Internship report

Thermal
study of a
workshop in
LEONI
TUNISIA
DATE \@ "MMMM d" \* MERGEFORMAT July
31

LEONI TUNISIE
Prepared by: Razane Chatti
Supervised by: Mrs. Sahar Slimen
 Acknowledgement

I would like to acknowledge and give my warmest thanks to Mr. Mohammed Riadh Amimi, energy
engineer, and the entire LEONI TUNISIE team for accepting me to have my internship in this
company.

Also, I would like to express my sincere gratitude to my supervisor Mrs. Sahar Slimen, energy
engineer, for her invaluable guidance and support throughout this journey.

It’s been an honor to be a part of this company, where I was fortunate to gain more knowledge in
relation to energy engineering as well as discovering this corporation’s history and production
process.
 Summary
Acknowledgement.................................................................................................. ii
Summary................................................................................................................ iii
List of figures........................................................................................................... v
List of tables........................................................................................................... vi
General introduction............................................................................................... 1
Chapter I:................................................................................................................ 3
Presentation of the host company: LEONI TUNISIE..................................................3
1.1 Introduction...................................................................................................... 3
1.2 History............................................................................................................... 5
1.3 Organizational charts.........................................................................................6
1.4 The production process......................................................................................7
1.5 Conclusion......................................................................................................... 7
Chapter II:............................................................................................................... 8
Literature and theory.............................................................................................. 8
2.1 Introduction...................................................................................................... 8
2.2 Literature.......................................................................................................... 8
2.2.1 the cooling process..................................................................................... 8
2.2.2 The refrigerants........................................................................................ 11
2.2.3 Multi-split system..................................................................................... 12
2.2.4 Textile duct............................................................................................... 14
2.2.5 Packaged rooftop unit...............................................................................15
2.3 Air conditioning study......................................................................................18
2.3.1 Thermal balance........................................................................................18
2.3.2 External heat loads....................................................................................18
2.3.3 Internal heat loads....................................................................................20
2.3.4 Total heat loads........................................................................................ 20
 2.3.5 Duct network’s calculation........................................................................21
2.3.6 Textile ducts calculation............................................................................22
2.4 Conclusion....................................................................................................... 23
Chapter III:............................................................................................................ 24
Sizing and results...................................................................................................24
3.1 Introduction:................................................................................................... 24
3.2 Basic conditions............................................................................................... 24
3.2.1 The PDR room........................................................................................... 24
3.2.1.1 Heat balance...................................................................................... 24
3.2.1.2 External air flow renewal....................................................................25
3.2.1.3 The cooling system.............................................................................26
3.2.2 The testing workshop................................................................................28
3.2.2.1 External air flow renewal....................................................................28
3.2.2.2 Heat balance...................................................................................... 28
3.2.2.3 Rooftop unit....................................................................................... 28
3.2.2.4 Air networks calculation and sizing.....................................................29
3.2.3 Board manufacturing room.......................................................................31
3.2.3.1 External air flow of renewal................................................................31
3.2.3.2 Heat balance...................................................................................... 31
3.2.3.3 Rooftop unit....................................................................................... 32
3.2.3.4 Air network calculation and sizing......................................................33
3.3 Conclusion....................................................................................................... 35
General conclusion................................................................................................ 36
Links...................................................................................................................... 37
ANNEXES:.............................................................................................................. 39
 List of figures

Figure 1: car companies...........................................................................................4

Figure 2: LEONI Tunisia's history..............................................................................5
Figure 3: LEONI Tunisia's organizational chart..........................................................6
Figure 4: production process................................................................................... 7
Figure 5: A four-way valve..................................................................................... 10
Figure 6: cooling mode Vs. heating mode...............................................................11
Figure 7: Different types of refrigerants.................................................................12
Figure 8: multi-split system....................................................................................13
Figure 9: different textile duct shapes....................................................................14
Figure 10: different types of rooftop units.............................................................16
Figure 11: rooftop unit components...................................................................... 17
Figure 12: DAIKIN FTXM71N.................................................................................. 27
Figure 13: 42QSH125D8S by CARRIER....................................................................29
Figure 14: duct selection bar(testing workshop room)...........................................30
Figure 15: FDYQN140LBV1 by DAIKIN....................................................................33
Figure 16: duct selection bar (board manufacturing room).....................................34
 List of tables

Table 1: advantages and disadvantages of multi-split system................................14

Table 2: advantages and disadvantages of fabric duct............................................15
Table 3: Advantages and disadvantages of a packaged rooftop unit.......................18
Table 4: summer’s basic conditions........................................................................24
Table 5: winter's basic conditions..........................................................................24
Table 6: magazin PDR heat balance....................................................................... 25
Table 7: interior unit characteristics.......................................................................26
Table 9: testing workshop......................................................................................28
Table 10: CARRIER package rooftop unit characteristics.........................................29
Table 11: fabric duct characteristics (testing workshop room)................................31
Table 12: board manufacturing room heat balance................................................31
Table 13: rooftop unit characteristics.....................................................................32
Table 14: fabric duct characteristics (board manufacturing room)..........................35
 General introduction

In order to complete our daily tasks and manage our needs, comfort is a very important element
that should be provided for workers for suitable and appropriate work conditions.

Having a fit and convenient atmosphere is one of these conditions, and for that comes “air
conditioning”.

In fact, air conditioning existed since the prehistoric period in its passive primitive forms. However,
the major revolution started in the 20th century with the invention of the first air conditioning unit.

The term "air conditioning" refers to a group of technologies and processes for providing heating,
ventilation, and air conditioning (HVAC) of which the objective is to produce a better air quality by
removing heat and controlling humidity. Installing this system needs a study beforehand in order to
comply with regulations and standards in order to reduce energy losses, as well as selecting the
appropriate equipment and materials.

The goal behind an air conditioning system is to produce a better air quality by removing heat and
controlling humidity.

To install this unit, a detailed study should be done beforehand in order to comply with the
regulations and standers. Also, reducing energy losses should be taking in consideration throughout
the process.

As for our project, this study will be done on a workshop in LEONI, which is a new extension that is
in the process of construction.
This report will be including three chapters:

 The first chapter is dedicated to present the host company: LEONI Tunisia as well as
describing the procedures taken while production.

 The second chapter will include a brief presentation to the air conditioning systems that
were chosen for this establishment.

1
 In the final chapter, we will calculate the heat balance for each zone, air flow rates,
mass
blow rate and so on to select the proper sizing for the air conditioner

2
 Chapter I:

Presentation of the host company: LEONI TUNISIE

1.1 Introduction
LEONI is a German company founded in 1917 and it is a global supplier that specializes in the field
of cables, fiber optics, cabling systems and other related development services for applications in
the automotive industry and other industries.

It has over 60 000 employees and operates in 31 different nations, including Tunisia.

The first Tunisian production site was built in Cds Thrayet in 1977.

And to this day, LEONI is present in 4 different sites with over 22 000 employees:

 Sousse:
 Production space: 70.900 m2
 Total space: 141.055 m2
 Mateur North:

 Production space: 12.357 m2

 Total space: 30.740 m2

 Mateur South:

 Production space: 19.381 m2

 Total space: 48.265 m2

 Manzel Hayet:

 Production space: 38.040 m2

 Total space: 102.000 m2

LEONI is considered as a leader for the automotive industry as it deals with the biggest car brands
such as:

3
 BMW Audi MERCEDES BENZ

RENAULT PEUGEOT VOLKSWAGEN

Figure 1: car companies

The company has a very modern equipment and very sophisticated control and measurement
means that are used from the input phase of the raw material to the storage of the finished
product in the store to ensure a better quality.

Better still the LTN is certified ISO 9001 IN 1995 then it obtained, as one of the first companies in
Tunisia, the certification according to the international standard (specific for the automotive
industry) ISO TS 16949 what represents a firm proof that LTN has a system, quality, production and
management that meets the requirements of standardized production.

4
1.2 History
In this part, we will discuss the company’s history in Tunisia as shown in this figure:

foundation of the first productionsite of LEONI WSD outside outside of Europe

19 in Csd Thrayet
77

19 relocation from Thrayet to Messadine-Sousse

96

19 start of production in the new unit

97

19 change of the name from Cds Thrayet to LEONI Tunisia (LTN)

98

20 extension (LTN2)
02
extension(LTN4)
20 introduction of AVW
04
extension (LTN3)
20 introduction of OEM
08

20 consolidation of 4 legal identities into a single identity LTG

12

20 introduction of Porshe and Bently projects.

15

20 introduction of CBEV projeects, Electric car...

17
extension Menzel Hayet (LTNMH)
20 introduction of MEB project, Modularer Elektrobaukasten
18

Figure 2: LEONI Tunisia's history

5
1.3 Organizational charts
Country Management
Tunisia
WO TN
Mohamed Larbi Rouis

Nour Ben Taher

Wifak Ghannam
Mariem Tayabi

Value Chain
Quality Managemant Human Resources Management Plant Management Plant Management
Tunisia Tunisia Tunisia Mateur South LTN3AB
Faical Derbel Yossra Rouis Ahmed Hamed Helmi Sofiene Sadkaoui Taher Ellajmi
Zahmoul

Safety Health/ Project

Environment Management Plant Management Plant Management Plant Management
Tunisia Tunisia Menzel Hayet LTN4 LTN3C
Feten Torkhani Bechir Tiss Fethi EL Khlifi Laid Ben Youssef Ridha Ben Hassen

Production &
Infrastructure
Legal Tunisia Management Plant Management Plant Management Plant Management
Moncef Touati Tunisia Menzel Hayet LTN1 Sidi Bou Ali
Mohamed Sammir Bouasker Kais Zaaboub Chiheb Alaya
Romdhane

Finacial
Communication Operation Plant Management Plant Management
Management
Tunisia Excellence Tunisia Mateur North LTN3AD
Tunisia
Sabrine Ksouri Amani Guesmi Karim Zinedine Hichem Ben Nasr
Haikil Ben Hassine

Figure 3: LEONI Tunisia's organizational chart

6
1.4 The production process
In this part we will include a brief explanation on the different steps followed during production:

Raw material
Storage
acceptance

Feed cutting kanban

machine storage

Mounting unit Test

Quality control
and export

Figure 4: production process

1.5 Conclusion
In this part, we had a brief introduction to this company and its history as well as learning the
different steps in the production process.

For the next chapter, we will focus on the different air conditioning systems that we can adapt for
our project.

7
 Chapter II:

Literature and theory

2.1 Introduction
In this chapter, we will discuss the various air conditioning systems that have been selected for the
establishment such as the multi-split system for the administration and textile sheaths for the
workshop. But first, we will be giving a brief presentation for the air conditioning systems, their
advantages and disadvantages…and finally, we will describe how to determine the heat balance for
both zones, administration and workshop, using a mathematical theory model equation.

2.2 Literature
2.2.1 the cooling process
 air conditioner’s elements:

We can’t make cold, but we can remove heat, which is the goal of the cooling cycle, also known as
heat pump cycle.

Directing the heat away from the area that needs to be cooled is done by compressing and
expanding the working refrigerant’s pressure.

The following components are required for this process:

 compressor
 condenser
 evaporator
 expansion valve
1) the compressor is the piece that increases the working gas’s pressure.
The refrigerant enters the compressor at a low-pressure, low-temperature and exists as a
high-pressure, high-temperature gas.
2) Next, we have the condenser, one of the two heat exchangers that exists in the cycle.
This component receives vaporized, High-temperature, high-pressure refrigerant and then
removes its heat which results in a refrigerant with a saturated liquid form: high-pressure,
low-temperature liquid.

8
 3) The third step would be injecting the liquid into the loop’s expansion mechanism.
This device creates a pressure drop and it leads into the quick boiling of the refrigerant,
resulting in a two-phase mixture.
4) In a conventional refrigerant circuit, the evaporator is the second heat exchanger. The
goal behind it is to absorb heat.
When refrigerant enters the evaporator as a low-temperature, low-pressure liquid, and a
fan
blows air through the evaporator's fins, the air is cooled by the refrigerant absorbing heat
from the place in question. After that, the refrigerant is reintroduced to the compressor,
and the process starts again.
 Reversible air conditioner

The previous technique will be used in the testing workshop and board manufacturing room.

As for the (magasin PDR), we will install a reversible air conditioning system.

Unlike a conventional air conditioner, a reversible air conditioner produces both warm air, but also
to cool your home in case of high heat. So, it’s a useful device all year round.

The following components are required for this process:

 compressor

 condenser

 evaporator

 expansion valve

 four-way valve: The 4-way valve allows you to reverse the cooling cycle,
switching from a cooling mode in summer to a heating mode in winter.

9
 Figure 5: A four-way valve

Air conditioning does not move air like a fan, it cools it thanks to the presence of a refrigerant
circulating in a closed circuit inside the device and changes state. Its operation resembles that of a
refrigerator. Here are the steps of the air-cooling cycle by an air conditioning:

 The room’s calories (hot air) are absorbed into the evaporator (the inside of the air
conditioner). They heat the refrigerant, then in the gaseous state in the evaporator.
 The gas has arrived in the compressor, increasing the pressure of the gas that heats even
more.
 Arriving at the condenser (the outer block) a fan expels the heat stored by the gas, which
passes at the same time in the liquid state.
 the fluid then arrives at the regulator, the pressure drops, it goes back to the gas state and
its temperature drops even more.
 The fresh gas comes from towards the evaporator, on its contact the surrounding air cools
down. It is blown to the room by a fan.

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  the cycle begins again.
To summarize in a few words: an air conditioner produces cold air from a physical principle. When
the pressure goes up, the temperature goes up, and vice versa. You just have to play these
principles intelligently to get cold air.

Figure 6: cooling mode Vs. heating mode

2.2.2 The refrigerants

In the cooling cycle of air conditioners and heat pumps, refrigerants are working fluids that typically
go through numerous phase changes from a liquid to a gas and back again. Due to their toxicity,
flammability, and roles in ozone depletion and climate change, CFC and HCFC refrigerants as well as
HFC refrigerants are extensively controlled:

11
 CFC: chloroFluoroCarbons
R11
R12
R115

HCFC: HydroChloroFluoroCarbons
R22
R123
R124

HFC: HydroFluoroCarbons
R32
R125
R134a
R245ca
R245fa
R404A
R407C
R410A
R507A
R508B

FC: FluoroCarbons
R218

Figure 7: Different types of refrigerants

2.2.3 Multi-split system

 History:

Willis H. Carrier, an American inventor, invented the first modern electrical air conditioning unit in
1901, and 1902 would be the year of the first installed air conditioning system that could control
both temperature and humidity.

Stuart W. Cramer began looking for techniques to introduce moisture to the air in order to benefit
his textile mill in 1906, as the humidity level in the textile plants is critical. Cramer has blended
moisture and ventilation in the past. Willis Carrier later used this strategy.

12
The first individual room air conditioning system was invented by H.H Schultz and J.Q Sherman in
1931.

The first multi-split air conditioning system was created in 1973 “DAIKIN”, the first Japanese
company to manufacture packaged air conditioning systems since 1951. By 1982, DAIKIN has
developed the first commercial multi-split air conditioners in the world.

 Operation process:

A multi-split air conditioner is a form of split air conditioner that can cool up to five zones at once
and connects one external compressor to four or five internal air outputs using refrigerant lines

rather than a complicated duct system. In addition to the refrigerant tubing, the interior air outputs
are connected to the outdoor unit via condensate drain lines and electrical wires.

The multi-split has a single condenser with a bigger cooling capacity and size. The intelligent control
board in the multi-split condenser receives and delivers signals from and to each of its evaporators.
All of the evaporators connected to the multi-split condenser can communicate with one another
and be controlled.

An inverter compressor is constantly present in a multi-split air conditioner. The condenser of a

multi-split air conditioner distributes refrigerant to each of its evaporators based on the signals
provided by each evaporator. The multi-split air conditioner can run even if just one of the
evaporators is turned on.

Figure 8: multi-split system

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  Advantages and disadvantages of multi-split:

Table 1: advantages and disadvantages of multi-split system

Advantages Disadvantages
- Room temperature settings can be - Bulky
- Restrictions on placement
controlled individually.
- High consumption
- Indoor units of various capacities can
be included in one system.
- More than two indoor units can be
linked to a single outdoor unit.

2.2.4 Textile duct

 Introduction:
Textile duct is a technology for refrigerating, air-conditioning, refreshing, ventilating the
atmosphere as well as heating or even transporting treated air.
It is a ventilation ducting solution that is made from polyster material and is available in a variety of
shapes:

round

half round

quarter round

ellipse

Figure 9: different textile duct shapes

The ventilation ducts all inflate to their given shape when air is introduced.

14
  Operation process:
The fabric duct is used as a transport system as well as a delivery system by diffusing air into the
space.
The air can be delivered in different ways due to the different models of diffusers. In fact, each
model is suitable to buildings with different shapes and activities:
 Micro-perforation: 0.2 mm laser cut holes:
It delivers high volume of air at a very low velocity.
 Large diameter fabric nozzles: it delivers a specific cone of air over a long distance and it is
ideal for heating from a high level.

 Advantages and disadvantages of fabric duct:

Table 2: advantages and disadvantages of fabric duct

Advantages Disadvantages
- Affordable. - Traps dust and debris in the system.
- Easy to install. - Traps mold and moisture.
- Aesthetically pleasing.
- Effective and efficient air distribution.

2.2.5 Packaged rooftop unit

 Introduction:
A packaged rooftop unit (RTU), is an HVAC system that includes all the components required to
supply conditioned air.
They are primarily used in small and large commercial applications and they are highly valued
by industrial and commercial buildings.
 Types of rooftop units:
The following figure shows the different types of rooftop unites:

15
 pulls the air from outside
treats the air

a basic RTU distributes the treated air

pulls intreated air from the outside

pulls treated air from the room in question
RTU: fro recirculation
mixes both air streams and treats them
recirculation introduces the treated air to the room

RTU: pulls intreated air from the outside

absorbes the air from inside the space in
question and rejects it (partially or fully) to
recirculation the atmosphere.

and discharge

RTU: pulls fresh air from the outside

air passes through a heat wheel
heat wheel catches the wasted hot/cold air
with a heat and transfers it over the incoming fresh air
without the mixing of the two air streams
wheel
Figure 10: different types of rooftop units

16
  Rooftop unit components:

fan

cooling coil

heating coil

filters

humidifiers

dampers
Figure 11: rooftop unit components

The unit is protected by a metal casing to protect the internal system, it includes a fan which is the
centerpiece of the system to push the cooled or heated air to different parts of the building.
We find two heat exchangers:
 Cooling coil: it is used to dehumidify the atmosphere as well as cooling the air
 Heating coil: it allows the heating of the air by using hot water or refrigerant condensation.
To prevent the spread of dust and other particles inside the facility, filters should be installed inside
the unit. Humidifiers produce water steam to increase the amount of moisture in the air. And
finally, dampers are metal sheets that either fully open to allow air into the unit or fully close to
prevent air from entering or exiting.

17
  Advantages and disadvantages of a packaged rooftop unit:
Table 3: Advantages and disadvantages of a packaged rooftop unit

Advantages Disadvantages
- Affordable. - Limited fan performance
- Saving space - Limited flexibility to change
- Fast to install components
- Limited filtration options

2.3 Air conditioning study

2.3.1 Thermal balance
A thermal balance is a tool that enables us to evaluate the energy deficiencies of an indoor
environment. The ultimate objective is to gather ideas for choosing the best energy improvement
projects, or at the very least for properly scheduling them starting with the most important.
By locating the thermal bridges in the house, the thermal balance may also be used to calculate
potential heat losses and to assess energy consumption as a whole. This audit offers the chance to
determine whether the house conforms with current thermal standards.
2.3.2 External heat loads
 Heat supply by transmission through the walls at constant speed:

QStr =K s × S × ( T e −T i ) [W ]

- S: wall or window surface area [m²]

- T e: outside air temperature [°C]

- T i: indoor air temperature [°C]

- K s : Overall heat transfer coefficient by conduction and convection [W/m²°C]

18
The overall heat transfer coefficient is determined by the exchanges caused by heat conduction
through the wall, air convection on the external surface, and radiation from the surrounding
surfaces:
1 1 1 en
= + +∑
K s hi he λn

- K s : The coefficient of surface transmission [W/m²°C]

- hi : The convective heat transfer coefficient at the interior surface [W/m²C]
- h e: The convective heat transfer coefficient at the outside surface [W/m²°C]
- e n: Layer thickness n [m]
- λ n: The thermal conductivity of layer n [W/m²°C]
 Solar heat:
 On the glazing
The amount of heat passing through the glazing:
QSRg =α × S × g × R g [W ]

- α : coefficient of absorption of the glazing

- g: The reduction factor is determined by how well the window is insulated from solar
radiation.
- S: glazed area [m²]
- R g: Intensity of solar radiation on cover glass[W/m²];

 Through the wall:

The amount of heat transferred through the wall:
QSRw =α × F × S × Rm [W ]

- α : The absorption coefficients of the radiation-receiving wall are affected by the color and
nature of the wall.
- S: Wall surface area [m²]
- F : Solar Factor
- Rm: Solar radiation absorbed by the wall surface[W/m²]

 Heat Due to ventilation/infiltration:

The key factor in determining the ventilation heat loss in a building is the ventilation rate, i.e. the
average rate at which air flows through it. For this raison, sensible and latent heat losses are
considered.

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  Sensitive heat gains from ventilation:
Q Rv=0.34 ×Q v × ( T e −T i ) [W ]

- Qv : Air ventilation or infiltration rate[m3/h]

- T e: Outside air temperature [°C]

- T i: Indoor air temperature [°C]

- 0.34 : The assumed heat capacity of air times the density of air[Wh/m3.K]
 Latent heat gains from ventilation:
Q Lv=0.84 × Qv × ( r e −r i ) [W ]

- Qv : Air ventilation or infiltration rate[m3/h]

- r e : Moisture content of outdoor air [g/ kgas]

- r i : Moisture content of indoor air [g/kgas]

- 0.84 : Latent heat of a vaporization of water by air specific heat at constant

volume [Wh. kgas /m3.g water]
2.3.3 Internal heat loads
 Heat supplied by occupants':
The ambient temperature and the type of activity performed by the occupant are used to
calculate resident inputs. The occupants' thermal inputs are classified into two categories:
sensitive and latent.
 Sensitive heat loss:
QSoc =n ×C Soc [W ]

 Latent heat loss:

Q Loc =n × L Loc [W ]

- n : Number of occupants
- C Soc: Sensitivespecific heat transfer coefficient of occupant [W]

- L Loc: Latent heat transfer coefficient of occupant [W]

 Lighting heat loss:

Qli =M e × P=Ps × S [W ]

- M e: Dimensionless correction coefficient that depends on the type of

lighting (fluorescence equal to 1.25; incandescence equal to 1)

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 - Ps : Installed Lighting Power [W/m2]

- P: Actual electrical power installed for lighting in [W]

- S: Space area [m2]

2.3.4 Total heat loads

The sum of all external and internal loads is the total thermal balance ( QT ). Summing sensitive (QS )
and latent (Q L) loads is more convenient.

QT =QS +Q L [W ]

 Total Sensitive Loads:

Due to the temperature difference between the interior and outside, the following are the
contributions of the sensitive heats in the assumption:

QS =QStr +QSRg +QSRw +QRv +QSoc + QSli +Q Sm [W ]

 Total Latent loads :

These are the contributions of latent heat caused by differences in the amount of water vapour in
outdoor and interior air.

QS =Q Lv+ QLoc +Q Lm [W ]

2.3.5 Duct network’s calculation

As a general rule, we will strive to obtain the simplest and most symmetrical layout possible. The
calculation of network pressure drops can be carried out by one of the methods following:
 Constant linear head losses
 Calculation according to the speed of the air circulating in the network
 Calculation by the method of static pressure gains

 Method of constant linear head losses

This method applies to supply, return and extraction networks. She is mainly used for approximate
and fast calculations during pre-studies. In this method, a linear pressure drop is fixed which will be

21
constant throughout the along the network. The pressure drop that the fan will have to combat will
be this loss of chosen load multiplied by the total length of the circuit. Usually coupled with the
method equivalent lengths, this pressure drop calculation is very fast and the fan must combat the
pressure loss of the longest or most uneven network. This type of calculation leads to an automatic
speed reduction in the network.
 Calculation method depending on the speed
In this method, we strive to respect the air flow speeds as much as possible. Depending on the
function and location of the duct. The loss of pressure combated by the fan will no longer
necessarily be due to the network longer, but may be the fastest network pressure loss. The
calculation can be made by the method of equivalent lengths or losses of singular load. This is the
type of calculation performed most often in industry.
 Static Pressure gain method
This method is undoubtedly the most complicated to use, which is why it is very little used in
industry. The principle of this method consists in sizing each section in such a way that the increase
in static pressure due to the variation in air speed after each tapping or diffuser, exactly
compensates the pressure drop of its section. This calculation method can only be applied to a
supply network and makes it possible to reduce the monomeric head of the fan since in theory,
only the pressure drop of the first stretch cannot be compensated. The disadvantage of this
calculation is that it requires a constant decrease in speed and larger duct sizes.
2.3.6 Textile ducts calculation
The textile duct, also known as a textile air diffuser, is a technical product that allows treated air to
be diffused or conveyed from one location to another based on highly particular conditions.
 Dynamic pressure
V²
Pd =ρ ×
2
- ρ : density (kg/m3)
- V : air velocity (m/s)
 Static pressure
l
Ps =β ( )Pd
d
- β : coefficient of friction linked to the number of Reynolds
- l : length of pipe (m)

22
 - d : diameter of pipe (m)
 Total pressure
Pt =Ps + Pd

- Ps : static pressure

- Pd : dynamic pressure

2.4 Conclusion
In this chapter, we focused on presenting the needed cooling systems, their advantages and
disadvantages as well as the important steps for an air conditioning study.

23
 Chapter III:

Sizing and results

3.1 Introduction:
In this last chapter, we'll determine how to size the air conditioner properly by calculating the heat
balance for each zone, air flow rates, mass blow rates, and other factors.

3.2 Basic conditions

This project is located in Messadine, Sousse. Its local geographic location is:
 Latitude: 32
 Longitude: 10.5952 35°45’35’ north 10°35’43’ east
 Altitude: 39 m
By 8:00 AM, all the exterior walls are exposed to the sun light.
Table 4: summer’s basic conditions

T(°c) HR% r(g/kgas)

External conditions 32 49 14.9

Internal conditions 25 45 9

Table 5: winter's basic conditions

T(°c) HR% r(g/kgas)

External conditions 7 81 5
Internal conditions 20 50 7.5

3.2.1 The PDR room

3.2.1.1 Heat balance

In this part we will focus on calculating the area’s transmission coefficients:
 The walls
1 1 1 e
= + +∑
K h i he λ

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 - K: The coefficient of surface transmission (W/m²C)
- hi : The convective exchange coefficient at the interior surface (W/m²°C)

- h e :The convective exchange coefficient at the outside surface (W/m²°C)

- e : Layer thickness n (m)

- λ :The coefficient of the layer n (W/m°C)
 North-East and South-East exterior walls:

1/k= 0.17+(0.005/52) +(0.30/0.029) = 1.734 m2°c/w

K = 0.576 w/m2°c

 North-West and south-west interior walls:

1/k = 0.22+(0.005/52) + (0.03/0.029) = 1.254 m 2°c/w

K = 0.79 w/m2°c

 The doors:

K = 5.8 w/m2°c

 The glazing:

K = 4 w/m2°c

3.2.1.2 External air flow renewal

QI= 50*5.6+28.24*7= 477.68 m3/h
Table 6: magazin PDR heat balance

external heat loads (magasin PDR)

air renewal and infltration loads

air flow Q total

surface (m2) ρ (kg/m3) Cp (J/kg K)
(m3/h) Q latent
∆T (k) Q sensitive
1206.03850
477.68 1.292 1005 7
3
50 air flow ∆w(kge/
ρ (kg/m3) Lv (J/kg) Q sensitive Q latent
(m3/h) kgas)
477.68 1.292 2360000 0.0059 2387.047635
total 2394.047635
solar heat
walls and Rm
surface (m2) α F Q sensitive Q latent
ceiling (W/m2 )
NE 32.84 0.4 471 0.08 494.96448

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 SE 35.64 0.4 459 0.08 523.48032
ceiling 85.68 0.4 471 0.08 1291.36896
glazing surface (m2) α G Rv (W/m2 ) Q sensitive Q latent
2 windows NE 2.4 1 0.22 395 208.56
2 windows SE 2.4 1 0.22 459 242.352
total 2760.72576
internal heat load
sensitive Q total
occupants latent heat
heat Q sensitive Q latent
3 139.208 80.594 417.624 241.782
lightning heat loads
Overcharging of sensitive heat due to
surface (m2) lighting Q sensitive Q latent
E (w/m2)
50 24 1200
total latent loads (w) 2628.829635
total sensitive load (w) 5584.388263
total loads(w) 8213.217898
total loads(BTU/h) 28024.66273

3.2.1.3 The cooling system

The total loads for this space are 8.213 kW.

After looking for suitable equipment, we determined that FTXM71N by DAIKIN is the right choice
for this project.

It’s a mono-split reversible air conditioning system.

This model belongs to the seasonal energy class SEER is A++ (cold) and SCOP is A (hot).

This system includes an interior unit and an exterior unit which they in include the following
characteristics:

Table 7: interior unit characteristics

Brand DAIKIN
Model FTXM71N
Nominal Cooling capacity 7.10 kW – 24200 BTU/h
Maximum cooling capacity 8.5 kW – 28 000BTU/h
Nominal Heating capacity 8.2 kW – 28 000 BTU/h
Maximum heating capacity 10.2 kW – 34 800 BTU/H
Air flow (m3/h) 1100
Refrigerant R32
Interior unit’s Dimensions (mm) 140*30*30
Exterior unit’s dimensions 94*73*38
Weight (kg): interior unit – exterior unit 10 kg – 50 kg

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The maximum length for the pipe is 30 m and it functions at the temperatures between – 21°c and
50°c.

Figure 12: DAIKIN FTXM71N

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3.2.2 The testing workshop

3.2.2.1 External air flow renewal

QI= 70*5.6+28.24*7= 589.68 m3/h

3.2.2.2 Heat balance

Table 8: testing workshop

external heat loads (workshop testing)

air renewal loads
air flow Q total
surface (m2) ρ (kg/m3) Cp (J/kg K) ∆T (k)
(m3/h) Q sensitive Q latent
1488.81423
589.68 1.292 1005 7
6
70 air flow ∆w(kge/ Q total
ρ (kg/m3) Lv (J/kg)
(m3/h) kgas) Q sensitive Q latent
589.68 1.292 2360000 0.0059 2946.73055
total 2953.73055
solar heat
walls and Rm
surface (m2) α F Q sensitive Q latent
ceiling (W/m2 )
SE 50.92 0.4 459 0.08 747.91296
SW 39.2 0.4 0 0.08 0
ceiling 85.68 0.4 471 0.08 1291.36896
total 2039.28192
internal heat load
sensitive Q total
occupants latent heat
heat Q sensitive Q latent
5 139.208 80.594 696.04 402.97
lightning heat loads
Overcharging of sensitive heat due to
surface (m2) lighting Q sensitive Q latent
E (w/m2)
70 24 1680
total latent loads (w) 3349.70055
total sensitive load (w) 8850.866706
total loads(w) 12200.56726
total loads (BTU/h) 41630.06348

3.2.2.3 Rooftop unit

Based on the total loads that we figured for this area, we determined that the packaged rooftop
42QSH125D8S Ducted Air Conditioner by CARRIER is the best choice.

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It features a wired controller secured to the wall, a set temperature range, a weekly schedule timer
which is convenient for setting different schedules for the weekends and weekdays and lastly three
fan speeds [annexe ]:
Table 9: CARRIER package rooftop unit characteristics

Model 42QSH125D8S CARRIER

Air flow (l/s) 792
Cooling capacity (kW) 10 (2.26 - 11.24)
COP 3.70
Compressor Twin Rotary
Refrigerant R410A

Figure 13: 42QSH125D8S by CARRIER

3.2.2.4 Air networks calculation and sizing

before selecting the duct network for this project, it is important to mention that:
 Air velocity in the duct is between: 6 m/s and 10 m/s [annexe ]
 Diffusion rate is 0.17 m/s [annexe ]
 Textile duct used for this project is circular: TEXTIL’AIR I from FRACE AIR[annexe ]
 Air flow= 589.68 m3/h
For better results, we will consider air velocity in the duct = 6 m/s and air flow = 700 m 3/h

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 Figure 14: duct selection bar(testing workshop room)

According to the figure above, the duct’s diameter is: 450 mm

 Dynamic pressure:
V²
Pd =ρ ×
2
- ρ : density (kg/m3) = 1.204 kg/m3
- V : air velocity (m/s) = 6 m/s
Pd= 1.204 *(62/2) = 21.67 Pa
 Static pressure:
l
Ps =β ( )Pd
d
- β : coefficient of friction linked to the number of Reynolds = 0.020 l/d
- l : length of pipe (m) = 8m
- d : diameter of pipe (m) = 450 mm

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 Ps= 0.02 * (8/0.45)*21.67 = 7.7 Pa
Pt =Ps + Pd

- Ps : static pressure

- Pd : dynamic pressure

Pt = 29.27 Pa

Table 10: fabric duct characteristics (testing workshop room)

Air velocity (m/s) 6

Air flow (m3/h) 700
Duct size (mm) 450
Dynamic pressure (Pa) 21.67
Static pressure (Pa) 7.7
Total pressure (Pa) 29.27

3.2.3 Board manufacturing room

3.2.3.1 External air flow of renewal

Qv =Qi+Q s

 Qs: specific air flow [m3/h]: number of occupants*minimum air flow

 QI: air flow infiltered: since we are not going to infiltrate the air, QI= local volume.
Qs= 6*22 = 132 m3/h
QI= 105*5.6*28.24*6*2 = 926.88 m3/h
Qv= 132+926.88= 1058.88 m3/h

3.2.3.2 Heat balance

Table 11: board manufacturing room heat balance

external heat loads (board manufacturing)

air renewal loads
Q total
surface (m2) air flow (m3/h) ρ (kg/m3) Cp (J/kg K) ∆T (k)
Q sensitive Q latent
926.88 1.292 1005 7 2340.171176
Q total
105 air flow (m3/h) ρ (kg/m3) Lv (J/kg) ∆w(kge/kgas)
Q sensitive Q latent
926.88 1.292 2360000 0.0059 4631.7759
total 6971.947076
solar heat
walls and ceiling surface (m2) α F Rm (W/m2 ) Q sensitive Q latent
NE 27.24 0.4 0.08 471 410.56128
NW 51.32 0.4 0.08 0 0

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 SW 33.6 0.4 0.08 0 0
ceiling 146.88 0.4 0.08 471 2213.77536
glazing surface (m2) α G Rv (W/m2 ) Q sensitive Q latent
2 windows NE 2.4 1 0.22 395 208.56
2 windows NW 2.4 1 0.22 0 0
total 2832.89664
internal heat load
Q total
occupants sensitive heat latent heat
Q sensitive Q latent
6 139.208 80.594 835.248 483.564
lightning heat loads
Overcharging of sensitive heat due to
surface (m2) lighting Q sensitive Q latent
E (w/m2)
105 24 2520
total latent loads (w) 5115.3399
total sensitive load (w) 8528.315816
total loads(w) 13643.65572
total loads (BTU/h) 46554.08569

3.2.3.3 Rooftop unit

According to the heat balance, the total loads are 13.643 kW.
after carefully searching for a suitable exterior unit, we determined that “package rooftop unit
FDYQN140LBV1 by the company DAIKIN if the right choice for this establishment.
Table 12: rooftop unit characteristics

Model FDYQN140LBV1 by DAIKIN

Air flow (l/s) 1000
Cooling capacity (kW) 14
COP 3.01
Compressor Hermetically Sealed Scroll
Refrigerant R410A

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 Figure 15: FDYQN140LBV1 by DAIKIN

3.2.3.4 Air network calculation and sizing

 Air velocity: 6m/s
 Diffusion rate: 0.17 m/s
 Air flow: 926.88 m3/h ≈ 1000 m3/h
 Textile duct used for this project is circular: TEXTIL’AIR I from FRACE AIR [annexe ]

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 Figure 16: duct selection bar (board manufacturing room)

According to the figure above, the duct’s diameter is: 250 mm

 Dynamic pressure:
V²
Pd =ρ ×
2
- ρ : density (kg/m3) = 1.204 kg/m3
- V : air velocity (m/s) = 6 m/s
Pd= 1.204 *(62/2) = 21.67 Pa
 Static pressure:
l
Ps =β ( )Pd
d
- β : coefficient of friction linked to the number of Reynolds = 0.020 l/d
- l : length of pipe (m) = 15 m
- d : diameter of pipe (m) = 250 mm

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 Ps= 0.02 * (15/0.25)*21.67 = 26 Pa
Pt =Ps + Pd

- Ps : static pressure

- Pd : dynamic pressure

Pt = 47.67 Pa

Table 13: fabric duct characteristics (board manufacturing room)

Air velocity (m/s) 6

Air flow (m3/h) 1000
Duct size (mm) 250
Dynamic pressure (Pa) 21.67
Static pressure (Pa) 26
Total pressure (Pa) 47.67

3.3 Conclusion
In this chapter, we released a HVAC study, which includes heat balance, selection of equipment for
the three zones.

Both board manufacturing room and testing workshop had textile ducts to distribute the cooled air.
As for the third room, we installed a reversible air conditioning system.

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 General conclusion

I passed my internship at LEONI TUNISIE, located In Messadine, Sousse. Before being given the
needed details and information to start my report, I had the opportunity to tour the workshop and
to discover the different steps taken in the production process. I also had a second tour regarding
the compressed air, where I saw the different compressors used and the air distributing system.

As a first step after receiving the needed information about the project, I started my report by
introducing the company, its objective and its history. I did also mention the different procedures
taken and mentioned few of the car companies that they are dealing with.

For the second chapter, I presented the different air conditioning systems that will be used in this
project, their operation procedures and also the different types of refrigerants and their
classifications.
For the different air conditioning systems, I presented their different elements and their advantages
and disadvantages.
And finally, we have the representation of the different formulas used to calculate the heat loads
for the project.

The last chapter was dedicated to determine the right duct sizes and select the right materials for
the location after providing the heat balance for each zone.

In terms of conclusion, the field of air conditioning is an expanding field.

Technological innovations continue to emerge.

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 Links

4-way-valve: https://www.refrigera.eu/en/cases/thermo-fluid-dynamic-design-of-a-4-way-
reversing-valve
Reversible AC system: https://www.climatisationreversible.net/la-climatisation-reversible.htm
Refrigerant types: https://www.swep.fr/refrigerant-handbook/5.-refrigerants/sd4/
Packaged rooftop unit definition: https://www.buildingengines.com/blog/equipment-packaged-
rooftop-unit-rtu/#:~:text=A%20packaged%20rooftop%20unit%2C%20or,with%20retail%20and
%20industrial%20properties.
Fabric duct types: https://prihoda.ie/product/fabric-ducting/shapes/
Climatic data: https://www.anme.tn/
Daikin FDYQN140LBV1 Ducted Air Conditioner : https://rungegroup.com.au/product/supplied-
installed-14kw-daikin-fdyqn140lbv1-ducted-air-conditioner-with-8-outlets-8-zones/
arrier 42QSH125D8S Ducted Air Conditioner: https://rungegroup.com.au/product/supplied-
installed-12kw-carrier-42qsh125d8s-ducted-air-conditioner/
Daikin FTXM71N : https://climatiseurshop.com/puissance-75-kw-24000-btu/132-daikin-ftxm71n-
climatisation-r32-inverter-reversible-8-kw-jusqu-a-130-m-perfera-wifi-integre.html

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ANNEXES:

annexe 1

annexe 2

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annexe 3

annexe 4

39
annexe 5

annexe 6

40
annexe 7

annexe 8

41
annexe 9

annexe 10

42
annexe 11

43
annexe 12

annexe 13

44
annexe 14

annexe 15

45
annexe 16

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