AB Report ZHK AH

ADJUDICATION BOARD
NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY

PAKISTAN NAVY ENGINEERING COLLEGE
ADJUDICATION BOARD, PROJECT REPORT
DESIGN A SOFTWARE FOR CALCULATION OF HEAT LOAD

AND DESIGN AN AIR CONDITIONING SYSTEM FOR
SPECIAL PURPOSE VEHCILE OF THE GENESIS SOLUTIONS
PROJECT SUPERVISOR: DR. WAQAR A.KHAN
GROUP MEMBERS: Zeryab Hassan Kiani (ME-917)
S/Lt Aamir Bin Hamid (Pno: 7772)
DESIGNING OF HEAT LOAD SOFTWARE AND AIR CONDITIONING SYSTEM OF SPECIAL PURPOSE VEHICLE Page 1
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Table of Contents
ACKNOWLEDGEMENT ................................................................................................................................... 8
ABSTRACT ...................................................................................................................................................... 9
INTRODUCTION ........................................................................................................................................... 10
BACKGROUND ......................................................................................................................................... 10
AIM OF THE PROJECT .................................................................................................................................. 11
DETAILS OF SYSTEM .................................................................................................................................... 12
a. OUTSIDE SURFACE OF SYSTEM ........................................................................................................ 12
b. INSIDE OF SYSTEM ........................................................................................................................... 13
• SECTION ONE:............................................................................................................................... 13
• SECTION TWO:.............................................................................................................................. 13
c. PEOPLE AND RATE OF DOOR OPENING ........................................................................................... 13
LITERATURE REVIEW OF COOLING LOAD CALCULATION............................................................................ 14
DESIGN CONDITIONS .............................................................................................................................. 14
a. Dry bulb temperature (DB): ......................................................................................................... 14
b. Wet bulb temperature (WB): ....................................................................................................... 14
c. Dew Point Temperature (DP): ...................................................................................................... 14
d. Humidity Ratio (W’):..................................................................................................................... 14
e. Relative humidity (RH): ................................................................................................................ 14
f. Daily range (DR):........................................................................................................................... 14
JACOBABAD - HOTTEST CITY ....................................................................................................................... 15
a. CLIMATE CONDITIONS OF JACOBABAD ........................................................................................... 15
b. CLIMATE CLASSIFICATION SYSTEM .................................................................................................. 15
ANALYSIS OF CLIMATE CONDITIONS OF JACOBABAD ................................................................................ 16
a. TEMPERATURE DETAILS ................................................................................................................... 16
MOISTURE CONTENTS ............................................................................................................................ 17
b. WIND SPEED ..................................................................................................................................... 18
HEAT GAINED BY SYSTEM ........................................................................................................................... 19
SOLAR RADIATIONS ................................................................................................................................. 20
DEPLETION OF SOLAR RADIATION DUE TO EARTHS ATMOSPHERE ....................................................... 20
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TOTAL SOLAR IRRADIANCE: .................................................................................................................... 21

SOLAR GEOMETRY .................................................................................................................................. 22
a. LATITUDE ANGLE, l: ...................................................................................................................... 23
b. HOUR ANGLE, h: ........................................................................................................................... 23
c. DECLINATION ANGLE, d: .............................................................................................................. 23
DERIVED SOLAR ANGLES ......................................................................................................................... 23
a. ALTITUDE ANGLE, β: ..................................................................................................................... 24
b. ZENITH ANGLE (ψ): ....................................................................................................................... 24
c. SOLAR AZIMUTH ANGLE (ϒ): ........................................................................................................ 25
INCIDENT ANGLES OF SUNRAYS θ .......................................................................................................... 25
a. FOR HORIZONTAL SURFACES ....................................................................................................... 25
b. FOR VERTICAL SURFACES ............................................................................................................. 26
c. WALL SOLAR AZIMUTH ANGLE, (α): ............................................................................................. 26
CALCULATION OF SOLAR RADIATIONS ................................................................................................... 27
a. DIRECT SOLAR RADIATIONS COMING FROM SUN (IDN)................................................................ 27
b. DIFFUSED RADIATION FROM SKY Id ............................................................................................. 27
c. REFLECTED SOLAR RADIATION, Ir................................................................................................. 28

INTERNAL LOADS .................................................................................................................................... 28
a. LOAD DUE TO OCCUPANTS .......................................................................................................... 28
b. LOAD DUE TO LIGHTING ............................................................................................................... 29
c. LOAD DUE TO EQUIPMENT AND APPLIANCES ............................................................................. 30
CONDUCTION THROUGH EXTERIOR STRUCTURE ................................................................................... 31
a. PAINT ............................................................................................................................................ 32
b. MILD STEEL ................................................................................................................................... 32
c. POLY-URETHANE .......................................................................................................................... 32
d. ACP ............................................................................................................................................... 32
PROGRAM FOR THE CALCULATION OF COOLING LOAD ............................................................................. 32
STRUCTURE OF PROGRAM...................................................................................................................... 32
a. FIRST FORM .................................................................................................................................. 32
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b. SECOND FORM: ............................................................................................................................ 33

d. FOURTH FORM: ............................................................................................................................ 34
TABLES FOR CODING OF SOFTWARE: ......................................................................................................... 34
DESIGNING OF AIR CONDITIONING SYSTEM .............................................................................................. 37
COMPRESSOR.......................................................................................................................................... 40
CLASSIFICATION BY WORKING PRINCIPLE .............................................................................................. 40
a. POSITIVE DISPLACEMENT TYPE .................................................................................................... 40
b. ROTO DYNAMIC TYPE ................................................................................................................... 40
CLASSIFICATION BY ARRANGMENT ........................................................................................................ 41
MAIN CHARACTERISTICS OF POSITIVE DISPLACEMENT TYPE COMPRESSORS ....................................... 41
RECIPROCATING COMPRESSOR .................................................................................................................. 42
SELECTION OF RECIPROCATING COMPRESSOR ...................................................................................... 43
WHY DANFOSS? ...................................................................................................................................... 43
CONDENSERS .............................................................................................................................................. 44
AIR COOLED CONDENSERS...................................................................................................................... 44
WATER COOLED CONDENSERS ............................................................................................................... 44
WHY AIR COOLED CONDENSERS? ........................................................................................................... 44
SELECTION OF FINNED TYPE AIR COOLED CONDENSER ............................................................................. 45
TECHNICAL SPECIFICATIONS ................................................................................................................... 45
EXPANSION DEVICE ..................................................................................................................................... 46
ELECTRONIC EXPANSION VALVE ............................................................................................................. 46
SELECTION OF INSIDE UNIT......................................................................................................................... 47
TECHNICAL SPECIFICATIONS ................................................................................................................... 47
MATHEMATICAL MODELLING OF SYSTEM ................................................................................................. 48
EQUATIONS OF COMPRESSOR ................................................................................................................ 48
EQUATION OF COOLING CAPACITY......................................................................................................... 48
EQUATION OF POWER ................................................................................................................................ 49
EQUATION OF MASS FLOW RATE ........................................................................................................... 50
EQUATION OF CONDENSER .................................................................................................................... 51
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EQUATION OF EVAPORATOR .................................................................................................................. 51

RESULTS OF SIMULATION OF THE SYSTEM ................................................................................................. 52
POWER CONSUMPTION .......................................................................................................................... 52
COOLING CAPACITY................................................................................................................................. 54
HEAT REJECTED BY CONDENSER ............................................................................................................. 55
CONDENSING TEMPERATURE ................................................................................................................. 56
EVAPORATOR TEMPERATURE ................................................................................................................. 57
MASS FLOW RATE ................................................................................................................................... 58
COEFFICIENT OF PERFORMANCE ............................................................................................................ 59
REFERENCES ................................................................................................................................................ 60
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LIST OF FIGURES
Figure 1: GROUND CONTROL STATION ......................................................................................................... 9
Figure 2: AIM OF PROJECT .......................................................................................................................... 11
Figure 3: EXTERIOR SURFACE OF GCS ......................................................................................................... 12
Figure 4: INSIDE OF GCS .............................................................................................................................. 13
Figure 5: CLIMATE VARIATIONS .................................................................................................................. 16
Figure 6: HUMIDITY VARIATIONS ................................................................................................................ 17
Figure 7: WIND SPEED ................................................................................................................................. 18
Figure 8: ALTITUDE ANGLE .......................................................................................................................... 21
Figure 9: INCIDENT ANGLE .......................................................................................................................... 22
Figure 10: SOLAR ANGLES ........................................................................................................................... 22
Figure 11: DERIVED SOLAR ANGLES ............................................................................................................ 24
Figure 12: INCIDENT ANGLE ON HORIZONTAL SURFACE ............................................................................ 25
Figure 13: INCIDENT ANGLE OF VERTICAL SURFACE .................................................................................. 26
Figure 14: EXTERIOR SURFACE OF GCS ....................................................................................................... 31
Figure 15: AIR CONDITIONING SYSTEM AND T-S DIAGRAM ....................................................................... 39
Figure 16: RECIPROCATING COMPRESSOR ................................................................................................. 42
Figure 17: COOLING CAPACITY GRAPH ....................................................................................................... 48
Figure 18: COMPRESSOR POWER ............................................................................................................... 49
Figure 19: GRAPH OF COMPRESSOR POWER ............................................................................................. 53
Figure 20: GRAPH OF COOLING CAPACITY.................................................................................................. 54
Figure 21: HEAT REJECTED BY CONDENSER GRAPH ................................................................................... 55
Figure 22: CONSDENSING TEMPERATURE GRAPH ..................................................................................... 56
Figure 23: GRAPH OF EVAPORATOR TEMPERATURE .................................................................................. 57
Figure 24: GRAPH OF MASS FLOW RATE .................................................................................................... 58
Figure 25: GRAPH OF COP ........................................................................................................................... 59
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LIST OF TABLES
Table 1: TYPES OF RADIATIONS .................................................................................................................. 20
Table 2: HEAT DISSIPATED BY HUMAN ACTIVITIES..................................................................................... 29
Table 3: INTERNAL LOAD OF SOME APPLIANCES ....................................................................................... 30
Table 4: MATERIALS AND THERE TIME LAG AND DECREMENT FACTORS] ................................................. 34
Table 5: LATITUDE ANGLES AND HUMIDITY RATIOS OF VARIOUS CITIES ................................................. 35
Table 6: REFLECTIVITY OF SURFACES ......................................................................................................... 36
Table 7: EMISSITIVY RATIO AND ABSORPTION RATIO OF SURFACES ........................................................ 36
Table 8 AIR DENSITIES AT VARIOUS TEMPERATURES ................................................................................ 37
Table 9 KINEMATIC VISCOUSITY OF AIR ..................................................................................................... 37
Table 10 HEAT DISSPIATED BY COMPUTERS .............................................................................................. 37
Table 11: CHARACTERISTICS OF COMPRESSOR .......................................................................................... 41
Table 12: POWER CONSUMPTION OF COMPRESSOR ................................................................................. 52
Table 13: COOLING CAPACITY ..................................................................................................................... 54
Table 14: HEAT REJECTED BY THE CONSDENSER ........................................................................................ 55
Table 15: CONDENSING TEMPERATURES ................................................................................................... 56
Table 16: EVAPORATOR TEMPERATURE ..................................................................................................... 57
Table 17: MASS FLOW RATE ....................................................................................................................... 58
Table 18: COP .............................................................................................................................................. 59
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ACKNOWLEDGEMENT
1. First of all thanks are due to Almighty Allah for his everlasting blessings which made the
completion of this project possible because this was one of the major milestones in obtaining
Bachelors degree in Mechanical Engineering.
2. Next, we wish to express our sincere appreciation to our project Advisor Dr Waqar A Khan for
his commitment, encouragement and academics guidance that helped us conclude this
evaluation.
3. We would like to take this opportunity to extend our heartiest gratitude to Assistant Professor
Khurram Jamal Hashmi who helped us a lot right from the start of the project especially in the
calculations part and his valuable guidance & suggestions are also worth appreciating.
4. We would like to thank Squadron leader(R) Khalid (CEO Genesis Solutions PVT.Ltd) for giving us
the opportunity to practically implement the theoretical knowledge gained during this degree
and for his lovely hospitality and continuous support during our work. Appreciations also
extend to Mr. Akbar for helping us in surveying of companies and the market.
5. Finally, needless to mention and acknowledge the morale support, sincere wishes and prays of
our parents, help and assistance rendered by them during our complete Course of study. They
remained a source of inspiration to us during the completion & preparation of the Final report.
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ABSTRACT
1. Heating, Ventilation, and Air-conditioning systems are being widely used all around the
globe to provide comfort conditions to the occupants and for specialized uses in different
projects. This field of Mechanical Engineering deals with all the governing laws of Air-
Conditioning, Refrigeration, Fluid flow and Heat transfer to devise an economical,
environment friendly and efficient system to meet the needs.
2. We had to design software for calculating the cooling load and to design an Air conditioning
system for the special purpose vehicles (system) as shown in figure one. For this we have
studied and referred to various books of AIR CONDITIONING systems, ASHRAE handbooks &
Microsoft visual C-sharp book. Then several meetings with Squadron Leader(R) Khalid who
is the owner of the company were done to physically see the vehicle and also to learn about
the factors that would be considered in designing the air conditioning system.
3. This project covers the detailed load calculation of the special purpose vehicle considering
all the factors that govern the cooling capacity of the conditioned space. According to the
load capacity calculated the air conditioning system is designed by visiting various
companies such as EMRAC PVT. Ltd. , Fakhre Brothers PVT. Ltd. , Shabbier Brothers PVT.
Ltd. , Zamil International PVT. Ltd. & Bharmal International PVT. Ltd. which was helpful in
surveying the market and acquiring the data sheets to select the parts of the system
according to the design parameters in such a way that the system is cost effective and
efficient.
Figure 1: GROUND CONTROL STATION
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INTRODUCTION
BACKGROUND
1. Air conditioning systems are widely used in the world to provide conditioned air for human
comfort or required by a product or space within the given area.
2. In order meet the objective and to present the finest elucidation, system is designed that
depends upon certain factors that are:
• Load capacity
• Operating conditions
• System installation and commissioning cost
• Running cost
• Reliability and durability
3. Depending upon the need and the factors mentioned above the type of AIR CONDITIONING
system (air cooled or water cooled system) and proper equipment is selected that include
chillers, boilers, air handling units, fan coil units, evaporators, pumps etc.
4. An AIR CONDITIONING system cannot be designed until one has sound knowledge of the
codes and set of laws which govern and regulate building or container construction, product
design and fabrication. For this purpose a central body known as ASHRAE has been made to
design a set of rules and regulations that are followed over the globe.
5. To have such a system designed first the load is estimated after having the survey of the
system and taking into account all the heat sources. Then a suitable system is designed
keeping in view the ASHRAE Standards and Hand Books.
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AIM OF THE PROJECT

1. Genesis Solutions (company) which designs and fabricates special purpose vehicles (which
do calculations in remote area and has 10 computers) is facing a problem in the air
conditioning system of their special purpose vehicle i.e. the air conditioning system failed to
cool the container or special purpose vehicle once the vehicle was taken to internal Sindh as
the ambient temperature there increases in summers which is beyond the working load
capability of the air conditioning system.
2. Our task is to design such an air conditioning system which is compatible in such extreme
operating conditions once the ambient temperature is at 52 0C , the cooling inside the
container or special purpose vehicle has to be maintained at 180C to 260C. Apart from this
we have to design general software for calculating the cooling load of not only the special
purpose vehicle but any general system which is required by the company for their use.
3. The basic objectives of the project are as follow:
Figure 2: AIM OF PROJECT
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DETAILS OF SYSTEM
1. A System is a special mobile unit or vehicle that is specially designed to be used in the
military as a part of modern warfare. There sole purpose is to control the drones commonly
known as UAVs (Unmanned Aerial Vehicle).
2. As there must be collaboration between the designer and the owner in identifying and
evaluating the goals of the design so as far as our container of GCS is concerned we took a
number of survey and gathered the following data:-
a. OUTSIDE SURFACE OF SYSTEM

1. The System is in a shape of a rectangle and is 5.3848 meter long and 2.4384 meter wide.
The outer surface of the container is basically made of mild steel. The surface of the
container is bifurcated as follow:-
Figure 3: EXTERIOR SURFACE OF GCS
2. The above diagram shows the detailed structure of the outer surface of the System along
with the respective thickness of each layer. This composition is an important parameter in
calculating the heat load as it gives us the thermal loss that takes place before the heat
enters inside the container.[1]
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b. INSIDE OF SYSTEM
1. The inside of the System can be divided into two sections:-
• SECTION ONE: It contains a total of ten computers (35 Watt each) , three consoles
panels and six tube lights each of (25 Watt).
• SECTION TWO: This section is a small compartment which contains crates where UPS
of ( 3 KWA each) are housed. [1]
2. The following diagram shows the inside of the system
Figure 4: INSIDE OF GCS
c. PEOPLE AND RATE OF DOOR OPENING

1. The maximum numbers of people that are sitting inside the System are five and the average
rate of opening and closing of door which will be causing infiltration and hence be a factor
in the calculation of heat load. [1]
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LITERATURE REVIEW OF COOLING LOAD CALCULATION

DESIGN CONDITIONS
1. The System is to be designed at an ambient temperature of 52 degree Celsius, once the
container is in interior Sindh. As the problem faced by the company is that the pre-existing
air conditioners of the container fail to achieve the desired result.
2. Load calculations are usually based upon some design conditions of indoor and outdoor
air. The indoor design conditions are those which provide satisfactory human comfort. The
outdoor design conditions are according to the weather records.
3. These design conditions are usually a set of some properties which may include the
following:
a. Dry bulb temperature (DB): The temperature as measured without the
consideration of humidity. The dry bulb temperature is the temperature that is usually
thought of as air temperature, measured using a freely exposed thermometer. [2]
b. Wet bulb temperature (WB): It is temperature associated with moisture content
of the air. It is measured by surrounding the thermometer with wet wick and measuring
the temperature until water evaporates. Wet bulb temperature is always lower than dry
bulb because of evaporative cooling. [2]
c. Dew Point Temperature (DP): The temperature at which the water vapor in the
air would begin to condense if the air was cooled, at constant pressure. [2]
d. Humidity Ratio (W’): This is also called the moisture content; it is the weight of
water vapor per unit weight of dry air, in lb/lb or grains/lb. [2]
e. Relative humidity (RH): The ratio of the amount of moisture in the air, to the
maximum amount of moisture that air would contain if it were saturated, or the ratio of
the actual vapor pressure to the saturated vapor pressure. [2]
f. Daily range (DR): It is the difference between the maximum and the minimum
temperature on a chosen design day. [2]
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JACOBABAD - HOTTEST CITY

1. Jacobabad is the hottest place in Pakistan and has been chosen as extreme condition for
calculating the cooling load. This will help us in designing an air conditioning system that will
not only sustain the high ambient conditions in the interior Sindh but also make an efficient
air conditioning system.
2. Jacobabad also known as Yaqubabad is the capital city of Jacobabad district. It is located at
latitude of 28.277° North and at a longitude of 68.451° East in Sindh, Pakistan. It is one of
the hottest cities of Pakistan considering the climate conditions that prevail in the city
throughout the year.
3. The record maximum temperature that was attained in Jacobabad in the recent times was
in the month of June and it was measured to be 51° Centigrade or 123° Fahrenheit similarly
the record minimum temperature was measured to be 20° Centigrade which equals to 68°
Fahrenheit. [3]
a. CLIMATE CONDITIONS OF JACOBABAD

1. On the basis of the daily climate conditions researchers succinctly opine this city to be one
of the hottest cities of Pakistan. They have classified this on the basis of climate
classification system which is discussed as below:
b. CLIMATE CLASSIFICATION SYSTEM

1. It is a way or technique of classifying climate of a particular place or location. There are
basically three types of techniques used in such regard:-
• Aridity Index
• Koppen Climate classification
• Holdridge life zone classification
2. One of the common techniques used is the Koppen Climate classification in which climate is
expressed on the basis of native vegetation. It covers the average annual and monthly
temperature and precipitation. The climate is classified by this system in four groups which
are as follow:
• Group A Tropical climate
• Group B Dry climate
• Group C Temperate climate
• Group D Continental climate
• Group E Polar climate
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3. According to this classification Jacobabad lies in Group B which shows that it has hot
summers and mild winters. The rain fall is low and mainly occurs in the monsoon season.
ANALYSIS OF CLIMATE CONDITIONS OF JACOBABAD

Some of the important features or parameters of Jacobabad climate condition are as follow:
a. TEMPERATURE DETAILS
1. The month of June, February, November have the average temperature which is 27.2° C or
81° F based on these temperatures the average monthly temperature comes out to be 22°
C.
2. The peak or highest temperature obtained is 51° C in June and the coolest temperature is 7°
C or 45° F in January and December, on average the coolest month is January. [3]
Figure 5: CLIMATE VARIATIONS
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MOISTURE CONTENTS
1. Relative humidity is the moisture contents that are present in air or in the climate of
Jacobabad, on the average yearly basis the relative humidity is 34.2 percent.
2. If relative humidity is considered on monthly basis then it has a range from 27 percent in
May and 49 percent in August. The average daily humidity for the month of June is 48
percent. [3]
Figure 6: HUMIDITY VARIATIONS
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b. WIND SPEED
The record high wind speed that has been measured is 106 km/h which equals to 57 knots,
and especially in the month of June once the temperature is at its highest peak the wind
speed is 16 km/h and this equals to 8 knots. [3]
Figure 7: WIND SPEED
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HEAT GAINED BY SYSTEM

1. A conditioned space may receive heat from a number of sources. To maintain the indoor air
at a comfortable level, this heat needs to be removed. The amount of heat that must be
removed is called the cooling load. The components that contribute the heat gain of a room
are:
• Solar radiations
• Infiltration of outside air through openings of doors or windows
• Internal load
• Conduction through exterior structures i.e. walls, roof.
2. It is convenient to arrange the heat gains in two groups: sensible and latent. Sensible heat
gains result in increasing the air temperature, while the Latent heat gains are due to the
addition of water vapor and result in increasing humidity. [4]
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SOLAR RADIATIONS
1. The solar radiations that are incident on the rectangular System are dependent on three
major conditions:-
• The surface that the incident radiations strike whether it is horizontal surface or the
vertical surface.
• The orientation of the container and the suns position at a particular time as both vary
with respect to time.
• The type of solar radiation that is incident on the surface of the container i.e. whether
the radiation is diffused, directly incident or reflected or all three.
2. For calculation purposes, the sun may be treated as a radiant energy source with surface
temperature that is approximately equal to that of a blackbody at 6000 K. The spectrum of
wavelength of solar radiation stretches from 0.29 μm to about 4.75 μm, with the peak
occurring at about 0.45 μm (the green portion of visible spectrum).[4]
Table 1: TYPES OF RADIATIONS
Type of radiation Wavelength band (μm) % of total radiation

Invisible ultra-violet (UV) 0.29 to 0.40 7
Visible radiation 0.40 to 0.70 39
Near Infrared (IR) 0.70 to 3.50 52
DEPLETION OF SOLAR RADIATION DUE TO EARTHS ATMOSPHERE
1. In passing through the earth’s atmosphere, which consists of dust particles, various gas
molecules and water vapour, the solar radiation gets depleted due to reflection, scattering
and absorption. The extent of this depletion at any given time depends on the atmospheric
composition and length of travel of sun’s rays through the atmosphere. The length of travel
is expressed in terms of ‘air mass, m’ which is defined as the ratio of mass of atmosphere in
the actual sun-earth path to that which would exist if the sun were directly overhead at sea
level.
2. Hence the air mass is given by:
[4]
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TOTAL SOLAR IRRADIANCE:

1. In order to calculate the building heat gain due to solar radiation, one has to know the
amount of solar radiation incident on various surfaces of the building. The rate at which
solar radiation is striking a surface per unit area of the surface is called as the total solar
irradiation on the surface. This is given by:
2
• I = Total solar irradiation of a surface, W/m
iθ
2
• I = Direct radiation from sun, W/m
DN
2
• I = Diffuse radiation from sky, W/m
dθ
2
• I = Short wave radiation reflected from other surfaces, W/m
rθ
• θ = Angle of incidence, degrees
2. The first term on the RHS, i.e., IDN cos θ, is the contribution of direct normal radiation to
total
3. Irradiation. On a clear, cloudless day, it constitutes about 85 percent of the total solar
radiation incident on a surface. However, on cloudy days the percentage of diffuse and
reflected radiation components is higher. The objective of solar radiation calculations is to
estimate the direct, diffuse and reflected radiations incident on a given surface. These
radiations and the angle of incidence are affected by solar geometry. [4]
Figure 8: ALTITUDE ANGLE
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Figure 9: INCIDENT ANGLE

SOLAR GEOMETRY
1. The angle of incidence depends upon the location on earth, time of the day and day of the
year. These three parameters are defined in terms of the latitude angle, hour angle and the
declination angle.
2. Following figure shows the position of a point P on the northern hemisphere of the earth,
whose center is at point O. Since the distance between earth and sun is very large, for all
practical purposes it can be considered that the sun’s rays are parallel to each other when
they reach the earth.
3. With reference to the below figure the various solar angles are defined as follows: [4]
Figure 10: SOLAR ANGLES
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a. LATITUDE ANGLE, l:
1. It is the angle between the lines joining O and P and the projection of OP on the
equatorial plane.
2. Thus the latitude along with the longitude indicates the position of any point on earth
and it varies from 0 degree at equator to 90 degree at the poles.
b. HOUR ANGLE, h:
1. It is the angle between the projection of OP on the equatorial plane i.e., the line OA and
the projection of the line joining the center of the earth to the center of the sun, i.e., the
line OB. Therefore:
2. The hour angle is a measure of the time of the day with respect to solar noon. Solar
noon occurs when the sun is at the highest point in the sky, and hour angles are
symmetrical with respect to the solar noon.
c. DECLINATION ANGLE, d:
1. The declination angle is the angle between the line joining the centre of earth and sun
and its projection on the equatorial plane, hence the angle between OO and OB is given
as follow:
2. For the northern hemisphere declination angle varies from +23.5 degrees to – 23.5
degrees i.e. from June 21st to December 21st. [4]
DERIVED SOLAR ANGLES
In addition to the three basic solar angles, i.e., the latitude, hour angle and declination, several
other angles have been defined (in terms of the basic angles), which are required in the solar
radiation calculations. Figure 32.6 shows a schematic of one apparent solar path and defines
the altitude angle (β), zenith angle (ψ) and solar azimuth angle (γ). It can be shown by analytical
geometry that these angles are given by:
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a. ALTITUDE ANGLE, β:
It is the angle between sun rays and projection of the sun rays on to the
horizontal surface.
b. ZENITH ANGLE (ψ):

1. It is the angle between sun rays and surface normal to the horizontal plane at the position
of the observer. Hence it can be mathematically shown as:
Figure 11: DERIVED SOLAR ANGLES
2. The altitude angle beta is maximum at the solar noon . Since the hour angle h is at zero
degree at solar noon hence the maximum altitude angle on any particular day and on any
particular location is given by taking (h= zero degree) hence the expression of beta given
above can be subustituted into:-
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c. SOLAR AZIMUTH ANGLE (ϒ):
1. It is the angle in the horizontal plane and measured forms the north to the horizontal
projection of the sunrays. This angle is as shown in the above figure and mathematically it
can be written as follow:-
2. At solar noon when the hour angle is zero at that time the solar azimuthal angle is equal to
180 degrees. [4]
INCIDENT ANGLES OF SUNRAYS θ

1. The incident angle of sunrays is basically the angle between the sun rays and normal to the
surface under consideration. This angle depends not only on the solar geometry but also on
the orientation of the surface. [4]
a. FOR HORIZONTAL SURFACES

1. For the horizontal surface the incident angle is nothing but equal to the zenith angle no
matter how is the orientation of the surface it will always be equal to the zenith angle in this
case.
Figure 12: INCIDENT ANGLE ON HORIZONTAL SURFACE

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b. FOR VERTICAL SURFACES

1. Following figure shows an arbitrarily orientated vertical surface (shaded) that is exposed
to solar radiation. The angle of incidence of solar radiation on the vertical surface
depends upon the orientation of the wall, i.e., east facing, west facing etc. Additional
angles have to be defined to find the angle of incidence on the vertical wall.
Figure 13: INCIDENT ANGLE OF VERTICAL SURFACE

c. WALL SOLAR AZIMUTH ANGLE, (α): This is the angle between normal to the wall
and the projection of sun’s rays on to a horizontal plane.
d. SURFACE AZIMUTH ANGLE, (ξ):

1. This is the angle between the normal to the wall and south. Thus when the wall is facing
south, then the surface azimuth angle is zero and when it faces west, then the surface
azimuth angle is 90o and so on. The angle is taken as +ve if the normal to the surface is to
the west of south and –ve if it is to the east of south.
2. Hence it can be seen that the wall solar azimuth angle is given by
3. Here F will be equal to -1 for noon and +1 for after noon. Now it can be shown that the
angle of incidence of the vertical surface is given by: [4]
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CALCULATION OF SOLAR RADIATIONS

Solar radiations have an important effect in calculation of the cooling load of any system under
consideration. The solar radiations can be classified into three categories i.e. direct, diffused &
reflected solar radiations. These radiations are explained as follow:
a. DIRECT SOLAR RADIATIONS COMING FROM SUN (I )

DN
1. One of the most common method for the calculation of the direct solar radiations coming from
sun is given by ASHRAE and according to it direct solar radiations can be mathematically written
as follow:
2
2. Now here “A” is the apparent solar irradiation which is taken as 1230 W/m for the months
2
of December and January and 1080 W/m for mid-summer. Whereas “B” is the atmospheric
extension coefficient which has the value of 0.14 in winter and 0.21 in summer.
b. DIFFUSED RADIATION FROM SKY Id

1. The diffused radiation according to the ASHRAE standards is given by
2. The value of C is assumed to be constant for a cloudless sky for an average day of a month.
The value of C can be taken as 0.135 for mid-summer and as 0.058 for winter. The factor
FWS is called as view factor or configuration factor and is equal to the fraction of the
diffuse radiation that is incident on the surface. For diffuse radiation, FWS is a function of
the orientation of the surface only. It can be easily shown that this is equal to:
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c. REFLECTED SOLAR RADIATION, Ir
1. The amount of solar radiation reflected from the ground onto a surface is given by
2. Where ρg is the reflectivity of the ground or a horizontal surface from where the solar
radiation is reflected on to a given surface and FWG is view factor from ground to the
surface. The value of reflectivity obviously depends on the surface property of the ground.
The value of the angle factor is [4]
INTERNAL LOADS
1. The internal loads consist of load due to occupants, due to lighting, due to equipment and
appliances. All these above mentioned loads are discussed in detail as follow:
a. LOAD DUE TO OCCUPANTS

1. The internal cooling load due to occupants consists of both sensible and latent heat
components. The rate at which the sensible and latent heat transfer take place depends
mainly on the population and activity level of the occupants. Since a portion of the heat
transferred by the occupants is in the form of radiation, a Cooling Load Factor (CLF) should
be used similar to that used for radiation heat transfer through fenestration. Thus the
sensible heat transfer to the conditioned space due to the occupants is given by the
equation:
ADJUDICATION BOARD
2. Following table shows typical values of total heat gain from the occupants and also the
sensible heat gain fraction as a function of activity in an air conditioned space. However, it
should be noted that the fraction of the total heat gain that is sensible depends on the
conditions of the indoor environment. If the conditioned space temperature is higher, then the
fraction of total heat gain that is sensible decreases and the latent heat gain increases, and vice
Table 2: HEAT DISSIPATED BY HUMAN ACTIVITIES
versa.
3. The value of Cooling Load Factor (CLF) for occupants depends on the hours after the
entry of the occupants into the conditioned space, the total hours spent in the
conditioned space and type of the building. Values of CLF have been obtained for
different types of buildings and have been tabulated in ASHRAE handbooks.
4. Since the latent heat gain from the occupants is instantaneous the CLF for latent heat
gain is 1.0, thus the latent heat gain due to occupants is given by:
b. LOAD DUE TO LIGHTING

1. Lighting adds sensible heat to the conditioned space. Since the heat transferred from the
lighting system consists of both radiation and convection, a Cooling Load Factor is used to
account for the time lag. Thus the cooling load due to lighting system is given by:
ADJUDICATION BOARD
2. The usage factor accounts for any lamps that are installed but are not switched on at the time
at which load calculations are performed. The ballast factor takes into account the load
imposed by ballasts used in fluorescent lights. A typical ballast factor value of 1.25 is taken for
fluorescent lights, while it is equal to 1.0 for incandescent lamps. The values of CLF as a
function of the number of hours after the lights are turned on, type of lighting fixtures and
the hours of operation of the lights are available in the form of tables in ASHRAE handbooks.
c. LOAD DUE TO EQUIPMENT AND APPLIANCES

1. The equipment and appliances used in the conditioned space may add both sensible as well
as latent loads to the conditioned space. Again, the sensible load may be in the form of
radiation and/or convection. Thus the internal sensible load due to equipment and
appliances is given by:
2. The installed wattage and usage factor depend on the type of the appliance or equipment.
The CLF values are available in the form of tables in ASHARE handbooks. The latent load due
to appliances is given by:
3. For example the following table shows the total load produced by some of the electrical
appliances:
Table 3: INTERNAL LOAD OF SOME APPLIANCES
4. For other equipment such as computers, printers etc, the load is in the form of sensible heat
transfer and is estimated based on the rated power consumption. The CLF value for these
equipment may be taken as 1.0 as the radiative heat transfer from these equipment is
generally negligible due to smaller operating temperatures.
ADJUDICATION BOARD
5. When the equipment is run by electric motors which are also kept inside the conditioned
space, then the efficiency of the electric motor must be taken into account. Though the
estimation of cooling load due to appliance and equipment appears to be simple as given by
the equations, a large amount of uncertainty is introduced on account of the usage factor
and the difference between rated (nameplate) power consumption at full loads and actual
power consumption at part loads. Estimation using nameplate power input may lead to
overestimation of the loads, if the equipment operates at part load conditions most of the
time. [4]
CONDUCTION THROUGH EXTERIOR STRUCTURE

1. As discussed before the exterior or outer surface of the System is bifurcated into four
different layers which are as follow:
• Paint
• Mild Steel
• Poly Urethane
• Aluminum Composite Panel
2. As these entire layer contribute in the thermal loss before the heat from the exterior enters
in to the interior of the container hence they can be considered as individual resistances in
series which add up and help in contributing to the overall loss of heat as shown in the
following figure:
Figure 14: EXTERIOR SURFACE OF GCS
ADJUDICATION BOARD
a. PAINT
It is chosen according to its reflective properties that the rays which are incident on the
container are reflected away so as the surface of the container becomes less hot in high
ambient conditions.
b. MILD STEEL
The sole purpose of using this metal is to give rigidity and toughness to the structure of
Ground Control Station.
c. POLY-URETHANE
Poly urethane is used as an insulator in the outer surface of the Ground Control Surface.
d. ACP
The aluminum composite plan is used to give decoration to the interior of the container. [1]
PROGRAM FOR THE CALCULATION OF COOLING LOAD

1. One of the requirements of GENESIS SOLUTIONS PVT. Ltd. was the development of software
for the calculation of cooling load. After studying and considering all the above mentioned
parameters cooling load calculations were practically done on the System and it was found
that the cooling load for the special vehicle comes out to be approximately 4 tones.
2. On C-sharp language a cooling load calculations program has been developed which has the
ability to measure the load for a vehicle having any dimension, having any configuration of
construction and even present in different cities of Pakistan apart from the interior Sindh.
This will help the company in manufacturing Systems of various dimensions as required.
STRUCTURE OF PROGRAM
The structure of the program is as follow:-
a. FIRST FORM:
• This form is for the calculation of cooling load due to temperature difference.
• Ambient temperature, surface temperature and inside design temperature are to be
inserted in the three text boxes at the top.
• After that select the emissivity from the drop down menu and if it is not listed then
insert in the text box as desired. (values from table 5)
• Button of film temperature should be pressed so that program calculates the film
temperature of air and other properties such as kinetic viscosity and thermal
conductivity etc. (values from table 7 & 2 for time lag and decrement factors value)
• The program has the feature of selecting the exterior surface of the vehicle and it
extends to eight layers, there is a thirty two different materials drop box menu which
can be selected as desired and if the desired option is not available then it can be
enlisted in the text box manually this will then give us the thermal resistance of the wall.
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• For the calculation of thermal resistance between the exterior surface and envoirment
there are various parameters that are calculated by the program which includes the
characteristic length, Grashof number, nusselt number, prandtl number & raleigh
number.
• Using the area, temperature difference and thermal resistances we can calculate the
heat loss that is coming in the system from the surrounding.
b. SECOND FORM:
• This form is for the calculation of the solar radiations that are coming from the sun and
incident on the vehicle.
• First thing that needs to be done is to select the city in which the System is at the
present, there is a drop down menu which enlists major cities of Pakistan this will give
us the latitude angle for that particular city. If the city is not enlisted it can be inserted
manually. ( values from table 3)
• For northern hemisphere declination angle is taken to be +23.5 degree as it is the
extreme conditions and favorable for the calculation of the cooling load.
• The hour angle will be calculated by using the thermal delay of the wall which was
selected in the previous form using research paper (form one).
• The largest side that is facing the sun is assumed as the reference side now the software
requires an input of surface solar azimuth angle for which the text box has been
provided.
• After this the program will calculate the surface azimuth angle for the other side facing
sun and then it will calculate the solar azimuth angle ϒ and wall solar azimuth angles α1
and α2 with the help of the formulas as mentioned in the literature review and enlisted
in the coding.
• Now the solar radiations incident angle θ for the horizontal and vertical surfaces will be
calculated by the software.
• Now the direct, diffused, incident radiations are calculated and then all of these are
added and the total is multiplied by absorbitivity of the exterior surface.
• Hence after the calculation these radiations are multiplied with their respective areas of
wall on which they are incident to get the overall heat absorbed by the surface.
c. THIRD FORM:
• This form helps the user in calculating load due to infiltration and internal loads i.e.
Load due to equipments and people.
• The first thing that this form requires is the number and types of lights i.e. whether it is
fluorescent tube or incandescent bulb and their respective wattage used. ( values from
table 8)
• Now the user has to enter the number and types of CPUs being used and their
respective wattage along with the utility factor.
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• Now the software requires input for the types of monitor being used and there number
and wattage along with the utility factor.
• Now the program asks for any general heat dissipating item that might be present inside
the system which needs to be enlisted along with their wattage, quantity being utilized
and their utility factor respectively.
• Now it is required from the user to enlist the number of people present inside the
system and their activities.
• The user should enter the type of envoirment being under consideration which can be
selected from the drop down menu i.e. the system is office, bed room etc. It is also
required to enlist that whether the envoirment is smoking or non smoking.
• Now the software asks for using the infiltration rate as recommended be ASHRAE but
the leverage has been given to the user to enter the infiltration rate as desired and
finally the program calculates the internal load.
d. FOURTH FORM:
This form takes all the values of previous loads that have been calculated in the previous
forms and sums them up to get the overall cooling load required.
TABLES FOR CODING OF SOFTWARE:
Table 4: MATERIALS AND THERE TIME LAG AND DECREMENT FACTORS [5]
Thickness 10mm 25mm 50mm 100mm 200mm

Material TL DF TL DF TL DF TL DF TL DF
Asbestos 0.37 0.557 1.23 0.396 3.39 0.230 7.97 0.069 17.41 0.004
Bakelite board 0.34 0.603 0.96 0.466 2.32 0.315 5.76 0.136 12.53 0.136
Poly urethane 0.01 0.632 0.03 0.271 0.12 0.139 0.42 0.07 1.63 0.04
PVC board 0.2 0.559 0.65 0.406 1.9 0.265 5.1 0.116 11.92 0.019
Wood 0.24 0.559 0.79 0.403 2.27 0.259 5.89 0.103 13.31 0.014
TL stands for time lag and DF stands for decrement factor
ADJUDICATION BOARD
Table 5: LATITUDE ANGLES AND HUMIDITY RATIOS OF VARIOUS CITIES [6],[7]&[8]
Name Of City Latitude Angles Humidity Ratio g of

water/ Kg of dry air
Abbotabad 34.16 11
Dadu 26.75 26
Dera Ismail Khan 31.83 30
Faisalabad 30.52 38
Gawadur 25.12 14
Gujranwala 32.15 38
Hyderabad 25.38 42
Jacobabad 28.3 42.75
Jaffarabad 35.43 36
Jhang 31.31 38
Karachi 24.91 40.5
Kohat 35.58 31
Lahore 31.34 37
Larkana 27.55 39
Lasbela 28.91 39
Mansehra 31.88 31
Mardan 34.20 31
Mirpur Khas 24.20 42
Multan 30.2 28.5
Nawabshah 26.25 26
Nowshera 34.01 23.5
Peshawar 34.008 31.5
Quetta 30.186 39.5
Rawalpindi 33.598 31.5
Sargodha 32.17 38
Sheikhupura 31.71 21
Shikarpur 27.95 39.5
Sialkot 32.52 39
Sibi 29.545 35.5
Sukkhar 27.7 39.5
Zhob 31.34 31.5
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Table 6: REFLECTIVITY OF SURFACES [9]
Type of ground Reflectivity %

Brick 0.3
Cement Board 0.25
Concrete 0.23
Crops 0.25
Forests 0.15
Grass 0.26
Isolated Rural Site 0.7
Desert Sand 0.4
Typical City Centre 0.2
Typical Rural Site 0.5
Typical Urban Site 0.4
Wood 0.39
Table 7: EMISSITIVY RATIO AND ABSORPTION RATIO OF SURFACES [10]
Outer Most Surface Emissivity ratio Absorption ratio

Aluminum Anodized 0.84 0.14
Aluminum Paint 0.6 0.50
Aluminum Polished 0.03 0.09
Brass 0.30 0.65
Copper 0.30 0.65
Dupont Lucite Acrylic Layer 0.90 0.35
Galvanized Steel 0.30 0.65
Magnesium Oxide Paint 0.90 0.09
Paint White Zinc Oxide 0.93 0.16
White Paint 0.89 0.25
ADJUDICATION BOARD
Table 8 AIR DENSITIES AT VARIOUS TEMPERATURES [11]
Temperature in Degree Centigrade Density kg/m3

0 1.293
20 1.205
40 1.127
60 1.067
80 1.000
Table 9 KINEMATIC VISCOUSITY OF AIR [11]
Temperature in Degree Centigrade Kinematic Viscosity ( × 10-6) m2/sec

0 13.30
20 15.11
40 16.97
60 18.90
80 20.94
Table 10 HEAT DISSPIATED BY COMPUTERS [12]
Equipments Heat Generated (Watts)

Computer Intel Pentium 4 100
Computer Intel Pentium D 105
Computer Intel Core 2 Duo 65
Computer Intel Core 2 Quad 105
Computer Intel Core 2 Extreme 150
Computer Intel Core I -3 73
Fax Machine 90
Fax Machine (small) 20
LCD flat paneled (Average size) 30
LCD flat paneled (Large size) 45
Monitor, TV (21 inch) 90
Monitor, TV (14 inch) 90
Multifunctional (photo copy, printer, scanner) 30
Plasma Flat Paneled (Average size) 30
Plasma Flat Paneled (Large size) 45
Printer 130
25 Watts will be added for the power supply with various models of computers
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Screen Shots of
the Software
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DESIGNING OF AIR CONDITIONING SYSTEM

1. Based on the manual and software calculation for the cooling load which comes out to be
equal to 6 Kilo Watts the air conditioning system of the special purpose vehicle or the
Ground Control Station has to be designed by selecting the major parts of the system with
the help of various data sheets.
2. The main components that are required in making of an air conditioning system are
compressor, condenser, evaporator and expansion valve as shown in the following figure
along with its T-s diagram:
Figure 15: AIR CONDITIONING SYSTEM AND T-S DIAGRAM
3. Each of the above mentioned part was selected by visiting various companies and by
acquiring the data sheets and comparing the ratings according to the design parameters as
described by Genesis Solution PVT .Ltd.
ADJUDICATION BOARD
COMPRESSOR
1. It is one of the main components or the heart of an air-conditioning system it is one of the
costliest items of any vapour compression cycle, the purpose of the compressor is to take
the refrigerant from the evaporator at low pressure and temperature and raising it by
compression to high pressure and temperature. [4]
2. There are various types of compressor based upon their arrangement and working
principle:
CLASSIFICATION BY WORKING PRINCIPLE

Based on the working principle they are broadly categorized into two categories:-
• Positive displacement type
• Roto Dynamic Type
a. POSITIVE DISPLACEMENT TYPE

In this type of compressor compression is achieved by trapping the refrigerant in an enclosed
space and then reducing its volume. Depending upon the construction, positive displacement type
compressors used in refrigeration and air conditioning can be classified into:-
• Reciprocating type
• Rotary type with sliding vanes (rolling piston type or multiple vane type)
• Rotary screw type (single screw or twin-screw type)
• Scroll compressors
b. ROTO DYNAMIC TYPE

1. In roto-dynamic compressors, the pressure rise of refrigerant is achieved by imparting kinetic
energy to a steadily flowing stream of refrigerant by a rotating mechanical element and then
converting into pressure as the refrigerant flows through a diverging passage.
2. Depending upon the construction, roto-dynamic type compressors can be classified into:
• Radial flow type

• Axial flow type
3. These compressors are used for very high capacity hence they were not considered for the
designing of air conditioning system.
ADJUDICATION BOARD
CLASSIFICATION BY ARRANGMENT
Based on the arrangement of compressor motor or external drive compressors can be classified
as:
• Open type
• Hermatic or sealed type
• Semi Hermatic or semi sealed type [4]
MAIN CHARACTERISTICS OF POSITIVE DISPLACEMENT TYPE COMPRESSORS

Table 11: CHARACTERISTICS OF COMPRESSOR
1. Based on the above chart which shows in details of all those parameters that were required as
per the design parameters, the ticks show the parameters that were suitable to our
requirement and the cross shows those which were not suitable according to the design
conditions.
2. From the chart the best possible option is reciprocating compressor hence it has been selected.
Some of the details of the reciprocating compressor about its working are as follow:-
ADJUDICATION BOARD
RECIPROCATING COMPRESSOR
1. The working of the reciprocating compressor is based on the back and forth motion of
piston in the cylinder which gives rise to suction and compression. It is the most widely used
compressor with cooling capacities ranging from a few Watts to hundreds of kilowatts.
2. Modern day reciprocating compressors are high speed (≈ 3000 to 3600 rpm), single acting,
single or multi-cylinder (up to 16 cylinders) type. Following figure shows the schematics of the
reciprocating compressor having suction and discharge valves as shown:-
Figure 16: RECIPROCATING COMPRESSOR
3. Its construction and working are somewhat similar to a two-stroke engine, as suction and
compression of the refrigerant vapor are completed in one revolution of the crank. The suction
side of the compressor is connected to the exit of the evaporator, while the discharge side of
the compressor is connected to the condenser inlet.
4. The valves used are of reed or plate type, the suction (inlet) and the discharge (outlet)
valves open and close due to pressure differences between the cylinder and inlet or outlet
manifolds respectively. The pressure in the inlet manifold is equal to or slightly less than the
evaporator pressure. Similarly the pressure in the outlet manifold is equal to or slightly
greater than the condenser pressure. The purpose of the manifolds is to provide stable inlet
and outlet pressures for the smooth operation of the valves and also provide a space for
mounting the valves. [4]
ADJUDICATION BOARD
SELECTION OF RECIPROCATING COMPRESSOR

Most popular brands of compressors are YORK, BITZER, BRISTOL, COPELAND and DANFOSS.
WHY DANFOSS?
1. From the above companies DANFOSS was chosen because of the following reasons:
• Compressors are easily available in Pakistan.
• Detailed data sheets are available.
• Good feedback from the experts.
• Compressor are efficient, reliable and of high quality.
• Danfoss has signed a UN global pact to make there every product environment friendly.
2. Five compressors were selected from the database of Danfoss Company, which were
according to the design parameters i.e. they were capable of being operated at an ambient
temperature of 52°C and indoor temperature to be 18°C.
3. With the help of the data sheets available each of the compressors was analyzed to find out
the best suitable compressor for our air conditioning system.
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CONDENSERS
1. Condensers are an important part of an air conditioning system as they are heat exchangers
where change of phase of refrigerant takes place; they act as heat sink by rejecting heat to the
surrounding medium.
2. There are various types of condensers that are used based on the external fluid:
• Air cooled condensers
• Water cooled condensers
AIR COOLED CONDENSERS

As the name applies these condensers have air as the external fluid and the refrigerant rejects
heat to the air flowing over the condenser. They are further divided into two types:-
• Natural convection type

• Forced convection type
WATER COOLED CONDENSERS

In these types of condensers water is the external fluid i.e. with the help of water condensation
phenomena takes place. Based on their construction they can be further divided into following
types:-
• Double pipe or tube-in-tube type

• Shell-and-coil type
• Shell-and-tube type [4]
WHY AIR COOLED CONDENSERS?

Following are some of the reasons for the selection of air cooled condenser to be used in the air
conditioning system:-
• They are cheaper as compared to water cooled condensers.

• Water cooled condensers were not suitable because of the scarcity of water as the
container goes often too desert areas.
• No need of cooling tower and condensing water pump.
• Less maintenance.
ADJUDICATION BOARD
SELECTION OF FINNED TYPE AIR COOLED CONDENSER

1. AOXIN finned air cooled condenser is easily available in the market and from its manufacturers
catalogue FNH 7.1/18 condenser was selected according to the design parameters.
2. Finned air cooled condenser was chosen because of the fact that due to the presence of fins the
surface area of the condenser increases which helps in greater heat transfer capability.
3. Condensers come in wide variety like as a part of the air conditioning system or as a standalone
unit, in our case it’s a standalone unit having one fan used for forced convection. The fans used
commonly are axial flow, propeller fans, which are capable of moving large volumes of air,
while consuming less power.
4. Condenser coils are designed with a large face area, but limited to a few rows in order to
minimize the resistance to air flow offered by the coil & it also helps in minimizing the fouling
effect.
TECHNICAL SPECIFICATIONS
• Type of condenser is air cooled.
• It is supported for refrigerants R 410, R 407C, R 134A & R 22.
• Operating temperature -196oC to 200oC.
• Number of fans one.
• Tube material copper.
• Fin material aluminium. [13]
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EXPANSION DEVICE
1. The purpose of an expansion device in an air conditioning system is to reduce pressure of
refrigerant from condenser pressure to evaporator pressure or it helps in regulating the
flow of refrigerant.
2. This flow of refrigerant depends upon the load if the load increase flow increases and vice
versa. They can be divided into various types:-
• Capillary tube
• Automatic Expansion Valve
• Thermostatic Expansion Valve
• Float Valve
• Electronic expansion valve [4]
ELECTRONIC EXPANSION VALVE

1. Electronic expansion valve was chosen for the air conditioning system for Ground Control
Station. It was selected from the catalogues of Copeland Emerson Inc.
2. The benefits of using electronic expansion valve are as follow:-

• Helps in energy saving as condenser pressure is reduced.
• It increases the cooling capacity and decreases refrigerant temperature at the discharge
of the compressor.
• It works best with the air cooled condenser.
3. Electronic expansion valves are programmed by the sellers we met the representatives of
energy systems private limited and they have provided us the CD about their control valves
during the HVACR exhibition in march 2013 held at expo centre Karachi
4. They require the simulated results of compressor, evaporators and condensers.
ADJUDICATION BOARD
SELECTION OF INSIDE UNIT

Inside unit is a complete package that contains evaporator, blower, sensors for
temperature and humidity and there is an option for fresh air infiltration. For all these purposes
there are special electronic circuit insides the unit. They are easy to operate with remote.
We studied data sheet of several indoor units and selected the LG inside unit ARNU 243 S5 L2
Some main features of this indoor unit are
• Auto operation
• Hot start
• Self diagnostic
• Sleep mode
• Timer
• Humdification can be done
• Auto direction swing (left/right , up/down)
• Washable filter
• Plasma resins
TECHNICAL SPECIFICATIONS
• Aluminum fins inside and grill out side
• Copper tubes
• Air flow is 494 CFM
• Diameter of tubes is 18mm
• Equivalent heat exchange area is 20.5m2
• Length of tubes is 14 m
• Fin spacing is 2.3
• Nominal heat capacity 7.1 kW [14]
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MATHEMATICAL MODELLING OF SYSTEM

In order to simulate compressor, condenser and evaporator simultaneously to check whether
the selected part performs according to the design parameters, data was collected for
compressor, condenser and evaporator from their respective sheets from which equations are
generated.
EQUATIONS OF COMPRESSOR
From the data sheet available of compressor at various temperatures of condenser and
evaporator values of cooling capacity, power and mass flow rate were analyzed which is
discussed in detail as below:-
EQUATION OF COOLING CAPACITY

The values taken from data sheet for cooling capacity were analyzed and from the following
graph by using langranian approach equation for cooling capacity were generated.
14000
12000
10000
35 centigrade
40 centigrade
8000 45 centigrade
50 centigrade
6000 55 centigrade
60 centigrade
65 centigrade
4000 70 centigrade
2000
0
-15 -10 -5 0 5 10 15 20
Figure 17: COOLING CAPACITY GRAPH
ADJUDICATION BOARD
Qe = a + bte + cte2 + dtc + etc2 + f tetc + g te2tc + h tetc2 + I te2 tc2…………. (1)
In this equation the values of constants are:-
• a= 7838
• b= 227.85
• c= 8.295
• d= -65.5
• e= -0.1
• f= 0.926667
• g= -0.09333
• h= -0.03533
• i= 0.000467
EQUATION OF POWER
From the following graph equation of power was generated:-
3500
3000
35 centigrade
2500
40 centigrade
2000 45 centigrade
50 centigrade
1500 55 centigrade
60 centigrade
1000
65 centigrade
70 centigrade
500
0
-15 -10 -5 0 5 10 15 20
Figure 18: COMPRESSOR POWER
ADJUDICATION BOARD
P = a + bte + cte2 + dtc + etc2 + f tetc + g te2tc + h tetc2 + I te2 tc2…………. (2)
In this equation the value of constants are as shown:
• a= -35
• b= 100.1
• c= -4.19
• d= 53.7
• e= -0.34
• f= -3.01333
• g= 0.118666
• h= 0.034666
• i= -0.0009333
EQUATION OF MASS FLOW RATE

By using the similar procedure equation of mass flow rate is as follow:-
ṁ = a + bte + cte2 + dtc + etc2 + f tetc + g te2tc + h tetc2 + I te2 tc2……………. (3)
In this equation the values of constants are as shown:
• a= 234
• b= -11.7
• c= 0.62
• d= -3.3
• e= 0.02
• f= 0.54333
• g= -0.01666
• h= -0.004666
• i= 0.0001333
Now in order to find the heat sinked by the condenser following equation is used:-
Q c = Qe + P………… (4)
Here “Q c” is the heat sinked by the condenser, “Qe” is the heat gained by the evaporator and
“P” is the power of the compressor.
ADJUDICATION BOARD
EQUATION OF CONDENSER
As in the above equations there are two unknown hence for finding heat sinked by the
condenser following equation is used:-
Qc = UAc (Tc - Ta)……………… (5)

Value of UAc found to be 1865.9 W/0C from the data sheet calculations [13]
EQUATION OF EVAPORATOR
And to find the heat gained by the evaporator following equation is used:-
Qe = UAe (Tr – Te)………….... (6)

Value of UAe was found to be 1012.266 W/0C from data sheet calculations[14]
By solving all the above mentioned six equations in engineering equation solver (EES) we get
the following results according to the peak conditions i.e. ambient temperature is 52°C and
room temperature is 18°C:-
• Power= 2509 W
• Tc= 56.67 °C
• Te= 11.72 °C
• Qe= 6380 W
• Qc= 8710 W
• m= 173.6 kg/hour
ADJUDICATION BOARD
RESULTS OF SIMULATION OF THE SYSTEM

Following are the results which show in detail the various characteristics of the system
selected:-
Range of Ambient temperature: 340C to 520C

Range of Inside room temperature: 180C to 260C
POWER CONSUMPTION
Following table and graph shows that if ambient temperature and room temperature are varied
then how it will affect the power consumption of compressor:-
Table 12: POWER CONSUMPTION OF COMPRESSOR
Room 18 19 20 21 22 23 24 25 26
Temperature
o
C
Ambient Power Consumed W
Temp OC
34 1986 2001 2015 2028 2040 2052 2062 2072 2081
36 2044 2060 2075 2089 2103 2115 2127 2138 2149
38 2102 2119 2135 2151 2165 2179 2192 2205 2217
40 2160 2178 2195 2212 2228 2243 2258 2272 2286
42 2218 2237 2256 2274 2291 2308 2324 2340 2355
44 2276 2296 2316 2336 2355 2373 2391 2409 2426
46 2334 2356 2377 2398 2419 2439 2459 2478 2497
48 2392 2415 2438 2461 2483 2505 2527 2548 2569
50 2450 2475 2500 2525 2549 2572 2596 2619 2641
52 2509 2536 2562 2589 2615 2640 2665 2690 2715
ADJUDICATION BOARD
Figure 19: GRAPH OF COMPRESSOR POWER
ADJUDICATION BOARD
COOLING CAPACITY
The respective graphs of cooling capacity are as follow:-
Table 13: COOLING CAPACITY
Room 18 19 20 21 22 23 24 25 26
TemperatureoC
Ambient Cooling Capacity W
TemperatureoC
34 7836 8072 8311 8554 8801 9052 9307 9566 9828
36 7689 7921 8158 8398 8642 8890 9142 9397 9656
38 7538 7768 8001 8238 8479 8724 8973 9225 9480
40 7384 7610 7840 8074 8312 8554 8799 9048 9300
42 7225 7449 7676 7907 8141 8379 8621 8866 9114
44 7063 7283 7507 7734 7965 8200 8438 8680 8924
46 6898 7114 7334 7558 7785 8016 8251 8488 8729
48 6728 6940 7157 7377 7601 7828 8058 8292 8529
50 6554 6763 6975 7191 7411 7634 7861 8090 8323
52 6375 6580 6789 7001 7217 7436 7658 7884 8113
Figure 20: GRAPH OF COOLING CAPACITY
ADJUDICATION BOARD
HEAT REJECTED BY CONDENSER

Following are the respective table and graph for it:-
Table 14: HEAT REJECTED BY THE CONSDENSER
Room 18 19 20 21 22 23 24 25 26
TemperatureoC
Ambient Heat Rejected By Condenser W
TemperatureoC
34 9642 9893 10146 10402 10662 10924 11189 11458 11729
36 9553 9801 10053 10308 10565 10826 11089 11356 11625
38 9460 9707 9956 10209 10465 10723 10985 11250 11517
40 9364 9608 9856 10107 10360 10617 10877 11140 11406
42 9263 9506 9751 10000 10252 10507 10765 11026 11290
44 9159 9400 9643 9890 10140 10393 10649 10908 11170
46 9051 9290 9531 9776 10024 10275 10529 10786 11046
48 8939 9176 9415 9658 9904 10153 10405 10660 10918
50 8824 9058 9295 9536 9780 10026 10276 10529 10785
52 8704 8936 9171 9410 9651 9896 10144 10394 10648
DESIGNING OF HEAT LOAD SOFTWARE

Figure AND AIR CONDITIONING
21: HEAT REJECTED BYSYSTEM OF SPECIAL
CONDENSER GRAPHPURPOSE VEHICLE Page 55
ADJUDICATION BOARD
CONDENSING TEMPERATURE
Following are the respective table and graph for it:-
Table 15: CONDENSING TEMPERATURES
Room 18 19 20 21 22 23 24 25 26
TemperatureoC
Ambient Condensing Temperature in degree centigrade
TemperatureoC
34 39.17 39.3 39.44 39.57 39.71 39.85 40 40.14 40.29
36 41.12 41.25 41.39 41.52 41.66 41.8 41.94 42.09 42.23
38 43.07 43.2 43.34 43.47 43.61 43.75 43.89 44.03 44.17
40 45.02 45.15 45.28 45.42 45.55 45.69 45.83 45.97 46.11
42 46.96 47.09 47.23 47.36 47.49 47.63 47.77 47.91 48.05
44 48.91 49.04 49.17 49.3 49.43 49.57 49.71 49.85 49.99
46 50.85 50.98 51.11 51.24 51.37 51.51 51.64 51.78 51.92
48 52.79 52.92 53.05 53.18 53.31 53.44 53.58 53.71 53.85
50 54.73 54.85 54.98 55.11 55.24 55.37 55.51 55.64 55.78
52 56.66 56.79 56.92 57.04 57.17 57.3 57.44 57.57 57.71
Figure 22: CONSDENSING TEMPERATURE GRAPH

ADJUDICATION BOARD
EVAPORATOR TEMPERATURE
Following are the graph and table:-
Table 16: EVAPORATOR TEMPERATURE
Room 18 19 20 21 22 23 24 25 26
TemperatureoC
Ambient Evaporator temprature in degree Centigrade
TemperatureoC
34 10.26 11.03 11.79 12.55 13.31 14.06 14.81 15.55 16.29
36 10.4 11.17 11.94 12.7 13.46 14.22 14.97 15.72 16.46
38 10.55 11.33 12.1 12.86 13.62 14.38 15.14 15.89 16.63
40 10.71 11.48 12.25 13.02 13.79 14.55 15.31 16.06 16.81
42 10.86 11.64 12.42 13.19 13.96 14.72 15.48 16.24 17
44 11.02 11.8 12.58 13.36 14.13 14.9 15.66 16.43 17.18
46 11.19 11.97 12.75 13.53 14.31 15.08 15.85 16.61 17.38
48 11.35 12.14 12.93 13.71 14.49 15.27 16.04 16.81 17.57
50 11.53 12.32 13.11 13.9 14.68 15.46 16.23 17.01 17.78
52 11.7 12.5 13.29 14.08 14.87 15.65 16.43 17.21 17.99
DESIGNING OF HEAT LOAD SOFTWARE AND

Figure 23: AIR CONDITIONING
GRAPH SYSTEM
OF EVAPORATOR OF SPECIAL PURPOSE VEHICLE Page 57
TEMPERATURE
ADJUDICATION BOARD
MASS FLOW RATE

Following are the graph and tables for mass flow rate in Kg/hour:-
Table 17: MASS FLOW RATE
Room 18 19 20 21 22 23 24 25 26
TemperatureoC
Ambient Mass flow rate kg/hour
Temperature
o
C
34 178.3 182.9 187.7 192.7 197.8 203.1 208.5 214.1 219.9
36 178.1 182.8 187.6 192.7 197.9 203.2 208.7 214.3 220.1
38 177.7 182.5 187.5 192.6 197.9 203.2 208.8 214.4 220.2
40 177.4 182.2 187.3 192.4 197.7 203.2 208.7 214.4 220.2
42 176.9 181.9 186.9 192.2 197.5 203 208.5 214.2 220
44 176.4 181.4 186.5 191.8 197.1 202.6 208.2 213.9 219.7
46 175.8 180.8 186 191.3 196.7 202.2 207.8 213.5 219.3
48 175.1 180.2 185.4 190.7 196.1 201.6 207.2 212.9 218.7
50 174.3 179.4 184.7 190 195.4 200.9 206.5 212.2 218
52 173.4 178.6 183.8 189.2 194.6 200.1 205.7 211.4 217.2
Figure 24: GRAPH OF MASS FLOW RATE
ADJUDICATION BOARD
COEFFICIENT OF PERFORMANCE
These tables and graph show that how the COP of the system varies with changing
temperatures:-
Table 18: COP
Room 18 19 20 21 22 23 24 25 26
TemperatureoC
Ambient COP (coefficient of performance)
Temperature
o
C
34 3.946 4.034 4.124 4.218 4.314 4.412 4.513 4.617 4.723
36 3.761 3.845 3.931 4.02 4.11 4.203 4.298 4.395 4.494
38 3.586 3.665 3.747 3.831 3.916 4.004 4.093 4.184 4.276
40 3.418 3.494 3.571 3.65 3.731 3.813 3.897 3.982 4.068
42 3.258 3.329 3.403 3.477 3.553 3.631 3.709 3.789 3.87
44 3.104 3.172 3.241 3.311 3.383 3.455 3.529 3.604 3.679
46 2.956 3.02 3.085 3.151 3.219 3.287 3.356 3.426 3.496
48 2.813 2.873 2.935 2.997 3.061 3.125 3.189 3.255 3.32
50 2.675 2.732 2.79 2.849 2.908 2.968 3.028 3.09 3.151
52 2.541 2.595 2.649 2.704 2.76 2.816 2.873 2.93 2.988
Figure 25: GRAPH OF COP

ADJUDICATION BOARD
REFERENCES
[1] Diagrams and details of Ground control station provided by Genesis Solutions PVT
.Ltd.
[2] Refrigeration and air conditioning by W.F Stoecker and JW Jones.
[3] http://www.myweather2.com/City-Town/Pakistan/Jacobabad/climate-
profile.aspx?month=6
[4] Air conditioning and refrigeration by Prof Ramgopal, IIT Kharagpur.
[5] Numerical computation of time lag and decrement factors for different building
materials by H.Asan.
[6] www.myweather2.com
[7] www.travelmath.com
[8] www.distancefrom.com
[9] www.bembook.ibpsa.us/index.php
[10] ASHRAE standards 2009 material properties
[11] www.engineeringtoolbox.com/air-properties
[12] en.wikipidea.org/wiki/list of CPU power dissipation
[13] DATA SHEET AOXIN air cooled condensers.
[14] DATA SHEET LG ARNU SERIES inside units of air-conditioning.

AB Report ZHK AH

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ADJUDICATION BOARD

NATIONAL UNIVERSITY OF SCIENCES AND TECHNOLOGY

ADJUDICATION BOARD, PROJECT REPORT

DESIGN A SOFTWARE FOR CALCULATION OF HEAT LOAD

PROJECT SUPERVISOR: DR. WAQAR A.KHAN

GROUP MEMBERS: Zeryab Hassan Kiani (ME-917)

S/Lt Aamir Bin Hamid (Pno: 7772)

TOTAL SOLAR IRRADIANCE: .................................................................................................................... 21

b. DIFFUSED RADIATION FROM SKY Id ............................................................................................. 27

c. REFLECTED SOLAR RADIATION, Ir................................................................................................. 28

b. SECOND FORM: ............................................................................................................................ 33

EQUATION OF EVAPORATOR .................................................................................................................. 51

Figure 1: GROUND CONTROL STATION

AIM OF THE PROJECT

3. The basic objectives of the project are as follow:

Figure 2: AIM OF PROJECT

a. OUTSIDE SURFACE OF SYSTEM

Figure 3: EXTERIOR SURFACE OF GCS

Figure 4: INSIDE OF GCS

c. PEOPLE AND RATE OF DOOR OPENING

LITERATURE REVIEW OF COOLING LOAD CALCULATION

JACOBABAD - HOTTEST CITY

a. CLIMATE CONDITIONS OF JACOBABAD

b. CLIMATE CLASSIFICATION SYSTEM

ANALYSIS OF CLIMATE CONDITIONS OF JACOBABAD

Figure 5: CLIMATE VARIATIONS

Figure 6: HUMIDITY VARIATIONS

Figure 7: WIND SPEED

HEAT GAINED BY SYSTEM

Table 1: TYPES OF RADIATIONS

Type of radiation Wavelength band (μm) % of total radiation

DEPLETION OF SOLAR RADIATION DUE TO EARTHS ATMOSPHERE

TOTAL SOLAR IRRADIANCE:

Figure 8: ALTITUDE ANGLE

Figure 9: INCIDENT ANGLE

Figure 10: SOLAR ANGLES

DERIVED SOLAR ANGLES

b. ZENITH ANGLE (ψ):

Figure 11: DERIVED SOLAR ANGLES

c. SOLAR AZIMUTH ANGLE (ϒ):

INCIDENT ANGLES OF SUNRAYS θ

a. FOR HORIZONTAL SURFACES

Figure 12: INCIDENT ANGLE ON HORIZONTAL SURFACE

b. FOR VERTICAL SURFACES

Figure 13: INCIDENT ANGLE OF VERTICAL SURFACE

d. SURFACE AZIMUTH ANGLE, (ξ):

CALCULATION OF SOLAR RADIATIONS

a. DIRECT SOLAR RADIATIONS COMING FROM SUN (I )

b. DIFFUSED RADIATION FROM SKY Id

c. REFLECTED SOLAR RADIATION, Ir

a. LOAD DUE TO OCCUPANTS

Table 2: HEAT DISSIPATED BY HUMAN ACTIVITIES

b. LOAD DUE TO LIGHTING

c. LOAD DUE TO EQUIPMENT AND APPLIANCES

Table 3: INTERNAL LOAD OF SOME APPLIANCES

CONDUCTION THROUGH EXTERIOR STRUCTURE

Figure 14: EXTERIOR SURFACE OF GCS

PROGRAM FOR THE CALCULATION OF COOLING LOAD

TABLES FOR CODING OF SOFTWARE:

Thickness 10mm 25mm 50mm 100mm 200mm

Table 5: LATITUDE ANGLES AND HUMIDITY RATIOS OF VARIOUS CITIES [6],[7]&[8]

Name Of City Latitude Angles Humidity Ratio g of