through type air washer

Q
Air flow rate in M3 /Hr =
0.288 [ Ta - (T2 + ∆T) ]

4.4.2 For blow-through type air washer

Q
Air flow rate in M3 /Hr =
0.288 [ (Ta + ∆T) - T2 ]

4.5 RECIRCULATING WATER FLOW RATE

In the absence of manufacturer’s data, para 3.1 above may be referred for
calculating recirculated water flow rate. Knowing the re-circulating water flow
rate, pumps capacity selection and piping sizing may carried out.

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4.6 FACE AREA OF AIR WASHER

Air flow rate in M3 /Hr

Face area of the air washer in M2 =
3600 x air face velocity (M/sec)
Depending on the available space, the height (H) and the width (W) of the air
washer may be arranged such that face area A=WH. It is preferable to arrange
the face area of the air washer such that width and height are equal. The length
of the double bank air washer may be minimum 2.5 M and may be as long as
3.5 M.

4.7 MAKE-UP WATER FLOW RATE

Make-up water flow rate varies from 1 to 1.5 % of recirculating water flow
rate. However, this may be specifically calculated considering evaporation and
blowdown. Blowdown rate shall be calculated considering the upper limit to
be maintained in the concentration of dissolved solids in the recirculated
water. Another criteria for the blowdown water quantity, are the scaling
characteristics of the recirculated water. Generally, the scaling criterion is not
applicable for air washers, as there is no change in the operating temperature
of water for recirculated spray air washers. However, this criterion may be
significant for pre-heated air and heated water spray air washers.

The blowdown quantity and the scaling criteria estimated from the Puckorious
Scaling Index (PSI) shall be calculated from the methods given in para 5.4.1
and para 5.3 respectively of TCE.M1-ME-127-201, Basic Study Guide for
Cooling Tower Make-up System.

5.0 REFERENCES

5.1 ASHRAE Handbook, HVAC Systems and Equipment - 2000 Edition

5.2 Handbook of Air-conditioning System Design, Carrier Air-Conditioning

Company, 1965 edition

5.3 TCE.M1-ME-127-201 Basic Study Guide for Cooling Tower Make-up System

5.4 TCE.M1-ME-811-302 Basic Study Guide for Ventilation System

5.5 TCE.M6-ME-811-301 Design Guide for Air-conditioning Load Calculations

5.6 TCE.M6-ME-811-309 Design Guide for Ventilation Heat Load Calculations

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REFRIGERATION LOAD CALCULATIONS FOR SHEET i OF iii
PROCESS COOLING

DESIGN GUIDE FOR

REFRIGERATION LOAD CALCULATIONS FOR
PROCESS COOLING

FILE NAME: M6ME313R3.DOC

REV. NO. R0 R1 R2 R3
ISSUE
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD. BY SCM Sd/- TPR Sd/- IYM Sd/- RRC

CHD. BY SJB Sd/- PRJ Sd/- PRJ Sd/- TPR

R3
APD. BY DHNR Sd/- RL Sd/- RL Sd/- RL

DATE 19.12.1980 10.12.1997 02.03.2001 01.03.2004

TCE FORM NO. 020R2
TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
DESIGN GUIDE FOR
TCE.M6-ME-811-313
REFRIGERATION LOAD CALCULATIONS FOR SHEET ii OF iii
PROCESS COOLING

CONTENTS

SL. NO. TITLE SH. NO.

1.0 SCOPE 1

2.0 GENERAL 1

3.0 PROCESS COOLING LOAD 2

4.0 HEAT GAIN DUE TO SUPPLY AND RETURN COOLANT 2

PIPING

5.0 HEAT GAIN DUE TO COOLANT PUMPS AND AGITATORS 4

6.0 HEAT GAIN IN MIXING TANK 5

7.0 REFRIGERATION LOAD 5

8.0 REFERENCES 6

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PROCESS COOLING

REVISION STATUS

REV. NO. DATE DESCRIPTION

R0 19.12.1980 --

R1 10.12.1997 Document number changed. British units deleted and SI

units incorporated. Generally revised.

R2 02.03.2001 Generally revised.

R3 01.03.2004 Para 8.0 revised and document reformatted.

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PROCESS COOLING

1.0 SCOPE

This design guide describes the method for calculating the refrigeration load on
the refrigeration equipment for process cooling where a secondary coolant like
chilled water or brine is used to remove heat from the various process equipment
in industrial and chemical plants.

2.0 GENERAL

The total load on the refrigeration equipment is the actual process cooling load
plus the heat gain by circulating coolant pumps, supply and return coolant
piping, mixing/storage tank, agitators etc. The following data shall be obtained
from the client or process engineer or process equipment designer before
proceeding with the calculations:

(a) Type of coolant i.e. chilled water or brine such as calcium chloride,
sodium chloride, glycol etc. If client or process engineer or process
equipment designer does not specifically indicate requirement of type of
coolant, it may be recommended by refrigeration system designer and
consent obtained from client or process engineer or process equipment
designer.

(b) Flow rate of coolant through various process equipment

(d) Coolant supply and return pressures with tolerances at battery limit or
process equipment

(e) Locations of process equipment and refrigeration equipment (Refer plot

plan and GA drawings)

(f) Routing of supply and return coolant piping from refrigeration

equipment to battery limit or process equipment (Refer piping layout
drawings. In case piping layout drawings are not available, the
refrigeration system designer shall assume the most probable pipe
routing)

(g) Diversity

(h) Special requirements, if any

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3.0 PROCESS COOLING LOAD

3.1 IN MKS UNITS

Process cooling load in Kcal/Hr = ρ × V × Cp × ∆t

Where, ρ = Density, Kg/M3

V = Flow rate, M3 /Hr

Cp = Specific heat, KCal/Kg OC

∆t = Temperature rise, OC

3.2 IN SI UNITS

Process cooling load in KW = ρ × V × Cp × ∆t

Where, ρ = Density, Kg/M3

V = Flow rate, M3 /Sec

Cp = Specific heat, KJ/Kg OC

∆t = Temperature rise, OC

3.3 For chilled water, value of ρ is 1000 in both MKS and SI units and values of Cp
are 1.0 and 4.1868 in MKS and SI units respectively. However, for brines the
values of ρ and Cp depend upon the type, temperature and concentration of
brines. The values of ρ and Cp for selected brines at various temperatures and
concentrations may be obtained from the references cited in para 8.0. These
properties have to be taken at mean operating temperature.

4.0 HEAT GAIN DUE TO SUPPLY AND RETURN COOLANT PIPING

4.1 IN MKS UNITS

ta - ti
Heat transferred per unit area in KCal/M2 Hr, q =
R

Total heat transferred in KCal/Hr, Q = q × AL

Where, ta = Ambient air temperature, OC

ti = Supply temperature of coolant, OC

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R = Overall thermal resistance of the pipe with insulation,

M2 HrOC/Kcal

AL = Pipe outside area with insulation, π × DL × L, M2

DL = Outside diameter of pipe with insulation, M

L = Length of pipe, M

4.2 IN SI UNITS

ta – ti
Heat transferred per unit area in W/M2 , q =
R

Total heat transferred in KW, Q = (q × AL)/1000

Where, ta = Ambient air temperature, OC

ti = Supply temperature of coolant, OC

R = Overall thermal resistance of the pipe with insulation,

M2OK/W

AL = Pipe outside area with insulation, π × DL × L, M2

DL = Outside diameter of pipe with insulation, M

L = Length of pipe, M

Overall thermal resistance of pipe, R = RI + RP + RL + RO

DL DL In (DO/DI) DL In (DL/DO) 1
R = + + +
hI DI 2 kP 2 kL hO

Where the abbreviations used are as follows:

ITEM COOLANT PIPE PIPE INSULATION AIR

Inside Outside Outside

Diameter, M -- --
DI DO DL
Thermal conductivity,
-- kP kP kL --
Kcal/MHrOC (W/MOK)
Heat transfer coefficient,
Kcal/M2 HrOC hI -- -- -- hO
(W/M2OK)

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ITEM COOLANT PIPE PIPE INSULATION AIR

Resistance,
M2 HrOC/KCal RI RP RP RL RO
(M2OK/W)

The resistance of finishing cement layer or any other protective layer for
insulation is neglected. Resistance of inside film, pipe material and outside film
may also be neglected. These neglected components do not significantly affect
the heat gain. For both supply and return piping, tc may be taken equal to the
temperature required at the inlet of battery limit/process equipment.

DL In (DL/DO)
Thus R =
2 kL

ta - tc
and q =
DL ln (DL/DO)
2 kL

4.3 Increase the value of ‘Q’ as calculated by 10% to account for heat gain through
pipe fittings, valves etc.

5.0 HEAT GAIN DUE TO COOLANT PUMPS AND AGITATORS

5.1 The power required to pump the coolant or drive the agitators adds heat to the
system. This may be estimated as follows:

Heat added = BKW × 860 KCal/Hr (MKS units)

= BKW (SI units)

Where BKW is the power required to drive the pump/agitator.

5.2 In case the actual power to drive the pump is not available same may be
calculated as given below:

BKW = (V × H × SG)/(ηP × 367)

Where, V = Flow rate, M3 /Hr

H = Total pump head, M

SG = Specific gravity

ηP = Pump efficiency

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PROCESS COOLING

For small pumps of capacities 4.5 to 22 M3 /Hr the pump efficiency may be
assumed as 50% and for pumps greater than 22 M3 /Hr it may be assumed as
70%.

5.3 In the absence of BKW of agitator, heat equivalent of 80% of driver motor rating
for agitator may be taken as heat added to coolant.

6.0 HEAT GAIN IN MIXING TANK

6.1 Surface of the tank through which there is heat transfer shall be considered and
the heat gain shall be calculated by the following formula:

q = (ta - tc)/(Z/kL)

Q = q × AL, Kcal/Hr (MKS units)

= (q × AL)/1000, KW (SI units)

Where, Z = Insulation thickness, M

AL = Total outside surface area with insulation, M2

6.2 For other symbols and assumptions, refer para 4.0.

7.0 REFRIGERATION LOAD

7.1 The cooling load on the refrigeration equipment is the sum of the process cooling
load (para 3.0) and the heat gain due to piping, pumps and agitators, and mixing
tank (paras 4.0 + 5.0 + 6.0). The diversity factor and special requirements, if any,
shall also be considered.

7.2 Apart from the refrigeration load, the temperatures of coolant required at the
battery limit/process equipment are also important. The heat gain due to pumps,
piping, tank etc. raises the temperature of the coolant. Therefore, the temperature
at the outlet of the chilling unit shall be lower than that required at the inlet of the
battery limit or process equipment. The temperatures at the outlet and inlet of the
chilling unit are calculated or specified as indicated in para 7.3.

7.3 The heat gain in the return coolant piping is a small percentage of the total heat
gain due to pumps, tank and supply piping. Therefore, for calculating the
temperature at the outlet of the chilling unit the entire heat gain is considered to
be on the supply side.

7.4 IN MKS UNITS

QT
Temperature rise in OC, ∆t =
ρ × V × Cp
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PROCESS COOLING

Where, QT = Heat gain due to piping, pumps, tanks etc. (paras 4.0 +
5.0 + 6.0), KCal/Hr

ρ = Density, Kg/M3

V = Flow rate, M3 /Hr

Cp = Specific heat, KCal/Kg OC

7.5 IN SI UNITS

QT
Temperature rise in OC, ∆t =
ρ × V × Cp

Where, QT = Heat gain due to piping, pumps, tanks etc. (paras 4.0 + 5.0 +
6.0), KW

ρ = Density, Kg/M3

V = Flow rate, M3 /Sec

Cp = Specific heat, KJ/Kg OC

The temperature to be specified at the outlet of the chilling unit shall be lower by
∆t than that at the inlet to battery limit or process equipment. The temperature to
be specified at the inlet of the chilling unit shall be the same as that at the outlets
of battery limit or process equipment.

8.0 REFERENCES

8.1 2001 ASHRAE Handbook - Fundamentals

8.2 Handbook of Air Conditioning System Design - Carrier Air Conditioning

Company - 1965 edition.

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HEAT RECOVERY WHEEL

DESIGN GUIDE FOR

HEAT RECOVERY WHEEL

FILE NAME: M6ME314R0.DOC AND M6ME314R0.DWG

FLOPPY NO :TCE-971-ME-FP-101

REV.NO. R0 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY SS

CHD.BY ST R0

APD.BY RNW/RL

DATE 01.08.16

FORM NO. 020R2

TCE CONSULTING ENGINEERS LIMITED SECTION:CONTENTS
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET ii OF iii
HEAT RECOVERY WHEEL

CONTENTS

SL.NO. TITLE SH.NO.

1.0 SCOPE 1

2.0 AIR TO AIR ENERGY RECOVERY DEVICES 1

3.0 HEAT RECOVERY WHEEL - OPERATING 1

PRINCIPLE

4.0 CONSTRUCTION 2

5.0 PERFORMANCE RATING 7

6.0 PSYCHROMETRIC ANALYSIS 10

7.0 APPLICATIONS 10

8.0 REFERENCES 11

APPENDICES

1. APPENDIX-1 - COMPARISON OF AIR TO AIR 13

ENERGY RECOVERY DEVICES.

2. APPENDIX-2 - SELECTION OF HEAT RECOVERY 15

WHEEL (WITH TABLE-1)

TABLE-1: TYPICAL MANUFACTURER’S 22

PERFORMANCE DATA FOR HEAT
RECOVERY WHEEL (HRW)

3. APPENDIX-3 - CONFIGURATION OF HRW & PURGE 23

SECTION

4. APPENDIX-4 - INSTALLATION GUIDE LIN ES (HRW) 24

5. APPENDIX-5 - PSYCHROMETRIC PROCESS OF HEAT 25

RECOVERY USING HEAT WHEEL

6. APPENDIX-6 - TYPICAL HRW CATALOGUE DATA - 26

PHYSICAL DIMENSIONS OF A HRW

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REVISION STATUS

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1.0 SCOPE

This document describes design and construction features of Heat

Recovery Wheels for air conditioning application and provides
guidelines for their selection.

2.0 TYPES OF AIR TO AIR ENERGY RECOVERY DEVICES

2.1 ASHRAE Equipment Handbook 1996 refers to the following six types
of air-to-air heat exchange devices.

♦ Rotary Energy Exchangers (Enthalpy or Heat Recovery Wheel)

♦ Coil Energy Recovery Loop (Run around coil loop)
♦ Twin-Tower Enthalpy Recovery Loop
♦ Heat Pipe Heat Exchangers
♦ Fixed Plate Exchangers
♦ Thermosyphon Heat Exchangers

2.2 Distinction is made between the sensible only and the total heat
exchangers – total heat meaning sensible plus latent heat or enthalpy.
The twin-tower loop is a total heat exchanger. The rotary exchanger,
or heat recovery wheel, may be constructed as either a sensible only or
a total heat device. The rest are essentially sensible heat exchangers in
which transfer of latent heat, if any, is incidental.

2.3 Because of their ability to transfer both sensible and latent heat, the
enthalpy devices are far more effective in energy recovery. It is found
that under summer design conditions, the total heat device typically
recovers nearly three times as much energy as the sensible heat device.
Under winter conditions, it recovers over 25% more (ASHRAE:
Equipment Handbook 1988).

2.4 From the comparison of Air-to-Air Energy Recovery Devices

APPENDIX-1, it is seen that the enthalpy wheel has the highest
effectiveness and the least pressure drop at any face velocity. The
other enthalpy device – twin-tower loop – has the highest pressure
drop for the same effectiveness.

3.0 HEAT RECOVERY WHEEL OPERATING PRINCIPLE

3.1 A rotary air-to-air energy exchanger, or heat recovery wheel, has a

revolving cylinder filled with an air-permeable medium having a large
inter surface area. Adjacent supply and exhaust airstreams each flow
through one-half of the exchanger in a counterflow pattern
(APPENDIX-3). Heat transfer media may be selected to recover only
sensible heat or total heat.
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3.2 Sensible heat is transferred as the medium picks up and stores heat
from the hot airstream and releases it to the cold one. Latent heat is
transferred as the medium (1) condenses moisture from the airstream
with the higher humidity ratio (either because the medium temperature
is below its dew point) or by means of adsorption for solid desiccants
with a simultaneous release of heat; and (2) releases the moisture
through evaporation (and heat pickup) into the airstream with the lower
humidity ratio. The dessicant coated wheel slowly rotates between the
outdoor and the return air stream. The higher temperature air stream
gives sensible heat to wheel media. The energy is then, given up to the
cooler air stream during the second half of the revolution. The
moisture is captured and released by the dessicant coating which has
an enormous internal surface area and strong attraction to water
vapour. Since the opposing air streams have different temperatures
and moisture contents, their vapour pressures differ. This vapour
pressure differential serves as the driving force which causes the
transfer of water vapour (latent energy). Thus, the humid air is dried
while the dried air is humidified. In total heat transfer, both sensible
and latent heat transfer occur simultaneously. Because heat recovery
wheels have a counterflow configuration and normally use small-
diameter flow passages, they are quite compact and can achieve high
transfer effectiveness.

4.0 CONSTRUCTION

4.1 Air contaminants, dew point, exhaust air temperature, and supply air
properties influence the choice of structural materials for the casing,
rotor structure, and medium of a rotary energy exchanger. Aluminium
and steel are the usual structural, casing, and rotor materials for normal
comfort ventilating systems. Exchanger media are fabricated from
metal or mineral and are classified as providing either random flow or
directionally oriented flow through their structures.

4.2 Random flow media are made by knitting wire into an open woven
cloth or corrugated mesh, which is layered to the desired configuration.
Aluminium mesh, commonly used for comfort ventilation systems, is
packed in pie-shaped wheel segments. Stainless steel and monel mesh
are used for high-temperature and corrosive applications. These media
should only be used with clean, filtered airstreams because they plug
easily. Random flow media also require a significantly larger face area
than directionally oriented media for given values of airflow and
pressure drop.

4.3 Directionally oriented media are available in various geometric

configurations. The most common consist of small 1.5 to 2 mm (0.06
to 0.08 in.) air passages parallel to the direction of airflow. Whether
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Aluminium foil, inorganic sheet, treated organic sheet, and synthetic

materials are used for low and medium temperatures. Stainless steel
and ceramics are used for high temperatures and corrosive
atmospheres.

4.4 Media surface areas exposed to airflow vary from 330 sq.m per cubic
meter to 3300 sq.m per cubic meter (100 to over 1000 sq.ft/cu.ft),
depending on the type of medium and physical configurations. Media
may also be classified according to their ability to recover only
sensible or heat or total heat. Media for sensible or total heat recovery
are made of aluminium, copper, stainless steel, and monel and treated
with a desiccant.

4.5 The enthalpy wheel is a cylinder, packed with a heat transfer medium
that has numerous small air passages, or flutes, parallel to the direction
of airflow. The flutes are triangular or semi-circular in cross-section.
The structure, commonly referred to as the honeycomb matrix, is
produced by interleaving flat and corrugated layers of a high
conductivity material, usually aluminium, coated with a desiccant.
Stainless steel, ceramic, and synthetic materials may be used, instead
of aluminium, in specific applications. The flutes in most wheels
measure between 1.5 mm to 2.0mm in height. Typical configuration of
Heat Recovery Wheel is shown in APPENDIX-3.

4.6 In a typical installation, the wheel is positioned in a duct system such

that it is divided into two half moon sections. Stale air from the
conditioned space is exhausted through one half while outdoor air is
drawn through the other half in a counter flow pattern. At the same
time the wheel is rotated slowly (2 to 20 rpm). The rotor is supported
by two pillow block bearings and is driven by an A.C. motor and
permanently lubricated gear reducer. The rotor media is segmented for
ease of field erection or replacement of one sector. The media is
cleanable with low temperature steam, hot water or light detergent,
without degrading the latent recovery. The recovery wheel casing is
manufactured from tubular structure to provide a self supporting rigid
structure complete with access panels, rotor, bearings, seals, drive
mechanism with belt.

4.7 DESICCANT OPTIONS

4.7.1 The desiccant is a key element in the enthalpy wheel technology. It is

relevant, therefore, to discuss briefly on the desiccant options currently
available on wheels and their distinguishing features. A desiccant is a
sorbent having particular affinity for water. Sorbents have been
classified by ASHRAE (Fundamentals Handbook 1997, Chapter 19)
into two basic categories, i.e. Absorbents and Adsorbents. The
absorbents are substances that undergo a physical or a chemical ISSUE
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of this is table salt, which changes from a solid to a liquid as it absorbs

moisture. Adsorbents, on the other hand, undergo no change except
increase in weight to the extent of moisture adsorbed. However,
absorbents are no more in use on enthalpy wheels.

4.7.2 Adsorbents are primarily solids with internal porosity of suc h order
that the developed surface area of the pores is several hundred square
meters per gram of the substance. Silica Gel, Activated Alumina, and
Molecular Sieve – are the desiccants currently being offered on
enthalpy wheels.

4.7.3 It is observed that molecular sieves have a relatively higher absorption

capacity at low concentration levels of water vapors. However, the
capacity does not increase significantly with increase in relative
humidity. Both silica gel and activated alumina, on the other hand,
have gradually increasing capacities, with silica gel adsorbing almost
twice as much as molecular sieve at 100% RH. The decrease in
adsorption capacity of molecular sieve with increase in temperature is
much smaller compared to the other two desiccants.

4.7.4 These characteristics influence wheel design in terms of its desiccant

mass, flute dimensions, rotational speed, etc., and determine moisture
transfer effectiveness of the wheel at different temperature and
humidity conditions of the two air streams. The overall performance of
a model, however, depends on a number of other factors and must be
established experimentally for each device. Manufacturers normally
have detailed performance data on their equipment which must be
consulted for a given application.

4.7.5 The adsorption behaviour of desiccants is regulated by (a) their total

internal surface area, (b) the total volume of their capillaries, and (c)
the range of their capillary diameters. A wide range of adsorption
characteristics are possible within a single desiccant with variations in
these parameters.

4.7.6 The desiccant is reactivated with building's exhaust air, and the air
reactivates the dessicant adiabatically. No energy apart from what is
contained in the exhaust air stream is required.

4.7.7 The desiccant of sufficient mass is coated with non masking porous
binder adhesive so as to allow quick and easy uptake and release of
water vapour. The weight of desiccant coating and the mass of
aluminium foil (substrate) shall be in a ratio as to ensure equal
recovery of both sensible and latent heat over the operating range.

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4.8 ADVANTAGES OF THE HEAT RECOVERY WHEEL

4.8.1 The Heat Recovery Wheel recovers both sensible and latent energy.

4.8.2 Latent recovery increases the energy savings potential as against

sensible recovery only.

4.8.3 Ideal for applications where large quantities of fresh air are required.

4.8.4 Reduces outdoor air load by about 80%, (depending on inside and
outside conditions) thus reducing first costs in capital equipment like
chillers and boilers.

4.8.5 Unique desiccant surface selectivity eliminates adsorption of

components other than water vapour.

4.8.6 Self-cleaning of rotor.

4.8.7 Better performance, higher efficiencies and lower pressure losses.

4.8.8 Reduced air volume requirements for purge and seal leakage.

4.8.9 Sectionalized media lends itself to a retrofit programme.

4.8.10 Special designs for sensible recoveries and for corrosive environments
are available.

4.9 CROSS CONTAMINATION

4.9.1 Cross contamination or mixing of air between supply and exhaust

airstreams occurs on all rotary energy exchangers by two mechanisms
– carryover and leakage. Carryover occurs as air is entrained within
the volume of the rotation medium and is carried into the other
airstream, Leakage occurs because the differential static pressure
across the two airstreams drives air from a higher to a lower static
pressure region. Cross-contamination can be substantially reduced by
placing the blowers so that they promote leakage of outside air to the
exhaust airstream rather than the other way around. Carryover occurs
each time a portion of the matrix passes the seals dividing the supply
and exhaust airstreams. Because carryover from exhaust to supply
may be undesirable, a purge section can be installed on the heat
exchanger to reduce cross-contamination.

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4.9.2 In many applications, recirculating some air is not a concern.

However, critical applications, such as hospital operating rooms,
laboratories, and clean rooms, require stringent control of carryover.
Carryover can be reduced by below 0.1% of the exhaust airflow with a
purge section (ASHRAE SYSTEMS & EQUIPMENT HAND BOOK
1996).

4.9.3 The theoretical carryover of a wheel without a purge is directly

proportional to the speed of the wheel and the void volume of the
wheel media (75 to 95% void, depending on type and configuration).

4.9.4 For example, a 3 m diameter, 200 mm deep wheel with a 90% void and
wheel volume operating at 14 rpm has a carryover volume of

π( 3 / 2) 2 ( 0.2)( 0.9)(14) × 60 = 1070CMH ( approx.)

If the wheel is handling a 34,000 CMH balanced flow, the percentage

carryover is

 1070 
 100 = 3.15%
 34,000 

The exhaust fan, which is usually located at the exit of the exchanger,
should be sized to include leakage, purge and carryover airflows.

4.9.5 Heat recovery wheels are provided with a purge section as a standard
design to limit trapped exhaust air from being carried over in the
thermal transfer media to supply side. Using a purge section, a small
stream of supply air is diverted, sent back through the wheel media and
exhausted to the outside. By maintaining a pressure difference
between the supply and exhaust ducts, exhaust carry over can be
minimised. The schematic purge operation is shown in APPENDIX-3.

4.9.6 In order to compensate for the outside air being exhausted through the
purge, the exhaust fan capacity should be increased depending on the
pressure differential between the downstream supply side and the
downstream exhaust side.

4.9.7 By utilising the correct fan arrangement, the seal and purge system can
operate at optimum efficiency, virtually eliminating cross
contamination. Installation guidelines are shown in APPENDIX-4.

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5.0 PERFORMANCE RATING

5.1 ASHRAE STANDARD 84, Method of Testing Air-to-Air Heat

Exchangers, establishes rating and testing procedures for commercial
air-to-air heat recovery devices.

5.2 ASHRAE STANDARD 84 defines effectiveness as

E = Actual transfer (of moisture or energy) …….. (1)

Max. possible transfer between air streams

Where E = Sensible, latent or total heat effectiveness

Refering to Fig 1,

We ( X 3 − X 4 )
E = WS ( X 2 − X 1 ) / WMIN ( X 3 − X1 ) = ……… (2)
WMIN ( X 3 − X 1 )

where X = humidity ratio, dry bulb temperature or total enthalpy

respectively at the locations 1,2, 3 & 4.

Ws = Mass Flow rate of Supply air, kg of dry air.

We = Mass Flow rate of Exhaust Air, kg of dry air.

Wmin = Minimum value Ws or We.

W 
The leaving supply air condition is X 2 = X1 + E  MIN ( X 3 − X1 ) ...(3)
 WS 

And the leaving exhaust air condition is

W 
X 4 = X 3 − E  MIN ( X 3 − X1 )  …(4)
 We 

(SOURCE : ASHRAE 1996 SYSTEMS & EQUIPMENT HANDBOOK/

CHAPTER 42)

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X2 X1 , WS
2. Supply Air Leaving 1. Supply Air Entering

Energy

Recovery device

We, X3 X4
3. Exhaust Air Entering 4. Exhaust Air Leaving

FIG.1 AIR STREAM NUMBERING CONVENTION

5.3 Air flow Arrangements and Effectiveness.

5.3.1 Heat Recovery Wheel effectiveness depends to a great extent on the air
direction and pattern of the supply and exhaust airstreams. Parallel
flow exchangers (Fig.2) have a theoritical max. effectiveness of 50%.
Counterflow exchangers (Fig.3) can have an effectiveness approaching
100% but units designed for typical applications have a much lower
effectiveness. The normal range is 50 to 85%. A median value of 80%
can be assumed for design.

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Outside Air Supply air

Energy

Recovery Device

Return Air Exhaust Air

FIG 2 : PARALLEL HEAT EXCHANGE

Supply Air Outside Air

Energy

Recovery device

Return Air Exhaust Air

FIG .3 : COUNTER FLOW HEAT EXCHANGE

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5.4 PRESSURE DROP

The pressure drop for each air stream through a heat recovery wheel
depends on many factors, including heat exchanger design, mass flow
rate, temperature, moisture and inlet/outlet air. The exchanger pressure
drop must be overcome by fans. However the actual pressure drop
shall be obtained from the manufacturer. Typical pressure drop value
is indicated in APPENDIX-1.

6.0 PSYCHROMETRIC ANALYSIS

In the skeleton Psychrometric Chart shown in APPENDIX-5, outdoor

(fresh) air at 40.4°C DB/25.6°C WB (15 grams/kg of dry air) (Ab.
Humidity) is drawn through the wheel (F1 ). Heat from return air from
space at 24°C/ 9.5 grams /kg of dry air (50% RH) (F3 ) is recovered.
Fresh air entering the space is cooled and dehumidified.

Considering an effectiveness of 80%, supply condition F2 will be

27.3 °C /10.6 gms per kg. of dry air as per calculations shown below.

40.4 − X 2
0.8 =
40.4 − 24

.. . 40.4 – X2 = 0.8 (16.4)

.. . X2 = 27.28°C Say 27.3 °C

Similarly,

15 − X 2
0.8 =
15 − 9.5

or 15 – X2 = 4.4 gms/kg of dry air.

X2 = 10.6 gms/kg of dry air.

7.0 APPLICATIONS

7.1 With the view to eliminate “Sick Building Syndrome” created due to
reduced outdoor air (fresh air) quantities, ASHRAE STANDARD
62-1989 for Indoor Air Quality came out with increased ventilation
rates. Reproduced below are the recommended ventilation rates under
the ASHRAE 62-1989 standard for some of the applications :

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APPLICATION RECOM. VENTILATION

RATE/PERSON (L/S)
Office spaces 10 (20 CFM)
Hotel rooms 15 (30 CFM) per room
Hospital rooms 12.5 (25 CFM)
Operating rooms 15 (30 CFM)
Auditorium 7.5 (15 CFM)
Smoking Lounge 30 (60 CFM)

(Conversion : 1 CFM ~ 0.5 L/SEC.)

7.2 The most widespread application of enthalpy (Heat) wheels is for

PRECONDITIONING fresh outside air before it is introduced to a
building. Because the system is capable of recovering 80% of the
heating or cooling energy that is exhausted from a building, the cost of
fresh air ventilation is reduced. However, an economic analysis has to
be made before recommending HRW for particular application.

7.3 Some typical applications where the Heat Wheel can be employed to
reduce the fresh air load and improve the IAQ are :

♦ Hotels, Restaurants.
♦ Hospitals, Nursing Homes
♦ Conference rooms
♦ Airports
♦ Auditoriums
♦ Offices
♦ Health Clubs, etc.

7.4 A typical calculation procedure for selection of Heat Recovery Wheel

for preconditioning outdoor air for air conditioning application, with a
sample problem has been presented in APPENDIX-2.

8.0 REFERENCES

8.1 ASHRAE Hand Book – HVAC SYSTEMS & EQUIPMENT 1996.

8.2 ASHRAE STANDARD 62-1989.

8.3 ECO-Fresh – Technical Data, Arctic India.

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8.4 “Carnes” Heat Wheel Catalogue.

8.5 ASHRAE JOURNAL OCT 1999 - "Evaluating Active Desiccant

Systems for Ventilating Commercial Buildings" by L.G.Harriman &
Others".

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APPENDIX-1

COMPARISON OF AIR-TO-AIR ENERGY RECOVERY DEVICES

Fixed Plate Heat Heat Pipe Runaround Thermosiphon Twin Towers

Heat Recovery Heat Coil Loop Enthalpy
Exchangers Wheel Exchangers recovery loop
Air flow arran Counterflow Counterflow Counterflow Counter flow Counterflow
-gements Crossflow Parallel flow Parallel flow Parallel flow Parallel flow
Parallel flow

Equipment 85 (50) and up 85 to 119000 170 (100) 170 (100) 170 (100)
Size range, (50 to 70,000) and up and up and up
CMH (cfm)
Type of heat Sensible (50 Sensible (50 Sensible (45 Sensible (55 Sensible (40 to Sensible (40 to
transfer to 80%) to 80%) Total to 65%) to 65%) 60%) 60%)
(typical (55 to 85%)
effectiveness)

Face velocity, 30.5 to 305 150 to 305 120 to 240 90 to 180 120 to 240 90 to 135
m/min (fpm) (61 to 305) (500 to 1000) (135 to 170) (300 to 600) (135 to 170) (300 to 450)
(most 100 to 1000 400 to 800 400 to 800
common (200 to 1000) (450 to 550) (450 to 550)
design
velocity)

Pressure drop, 5Pa to 450 Pa 100 to 180 100 to 500 100 to 500 100 to 500 180 to 305
Pa of water (25Pa to 380 (0.4 to 0.7) (0.4 to 2.0) (0.4 to 2.0) (0.4 to 2.0) (0.7 to 1.2)
(most likely Pa)
pressure) (in. 0.02 to 1.8
of water) (0.1 to 1.5)

Temperature -21 to 800 -21 to 800 -4.4 to 35 -10 to 480 -4.4 to 40 -4.4 to 46
range ºC (-70 to 1500 (-70 to 1500 (-40 to 95 °F) (-50 to 900 (-40 to 104°F) (-40 to 115°F)
(ºF) °F) °F) °F)

Typical mode 1.Exchanger 1 Exchanger 1. Exchanger 1.Coil only 1. Exchanger 1. Complete

of purchase only only only 2.Complete only system
2. Exchanger 2. Exchanger 2.Exchanger system 2. Exchanger
with with with with
enclosure enclosure enclosure enclosure
or casing or casing or casing or casing
3. Exchanger 3. Exchanger
and and
blowers blowers
Complete Complete
system system

ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-1
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 14 OF 26 OF
HEAT RECOVERY WHEEL

APPENDIX-1 (CONTD..)

Fixed Plate Heat Heat Pipe Runaround Thermosiphon Twin Towers

Heat Recovery Heat Coil Loop Enthalpy
Exchangers Wheel Exchangers recovery loop
Unique 1. No 1. Latent 1. No 1. Exhaust 1. No moving 1. Latent
advantages moving transfer moving airstream parts. transfer
parts 2. Compact parts can be 2. Exhaust from
2. Low large except separated airstream remo te
pressure sizes tilt . from can be airstreams
drop 3. Low 2. Fan supply air separated 2. Multiple
3 Easily pressure location 2. Fan from units in a
cleaned drop not location supply air single
critical not 3. Fan system.
3. Allow- critical location not 3. Efficient
able critical micro –
pressure biological
differen- cleaning
tial upto of both
60 in. of supply and
water exhaust
airstreams.
Limitations Latent avail - Cold climates Effectiveness High effective Effectiveness Few Suppliers
able in hygro- may increase limited by –ness requires may be limited
scopic units service pressure drop accurate by pressure
only Cross air and cost simulation drop and cost.
contam- Few suppliers model Few suppliers
ination
possible
Cross-leakage 0 to 5% 1 to 10% 0% 0% 0% 0.025%

Heat rate Bypass Wheel speed Tilt angle Bypass valve Control valve Control valve
control (HRC) dampers and control over down to 10% or pump over full range or pump speed
schemes ducting full range or maximum speed control control over
heat rate. over full full range.
range

SOURCE : ASHRAE 1996 SYSTEMS & EQUIPMENT HANDBOOK CHAPTER 42.

ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-2
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 15 OF 26
HEAT RECOVERY WHEEL

APPENDIX-2

SELECTION OF HEAT RECOVERY WHEEL

1.0 Selection of Heat Recovery Wheel is normally done using manufacturer’s data.
However a typical calculation procedure for HVAC system is given below for
guidance.

STEP-1
Determine the Design Conditions (Indoor as well as outdoor temperature/
Humidity and Enthalpy Conditions).

STEP-2
For certain applications, as many as four different wheel sizes may be utilised.
The ultimate selection is based on both performance and economic considerations.
A mid point selection can be made using the following formula :

Nominal wheel area (sq.m) = Supply or Exhaust Volume (CMH)

3600 x (wheel face velocity in m/s)

Manufacturer’s data furnishes the wheel size which approximates the required
face area. A typical (manufacturer’s) wheel face area Vs diameter (size) of wheel
is given in APPENDIX-3. A nominal face velocity of 3 to 3.5 m/s. can be
assumed to arrive at the wheel area.

STEP-3

Based on the wheel face velocity and the air flow requirements, the thermal
effectiveness and pressure drop can be determined, using manufacturer’s data. A
typical wheel selection chart is furnished in TABLE-2. In the absence of such
data, assume a thermal effectiveness of approx. 80% (for total heat recovery) and
a pressure drop of 10 to 18 mm (0.4 to 0.7 inches) of water column (as given in
APPENDIX-1).

STEP-4
Using the following equations, supply air and exhaust air conditions can be
found out.

Effectiveness = W s (X1 – X2 )/Wmin (X1 – X3 )

Effectiveness = We (X4 – X3 )/Wmin (X1 – X3 )
where Ws = Supply air volume
ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-2
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 16 OF 26
HEAT RECOVERY WHEEL

APPENDIX-2 (CONTD.)

We = Return air volume/ Exhaust air volume

X1, 2, 3 & 4 = Dry bulb temperatures, humidity ratios and

enthalpies corresponding to

X1 = Outdoor air (Entering)

X2 = Supply air (Leaving)

X3 = Return air (Entering)

X4 = Exhaust air (Leaving)

♦ For equal supply volume and exhaust volume

Wx = Wmin = WExhaust

♦ For unequal flow, the air flow to be divided as per the ratio = Wmax
Wmin

STEP 5

a. Calculate Performance by finding X1 , X2 , X3 & X4 : temperatures,

humidity ratios and enthalpies at Entering & Leaving conditions.

b. Calculate the potential reduction in plant capacity (Tons of Refrigeration)

using,

Energy recovered = Air flow x density of air x

(Enthalpy in – Enthalpy Out)

2.0 EXAMPLE PROBLEM

Building : TCS Sholinganallur – SSDC complex

Location : Chennai

Fresh Air
quantity : 15300 CMH (9000 CFM)

To find : Reduction in Refrigeration chiller capacity using HRW.

ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-2
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 17 OF 26
HEAT RECOVERY WHEEL

APPENDIX-2 (CONTD.)

Sl DB ° C (°° F) WB ° C (°° F) Absolute

No Conditions Humidity Enthalpy
(kg/kg)/ kJ/kg
(gr/lb) (Btu/lb)
1. Outdoor conditions

Summer 39.4 (103) 27.8(82) 0.019(133) 89 (45.9)

Monsoon 28.3(83) 26.7(80) 0.022(153) 84 (43.7)

Winter 18.3(65) 13.9(57) 0.0018(56) 39 (24.5)

2. Inside Conditions 24(75) 17.5(63.5) 0.01(71.4) 52 (29.1)

(55% RH)

1. Heat Recovery Wheel

Nominal Wheel area (sq.m) = 15300 CMH = 1.2 sq.m (13 sq.ft)
3600 x 3.5

where face air velocity across the wheel = 3.5 m/s (700 FPM)

2. From Manufacturer’s Performance data (TABLE-2)/APPENDIX-2.

For a face velocity of 3.5 m/s (700 FPM).

Model TE3-13 will handle 15580 CMH (9170 CFM) and the size of wheel
= 1930 mm x 1930 mm (76” x 76”)

Actual wheel area = 1.2 sq.m (13.1 sq.ft)

3. Effectiveness for the model selected = 78.5%

This can also be found out from manufacturer’s charts/software

4. Performance

Ws = Supply (Fresh air) air volume = 15300 CMH

Wmin = 15300 CMH

ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-2
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 18 OF 26
HEAT RECOVERY WHEEL

 15300
Using Equation (3) given in clause 5.0 X 2 = 39.4 +  (24 − 39.4)  0.785
 15300 

= 39.4 – 12.22 = 27.18 Say 27.2°C

(81°F)

i.e Fresh air (leaving HRW) DBT = 27.2°C (81°F)

Similarly

X2 (W) = 0.019 – 0.785 (0.019 – 0.01)

= 0.019 - 0.0071 = 0.0119 Say 0.012 kg/kg of dry air

(84 gr/lb)

X2 (H) = 89 - 0.785 (89-52)

= 59.955 say 60 kJ/kg (32.7 Btu/ lb)

Similarly for exhaust air conditions, using equation (4) as given in clause 5.0.

 15300
X4 = 24 − 0.785 (24 − 39.4 ) = 36.1°C = 97°F
 15300 
i.e. Exhaust air (leaving) DBT = TDB = 36.1 °C

X4 (W) = 0.010 + 0.785 (0.019 - 0.010)

= 0.0171 kg/kg of dry air (119.8 gr/lb)

X4 (H) = 52 + 0.785 (89-52) = 81.045 kJ/kg

Similar calculations can be made for Monsoon and Winter conditions - See
Sh. 19 of 28.

5. Energy Recovered considering supply air entering and leaving conditions.

Summer = 4.5 x 9000 x (45.9 – 32.7)

= 15300 x 1.2 x (89-60) = 147.9 kW = 42 TR

This is also equal to : 15300 x 1.2(81.1 - 52) = 1484.4 kW or 42.2 TR.,

considering exhaust air entering and leaving conditions.

ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-2
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 19 OF 26
HEAT RECOVERY WHEEL

APPENDIX-2 (CONTD.)

SITE DATA

ABSOLUTE ENTHALPY
HUMIDITY
DBT ºC WBT ºC
OUTSIDE
(°° F) (°° F) kg/kg OF DRY kJ/kg
COND.
AIR (GR/LB) (BTU//LB)

SUMMER 39.4(103) 27.8(82) 0.019 (133) 89.0(45.9)

MONSOON 28.3(83) 26.7(80) 0.022 (153) 84.0(43.7)

WINTER 18.3(65) 13.9(57) 0.008(56) 39.0(24.5)

INSIDE 24(75) 17.5°C(63.5°) 0.01(71.4) 52.0(29.1)

COND. 55 % RH

FRESH AIR 15300 CMH (9000 CFM)

QTY

DESIGN PARAMETERS (From TABLE-2)

DESIGN EFFECTIVENESS : 78.5%

FACE VELOCITY : 3.5 m/sec (700 FPM)

WHEEL DIA SELECTED : 1930 mm (76")

PR. DROP SUPPLY : 17 mm wc (0.67”)

PR. DROP EXHAUST : 17 mm wc (0.67”)

WHEEL MODEL SELECTED : HRW TE3-13 OF ECO-FRESH

(ARCTIC INDIA)

NOTE :

DBT : DRY BULB TEMPERATURE (ºC)

WBT : WET BULB TEMPERATURE (ºC)

ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-2
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 20 OF 26
HEAT RECOVERY WHEEL

APPENDIX-2 (CONTD.)

HEAT RECOVERY WHEEL MODEL NO. HRW –1800

SUPPLY AIR ENTERING

AIR QTY : 15300 CMH + (Purge air) [(9000 CFM + Purge Air)]
DBT WBT ABS. ENTHALPY
°C (°° F) ° C (°° F) HUMIDITY
kg/kg (gr/lb) kJ/kg (Btu/1b)

SUMMER 39.4 (103) 27.8 (82) 0.019 (133.0) 89.0 (45.9)

MONSOON 28.3 (83) 26.7 (80) 0.022 (153.0) 84.0 (43.7)

WINTER 18.3 (65) 13.9 (57) 0.008 (56.0) 39.0 (24.5)

SUPPLY AIR LEAVING

AIR QTY : 15300 CMH (9000 CFM)

DBT WBT ABS. HUMIDITY ENTHALPY

°C (°° F) ° C (°° F)
kg/kg (gr/lb) kJ/kg (Btu/1b)

SUMMER 27.2 (81) 20.5 0.012 (84.6) 60.0 (32.7)

MONSOON 25 (77) 20.0 0.0127 (88.9) 59.0 (32.3)

WINTER 22.8 (73) 17.2 0.0097 (68.1) 47.5 (28.1)

EXHAUST AIR LEAVING

AIR QTY : 15300 CMH + Purge Air [(9000 CFM + (Purge Air))]

DBT WBT ABS. HUMIDITY ENTHALPY

°C (°° F) ° C (°° F)
kg/kg (gr/lb) kJ/kg (Btu/1b)

SUMMER 36.1 (97) 26 0.017 (1119.8) 81.1 (42.3)

MONSOON 26.7 (80) 24.8 0.019 (135.5) 76.0 (40.6)

WINTER 19.4 (67) 14.8 0.0085 (59.3) 43.5 (25.5)

ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX-2
TCE.M6-ME-811-314 DESIGN GUIDE FOR SHEET 21 OF 26
HEAT RECOVERY WHEEL

APPENDIX-2 (CONTD.)
EXHAUST AIR ENTERING

AIR QTY : 15300 CMH (9000 CFM)

DBT WBT RH% ABS. HUMIDITY ENTHALPY
°C (°° F) ° C (°° F)
kg/kg (gr/lb) kJ/ kg (Btu/lb)
SUMMER 23.9 (75) 18°C 55 0.010 (71.4) 52 (29.1)
(64.4)
MONSOON 23.9 (75) 18°C 55 0.010 (71.4) 52 (29.1)
(64.4)
WINTER 23.9 (75) 18°C 55 0.010 (71.4) 52 (29.1)
(64.4)

ENERGY RECOVERED

SUMMER : 147.9 kW or = 42 TR
MONSOON : 127.4 kW or = 36.2 TR
WINTER : - - = 43.4 kW

NOTE 1 : The calculations shown above are typical and values approximate for the
purposes of illustration. Similar procedure could be used for preliminary
estimation. Actual reduction in Refrigeration Capacity (or Heating Capacity)
or energy recovered shall be obtained by Equipment Vendor.

NOTE 2 : Purge air quantities will be determined by manufacturer.

NOTE 3 : Calculation of Enthalpy

Enthalpy values could be obtained from a Psychrometric chart. However

Enthalpy Values can be calculated. ASHRAE Fundamentals Volume (S.I.
Units) 1997 gives formulae for calculation of Enthalpy for a given Dry Bulb
Temperature (ºC) and Humidity Ratio (Kg/Kg of dry air) (Refer Table 1 in
Chapter 6 of ASHRAE FUNDAMENTALS-1997)

IN S.I. UNITS

Moist air enthalpy = t + w (2501 + 1.805t) kJ/kg of dry air -- (1)

Where t = dry bulb temperature (saturated air)
W = Humidity Ratio.

 Pw 
W can be calculated using W = 0.622 
 P − Pw 

Where Pw = partial pressure of water vapour at tºC (kPa)

and P = Atmospheric pressure (kPa). ISSUE
R0

FORM NO. 120 R1

TCE CONSULTING ENGINEERS LIMITED SECTION: TABLE-2
TCE.M6-ME- DESIGN GUIDE FOR SHEET 22 OF 26
811-314
HEAT RECOVERY WHEEL

APPENDIX-2 (CONTD.)

TABLE-1

TYPICAL MANUFACTURER’S PERFORMANCE DATA

HEAT RECOVERY WHEEL (HRW)

Velocity Effic. Press MODEL NUMBERS

Drop
MODEL/ TE3- TE3- TE3- TE3- TE3- TE3- TE3- TE3- TE3- TE3- TE3-56 TE3-70
FPM % IN 03 05 09 13 18 24 28 35 43 46
M/S MM
AREA 2.8 5.3 8.6 13.1 18.1 23.8 28.3 35.2 42.9 46.4 56 70.4
(SQ.FT)
300 88.0 0.29 SCFM 840 1590 2580 3030 5430 7140 8490 10560 12870 13920 16800 21120
1.53 7.4 CMH 1430 2700 4380 6680 9230 12130 14430 17940 21870 23650 28540 35880

400 86.0 0.37 SCFM 1120 2120 3440 5240 7240 9520 11320 14080 17160 18560 22400 28160
2.03 9.4 CMH 1900 3600 5850 8900 12300 16170 19230 23920 29160 31530 38060 47840

500 82.5 0.45 SCFM 1400 2650 4300 6550 9050 11900 14150 17600 21450 23200 28000 35200
2.54 11.4 CMH 2380 4500 7310 11130 15380 20220 24040 29900 36440 39420 47570 59810

600 80.5 0.56 SCFM 1680 3180 5160 7860 10860 14280 16980 21120 25740 27840 33600 42240
3.05 14.2 CMH 2850 5400 8770 13350 18450 24260 28850 35880 43730 47300 57090 71770

700 78.5 0.67 SCFM 1960 3710 6020 9170 12670 16660 19810 24640 30030 32480 39200 49280
3.56 17.0 CMH 3330 6300 10230 15580 21530 33660 33660 41860 51020 55180 66600 83730

800 77.0 0.79 SCFM 2240 4240 6880 10480 14480 19040 22640 28160 34320 37120 44800 56320
4.06 20.1 CMH 3810 7200 11690 17810 24600 32350 38470 47840 58310 63070 76120 85690

900 76.0 0.94 SCFM 2520 4770 7740 11790 16290 21420 25470 31680 38610 41760 50400 63360
4.57 23.9 CMH 4280 8100 13150 20030 27680 36390 43270 53820 65600 70950 85630 107650

1000 74.5 1.05 SCFM 2800 5300 8600 13100 18100 23800 28300 35200 42900 46400 56000 70400
5.08 26.7 CMH 4760 9010 14610 22260 30750 40440 48080 59800 72890 78830 95140 119610

1100 73.5 1.18 SCFM 3080 5830 9460 14410 19910 26180 31130 38720 47190 51040 61600 77440
5.59 30.0 CMH 5230 9910 16070 24480 33830 44480 52890 65790 80180 86720 104660 131570
DIMENSIONS AND WEIGHTS
Height and Width ‘A’ In 40 52 64 76 88 100 112 124 136 141 154 172
mm 1016 1321 1626 1930 2235 2540 2845 3150 3454 3581 3912 4369

Depth in Flow Direction In 19 19 19 19 21 21 21 23 23 23 23 23

“B” mm 483 483 483 533 533 533 533 584 584 584 584 584

Net Weight lb 380 520 700 1070 1300 1640 2640 3000 3390 3570 4030 4680
Kg 173 236 318 486 590 745 1199 1362 1540 1621 1830 2125

SOURCE : ECO-FRESH HEAT WHEEL BY ARCTIC INDIA (FOR REFERENCE ONLY)

ISSUE
R0

FORM NO. 120 R1

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