Welcome to my Presentation

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 Presented By

Md. Abdulla Al Mamun

ID# 14307047

Department of Mechanical Engineering

IUBAT-International University of Business Agriculture and Technology

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 Topic Name

Ventilation and Air Conditioning System of

A.T.S Power & Technology

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 Contents
 Introduction
 Objective
 Limitations
 Organization Profile
 VAC System
 Equipments of VAC System
 Maintenance, Schedule and Operating Procedure
 Trouble Shooting , Diagnosis and Remedies Of VAC Equipments
 Problems Finding, Analysis and Solution
 Conclusion and Recommendations

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 Introduction
Ventilation and air conditioning (VAC) play an important role to ensuring the
manufacture of quality products. A well designed VAC system will also provide
comfortable conditions for operators.
VAC system design influences architectural layouts with regard to items such as
airlock positions, doorways and lobbies. The architectural components
have an effect on room pressure differential cascades and cross-contamination
control.
A.T.S Power & Technology used a complete VAC system to ensuring
the quality of the product.

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 Objective
Broad Objective:
The board objective of my internship is to manage the academic and
theoretical knowledge with practical knowledge of VAC system.
Specific Objective:
• To Study on Ventilation and Air Conditioning (VAC) system.
• To Achieve practical knowledge on VAC.
• To achieve practically knowledge on Test and check of VAC equipments.
• To achieve practical knowledge on Maintenance and Operation of VAC
Equipment’s.
• Find out the major problems during operation of VAC system.
Suggest probable solution of the identified problems.

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 Limitations
 Most of the areas are restricted, in plant trainee are not allow to entry this
areas.
 Three months are not enough time to achieve knowledge about overall
VAC System.
 I cannot have proper freedom to collect all information because of internal
rules.
 Not allow to use Bag, Note book, Mobile, Pen drive inside the factory.
 Most of the engineers are so mush busy with their work.
 Some of authorized person don’t have sufficient knowledge about VAC
systems.

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 Company profile
Concern Organization:
ATS Power & Technology was founded in the year 2009 as an electrical
engineering company of Bangladesh entrepreneur by a group of
professionally experienced which works for overall solution of power
distribution system of different projects.

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 Mission and vision
Mission:
Our mission is to add value to the
business we are involved. Our aim is
to achieve this mission by not only
providing quality products but also
rendering the excellence in our
service.

Vision:
The vision is rooted in the common
aspiration of the people to establish
Figure: ATS Factory
Bangladesh in the global mainstream
in capacity, potential and competence.
 Company profile

Location of the Organization:

Head Office
House: 58, Road: 12, Sector: 10
Uttara, Dhaka-1230. Bangladesh
Phone: +8801724826148
Mail: mdatspower@gmail.com

Factory
A.T.S Power & Technology
Dhaka-Mymensingh Hwy, Mawna Union
Phone: 01724-826148

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 VAC System

Ventilation and air conditioning (VAC) system:

“Ventilation and air conditioning” is a system which can provide
ventilation, comfortable temperature, reduce air in filtration and maintain
pressure relationship between spaces. VAC system constitutes of Air
Handling Unit (AHU), Fan Coil Unit (FCU), De-humidifiers,
Filtration equipments and also exists Fresh Air Unit (FAU ).

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 Filtration
Air filtration is the process to removing airborne particles from the air.

Coarse Filter Pre Filter HEPA

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 Filtration
The following filters are use in
VAC system of ATS Power & Technology-

Coarse Filter:
Coarse filters eliminate the largest
impurities, such as pollen and sand
dust from indoor air . It is disposable
Or washable type used specially in
the return line of the air handling
system and fan coil units. The grade
of Coarse -Filter is G4.

Figure: G4-type coarse filter

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 Filtration
Primary or Pre Filter:
Pre filters can remove impurities
from the air, which are indiscernible
to the eye. It is bag type filter and
Grade of Pre -Filter is G4.

Figure: Pre Filter

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 Filtration
Secondary or after filter:
It is a beg type filter located at after
the cooling coil. The grade of after
filter is F7 or F9. It has ability to
remove 0.4 µm dust. Capacity is less
than 95%.

Figure: Secondary or after

filter

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 Filtration
Terminal or HEPA Filter:
High efficiency particulate arresting filter
(HEPA) is a filter which either
washable or cleanable. It can replace
in case of fail integrity test commonly
use Poly Alpha Olefin (PAO)/Dioctyl
Phthalate (DOP) test. The efficiency
of the filter is 99.9998% .

Figure :Terminal or HEPA

Filter

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 Ventilation and Air Condition System
Refrigeration system:
Refrigeration system is the process to removal of unwanted heat from a
selected object, substance or space and its transfer to another object,
substance or space. Removal of heat lowers space temperature to higher
temperature space.

Vapor compression system:

It is a system where a working fluid or refrigerant transfer heat from low
temperature space to high temperature space by changing phase.

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 Ventilation and Air Conditioning System

Parts of the vapor compressor

system:
a) Compressor
b) Condenser
Compressor Condenser
c) Expansion valve
d) Evaporator

Expansion Valve Evaporator

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 Ventilation and Air Conditioning System

Working principle of simple vapor

Compressor System:
1. Compression
2. Condensation
3. Expansion
4. Evaporation

Figure: Vapor Compression Cycle

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 Ventilation and Air Conditioning System

Vapor absorption system:

The vapour absorption system used
heat energy instead of mechanical
energy and hence compressor is not
used. Instead it is replaced by an
absorber, a heat exchanger and a
generator. This system uses ammonia
as refrigerant.
Figure: Absorption Chiller

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 Ventilation and Air Conditioning System

Main parts of the absorption chiller:

1. Generator
2. Condenser
3. Expansion valve
4. Evaporator
5. Absorber
6. Heat exchanger
7. Pump

Figure: Absorption chiller

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 Ventilation and Air Conditioning System

Working Principle of Absorption

System:
1. Generation
2. Condensation
3. Evaporation
4. Absorption

Figure: Refrigeration Cycle of

Absorption System

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 Ventilation and Air Conditioning System

Centrifugal or Vapor compression chiller:

1. Compressor
2. Condenser
3. Expansion valve
4. Evaporator

Figure: Centrifugal Chiller

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 Ventilation and Air Conditioning System

Working principle Centrifugal chiller

:
1. Compression
2. Condensation
3. Expansion
4. Evaporation

Figure: Refrigerant Cycle of

centrifugal chiller

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 Required Equipment of VAC System:
Split type Air-Condition:
A split air conditioner consists of two
main parts; the outdoor unit and the
indoor unit.
Main parts:
Figure: Split Type AC
1. Compressor
2. Condenser
3. Expansion valve
4. Drier
5. Accumulator
6. Oil separator
7. Fan, Blower and Motor
Figure: Refrigerant Cycle of Split AC

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Required Equipments o VAC System:
Window type AC:
In this air conditioner all the
components, namely the compressor,
condenser, expansion valve, evaporator
and cooling coil are enclosed in a single
Figure: Window Type AC
box.
Main parts:
1. Compressor
2. Condenser
3. Expansion valve
4. Evaporator
Figure: Refrigerant and Air cycle of
5. Fan , Blower and Motor windows type AC

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Required Equipment of VAC System
Package type AC:
In the packaged air conditioners all
the important components of the air
conditioners are enclosed in a single
casing like window AC.
Main parts :
1. Compressor
2. Condenser
3. Expansion valve
4. Evaporator
Figure: Package type AC
5. Fan, Blower, and Motor

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 Required Equipment of VAC System

Portable Humidifier:
It is a device use to remove moisture
from air.
Main parts of refrigerant cycle:
1. Compressor
Figure: Portable Humidifier
2. Condenser
3. Expansion valve
4. Evaporator
5. Fan and motor

Figure: Refrigeration cycle

of Portable Humidifier
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 Required Equipment of VAC System

Fresh air unit (FAU):

The function of the Fresh Air unit
(FAU) provides conditioned outdoor
air suitable for mechanical ventilation
or make-up air. Figure: Fresh Air Unit
Main parts of the FAU: 1

1. Fresh air duct

2. Primary filter 5

3. Cooling coil 2
4
3
4. Supply fan and motor AHU
5. Supply duct.
Figure: Schematic diagram of FAU (GP Building)

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 Required Equipment of VAC System

Air handling unit (AHU):

An air handling unit is a piece of equipment
that is used to condition and circulate air as
a component of a ventilating and
air conditioning system. AHU used to
control the following parameters-
1. Temperature
2. Humidity
3. Air Movement
4. Air Cleanliness

Figure : AHU (Bry Air)

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Required Equipment of VAC System
Specification of the Bry Air AHU:

Brand name Bry Air

Model no SWN68HSP
Temperature max/min -10/120 (C)
Weight 320 kg
Voltage 420
Frequency 50 Hz
Power 9 Kw
Refrigerant Water

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Required equipment of VAC System

Main part of Air Handling

Unit (AHU):
1. Fresh Air Duct
2. Heater
3. Filter
4. Humidifier
5. Cooling Coil
6. Heating Coil
7. Primary Filter
8. Supply Fan and Motor
9. After filter
10. Supply Duct
11. HEPA Figure : Schematic diagram of AHU
12. Return Grill (Production Building)

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 Refrigerant
Refrigerant :
A refrigerant is a fluid used in a
heat pump and refrigeration cycle
that can extract heat from body or
substance.
Figure : Refrigerant Cylinder
Desired Properties of a Refrigerant:
1. Vapor density
2. Enthalpy of vaporization
3. Thermal Conductivity
4. Dielectric strength
5. Leak tendency
6. Toxicity
7. Availability
8. Cost of refrigerants
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 Refrigerant
Name, Boiling and freezing points of different refrigerant:

No Name (Boiling point ( °F) Freezing point (°F)

R-11 Trichlorofluoromethane 74.9 -168

R-12 Dichlorodifluoromethane -21.8 -252

R-22 Chlorodifluoromethane 41.3 -256

R-134a Tetrafluoroethane -15 -142

R-717 Ammonia -28 -107.9

R-744 Carbon Dioxide -109.4 -70

R-744A Nitrous Oxide -127.3 -131.5

R-600 n-Butane 31.2 -217

Table: Boiling and Freezing point

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Refrigerant charging process in vapor compressor cycle

Required equipments:
1. Vacuum pump
2. Gauges
3. Service port
4. Refrigerant
5. Gas welding

Figure : Refrigerant charging

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 Duct system
Duct:
It is a collection of tubes that
distributes the heated or cooled
air to the different rooms. Duct
usually constructed by sheet
metal, fiberglass board, or a
flexible plastic.
Figure : Duct
Classification of Ducts:
The ducts may be classified as follows
1. Supply duct
2. Return air duct
3. Fresh air duct
4. Low pressure duct
5. Medium pressure duct
6. High pressure duct
7. Low velocity duct
8. High velocity duct
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 Maintenance, Schedule and Operating
Procedure
Maintenance :
It is the care of machine to reduce the
breakdown.
1. Corrective maintenance
2. Preventive Maintenance
3. Breakdown maintenance
Corrective action:
This are the immediate activities
to solve the reason of break down
for runing the machine again.
Preventive action:
It is the free caution of some
activities to reduce the breakdown
of the machine
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 Maintenance, Schedule and Operating
Procedure
Operating procedure of VAC Units:
1. Check the digital hygrometer position properly.
2 . Check whether the switch box the component has a tag whether the room under
consideration or not.
3. Switch on the VAC unit.
4. The room temperature and humidity must be checked after half an hour from the
starting state.
5. In case of relative humidity less than 55%, if the required humidity and temperature
are not attained within half an hour, it should be reported to engineering department.
6. In case where humidity must have to be less than 30%, if within half an hour the
required condition is not achieved, the report should be conveyed to engineering
department.
7. During the conditioned environment, no washing or room cleaning except vacuum
cleaning work should be done
8. Any deviation or activities of the VAC unit should be note in the respective
documents.
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 Maintenance, Schedule and Operating
Procedure
Maintenance Time:
Type of maintenance Interval of
maintenance
Cleaning Cleaning and checking the AHU/FCU Quarterly (90 days)

Cleaning & Checking filter of AHU/FCU for solid areas Fortnightly (15 days)

Cleaning Checking of AHU filter by viewing the red light Weekly (7 days)
Granulation l, 2 & 3, Tablet Press-7.

Delta p checking of AHU filter by viewing the red light Fortnightly (15 days)

Filtration
System Cleaning & Checking filter of AHU for liquid areas and Monthly (30 days)
aseptic areas.

Filter integrity test (PAO/DOP ) of HEPA filter Yearly (365 days)

Checking velocity of terminal HEPA filter Yearly (365 days)

Replacement of filter of AHU/FCU of pre-filter and Biennially (730 days)

secondary filter

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 Maintenance, Schedule and Operating
Procedure
Maintenance Time:

Type of maintenance Interval of maintenance

Cooling coil Cooling coil & condensate tray Half Yearly (180 days)
and tray cleaning with compressed air and
Water
Ducting system Cleaning supply diffuser and return Monthly (30)
grill
Greasing of AHU/FCU motor bearing Yearly (365 days)

Overall checking the all parts of Quarterly(90)

Blower blower
Cleaning the blower and motor drive Biennially (730 days)

Check vibration of blower & belt Yearly (365 days)

Replacement of belt Yearly (365 days)

Desiccant Replace motor bearing Five yearly (1825 days

dehumidifier

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 Maintenance, Schedule and Operating
Procedure
Maintenance Time:

Electric system Checking the electric connections Yearly (365 days) Yearly (365 days)

Checking configurations Yearly (365 days) Yearly (365 days)

Tighten connection & checking heater Yearly (365 days)

Cleaning the controller Yearly (365 days)

Desiccant Cleaning filter (for aseptic area) Fortnightly (15 days)

dehumidifier
Checking desiccant safety function Quarterly (90 days)

Clearing desiccant bed Quarterly Quarterly (90 days)

Tighten blower belt & all nut bolt Quarterly (90 days)

Tighten blower base Quarterly (90 days)

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Common Faults, Causes and Remedies of VAC
Equipments
Common faults of compressor:
Fault: Compressor does not start and no
sound.
Causes:
1. Electric supply line off
2. Motor shaft jam
3. Compressor motor coil burned
Remedies :
1. Ensuring the electric supply
2. Need to be free or replace Figure: Compressor
3. Rewinding or change the
compressor.

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Common faults, causes and remedies of VAC
Equipments
Common faults of the Window type Air-conditioner
Faults: Unit runs but no cooling.
Causes :
1. No refrigerant in the system
2. Unit leakage
3. Compressor pumping down
Remedies:
1. Need to be charge
2. Find out the leakage and close it Figure : Window type AC
3. Replace the compressor

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Common faults, Causes and Remedies of VAC
Equipments
Common fault of Split type AC
Fault: Unit runs but less cooling.
Causes:
1. Less Blower speed
2. Insufficient refrigerant in the system.
3. Condenser fins become dirty
4. Compressor pumping down
Figure: Split AC indoor unit
Remedies:
1. Increase the speed
2. Need to be charge sufficient refrigerant.
3. Need to be clean
4. Replace the compressor

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Common Faults, Causes and Remedies of VAC
Equipments
Common fault of Air Handling Units (AHU).
Fault: Increase the relative humidity.
Causes:
1. Rotor or bed become dirty
2. React air temperature decrease
3. Room seal leakage
4. Drain water does not pass
Remedies:
1. Need to be clean
Figure: AHU (Bry Air)
2. Increase the temperature
3. Need to be leakage proof
4. Remove the drain water or clean the drain line.

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Problems Finding, Analysis and
Solution

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 Problems Finding, Analysis and Solution

Problem:
CCTV control room air-Conditioner (AC-1) run but no cooling in the room
Reasons of the problem:
1. Temperature setting not correct
2. Thermostat lost
3. Condenser, Evaporator and filter become dirty.
4. No refrigerant in the system
Find Out The Reason:
No refrigerant in the system
Solution of the problem:
Charge refrigerant in the system

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 Problems Finding, Analysis and Solution
Problem:
CCTV control room air conditioner (AC-2) does not run and no cooling
in the Room.
Reasons of the problem:
1. No power supply
2. Electric circuits problem
3. Low line current and voltage
4. Relay lost
5. Starting capacitor lost
6. Compressor burnt out.
Find Out The Reason:
Compressor Burnt out
Solution of the problem: Figure: Checking the AC -2
Replaced the compressor

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 Problems Finding, Analysis and Solution

Problem: AC Indoor unit frosted in weir house.

Reasons of the problem:
1. Evaporator size small.
2. Expansion device lost
3. More refrigerant enter in the evaporator than required.
4. Extra gas charge in the unit.
find out the reasons:
Refrigerant charge is high more than required.
Solution of the problem:
Remove the extra refrigerant from the unit.

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 Problems Finding, Analysis and Solution
Problem: Supply air blower does not work in QC Lab.
Reasons of the problem:
1. Temperature setting not correct
2. Thermostat lost
3. Condenser, Evaporator and filter become dirty.
4. No refrigerant in the system.
Find out the reasons:
Blower motor is burnt out
Solution of the problem:
Replaced the motor

Figure: Control room

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 Problems Finding, Analysis and Solution
Problem:
Increased the relative humidity (RH %) in production building. The room
under the AHU-2, which is located at 1st service floor.
Reasons of the problem:
1. In sufficient temperature of Air Handling Unit heater
2. Door seal leakage
3. Drain water does not pass that means drain line block
Find out the reasons:
The drain line blocked. As a result the water evaporates and mixed with
supply air.
Solution of the problem:
Unblocked the drain line with the help of compressed air.

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 Problems Finding, Analysis and Solution
Problem:
Room temperature increase (Offline packing at GP Building)
Reasons of the problem:
1. Insufficient air supply
2. FCU free filter become dirty
3. Chilled water temperature high
4. Cooling coil become dirty
5. Door seal leakage
6. Cooling load high
Find out the reason:
Pre filter of FCU become dirty
Solution:
Cleaned the filter with water and compressed air

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 Problems Finding, Analysis and Solution
Problem:
Air pressure dropped of FCU-30 which is located at GP 1st service floor.
Reasons of the problem:
1. Supply Fan speed decrease
2. Primary and after Filters become dirty
Find out the reason:
After filter become dirty
Solution:
Cleaned the filters
Problem: Room pressure increased in general production building.
Reasons of the problem:
1. High air supply more than required.
2. Return air filter become dirty
Find out the reason :
Return Air filter become dirty
Solution:
Cleaned the filters
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 Discussions
In my training period I tried to achieve practical knowledge about the VAC
System. Most of time I invested to find out the solutions of the problems which
is occurs on VAC equipment during my training period.
In my whole training period I observed that, the leakage of the refrigerant
cycle, motor burnt out and drain line blocked are the major problem occur on
outside. Temperature, Pressure and Relative Humidity increases or decreases
in the controlled areas are the major problem occurs on production side.

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 Recommendations
• To control the VAC system authority using some old machines. The reasons
of break down occur on these machines after short time interval. As a result
the amount of production decreases due to the break down. So the old
machines should be replaced.
• “The safety and caution” signs are not enough in the factory. As result
Accident can be happened anytime. So hazard sign should be posted in
different areas in the factory. I suffered a problem in the high tech service
floor due to the leak of safety sign.
• According to problem analysis, at the time of breakdown maintenance
worker does not maintains the safety code. As result Accident can be
happened anytime. So at the time of breakdown maintenance operator
should take proper safety measures.
• The numbers of engineers and operator are not enough to control the whole
VAC system. So should be increased the numbers of engineers and expert
operator.

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 Conclusion
VAC system is the most important factor for any industry.
A complete VAC system can provide the comfortable production environment.
It also helps to ensuring the quality of products.
In my practicum training period at ATS Power & Technology, I achieved
Practical knowledge about the trouble shooting, maintenance and operating
process of Ventilation and Air Conditioning system. I wish the achieved
knowledge help me to buildup my career on this sector.

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Any Question?

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Thank You!

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