SERVICES VI ( AR-310B)

LECTURE 10

AIR-CONDITIONING – (1) ENERGY

SAVING TECHNIQUES (2) CLEAN
ROOM TECHNIQUES
 RECAP – HVAC

HVAC system Basics: (a) A Compressor (b) A

Condenser – water cooled or air-cooled (c) An
Evaporator and (d) An Expansion Valve
 RECAP – BASIC HVAC PROCESS
 Room air is drawn across Evaporator Coil that cools and
dehumidifies air during cooling cycle.

 The Compressor changes the refrigerant into a high pressure

high temperature liquid.

 Condenser condenses Refrigerant and converts high pressure

vapour into high pressure liquid.

 Heat is rejected via air drawn across the condenser coils using
fans or cooling tower method.

 Expansion valve converts high pressure high temperature

refrigerant into low pressure low temperature mixture of
refrigerant liquid and vapour.

 The mixture fully evaporates in the evaporator coil by chilled

water system or cooling the air drawn across the coil.
 ENERGY SAVING TECHNIQUES – AS PER ECBC
Mandatory Requirements put forward by ECBC:

• Natural Ventilation
• Equipment Efficiency
• Controls
• Piping & Ductwork
• System Balancing
• Condensers
• Economizers
• Hydronic Systems
 NATURAL VENTILATION
Natural Ventilation : Guidelines provided by NBC-
2005
Excerpts from ECBC and NBC-2005

By Wind Action
• Building may not be necessarily oriented perpendicular
towards prevailing wind. Any convenient angle between 0 – 30 is
OK. If it is from East to West or vice versa, orientation could be
45 degrees to the incident wind - keeping the wind-induced
ventilation but keeping away the heat.

• Maximum air movement is also guided by sill level, which in

turn is governed by activity type. 0.75M for sitting on a chair,
0.60M for sitting on a bed and so on.

• Inlet openings should not be obstructed by adjoining buildings,

 NATURAL VENTILATION
By Wind Action
continued..
• Greatest flow of air per unit
opening size is obtained inside
a room when inlet and outlet
openings are of the same size
and at the same level.

• Air motion is not obstructed

inside a building if a building is
constructed of same or smaller
height in the leeward side.
However, air motion is reduced
if the leeward side building is
higher than the windward side
building.
 NATURAL VENTILATION
Natural Ventilation : Guidelines provided by NBC-
2005
Excerpts from ECBC and NBC-2005

By Stack Effect
• Happens when temp inside room is higher than
outside.
• Cool air enters through openings at low levels and
exits from ventilators (should be as close to the ceiling
as possible) or cowls, ridge vents or vent-pipes.
• Maximum possible use of wind-induced ventilation
systems (fans).
• Height of fan blades : (3H + W)/4 where, H is ht of
the room and W is height of the working plane.
•
NATURAL VENTILATION
NATURAL VENTILATION
 MINIMUM EQUIPMENT EFFICIENCIES
ENERGY EFFICIENCY TERMS
• Coefficient of Performance (COP) – cooling or
Heating - Ratio of heating (or cooling) to the rate of
energy input .

• Energy Efficiency Ratio (EER) – Ratio of net cooling

capacity in Btu/Hr to total rate of electrical input in
Watts

• Integrated Part Load Value (IPLV) - The Integrated Part Load

Value (IPLV) is a performance characteristic developed by the Air-Conditioning, Heating and
Refrigeration Institute (AHRI).  It is most commonly used to describe the performance of a chiller
capable of capacity modulation.  Unlike an EER (Energy Efficiency Ratio) or COP (coefficient of
performance), which describes the efficiency at full load conditions, the IPLV is derived from the
equipment efficiency while operating at various capacities.  Since a chiller does not always run at
100% capacity, the EER or COP is not an ideal representation of the typical equipment
performance.  The IPLV is a very important value to consider since it can affect energy usage and
operating costs throughout the lifetime of the equipment.
 CONTROLS
 Time-Clock Control: Scheduling of Heating &
Cooling system based on time-clock, ability to retain
programming and time-setting during power cut for at
least 10 hours, manual override provisions.

 Temperature Control: Cooling or heating controls

are necessary. For units providing both heating and
cooling a temperature dead band of 3 ºC (5 ºF) should
be provided within which heating or cooling energy
should be shut off. When separate heating or cooling
systems are used thermostats should be interlocked to
prevent simultaneous heating and cooling.
 CONTROLS
 Control of Cooling Towers and closed circuit fluid
coolers: Should have at least two-speed or variable
speed motors. Variable Speed Drives (VSD) is an
electronic device that controls rotational speed of a
piece of motor-driven equipment like blower,
compressor, fan or pump. Speed control is adjusted to
the frequency of voltage applied to the motor.

Apart from these, Energy (through fan speed control,

proper location and size of cooling tower) & water
efficiency measures may also be adopted for Cooling
Towers.
 PIPING & DUCTWORK
 PIPE INSULATION:

Insulation exposed to weather shall be protected by Aluminium

sheet metal, painted canvas or plastic cover. Cellular foam
insulation may be protected by water retardant paint (as an
alternative to above measures)
 PIPING & DUCTWORK
 DUCTWORK INSULATION:
 SYSTEM BALANCING
 Balancing is achieved through optimizing Air/water
distribution rates for the HVAC system. Final
inspection is vital before start of operation or handover.

 It also requires proving construction documents to

the owner/operator in the form of an operations
manual which shall mention but not limited to:

 Equipment capacity
 HVAC system control, maintenance and calibration
information including wiring diagram etc.
 A complete written document as to how each
system is intended to operate.
 CONDENSERS
 Condenser is a heat exchanger which liquefies
refrigerant vapour through heat removal.

A typical condensing unit houses a compressor, a

condenser fan motors, coils and controls.

Code says:
 Location should be such that the heat sink is free from interference
from heat discharge by devices located in the adjoining spaces.

 Mineral deposit in condenser water should be avoided. Soft water is

recommended.
ECONOMIZERS
 HYDRONICS
 Hydronics is the use of a liquid heat-transfer
medium in heating and cooling systems.

The working fluid is typically water, glycol,

or mineral oil. Some of the oldest and most common
examples are steam and hot-water radiators.

Historically, in large-scale commercial buildings such

as high-rise and campus facilities, a hydronic system
may include both a chilled and a heated water loop, to
provide for both heating and air conditioning.
HYDRONICS
 CLEAN ROOM CONCEPT IN HVAC
 Cleanrooms are specially constructed,
environmentally controlled enclosed spaces where the
concentration of airborne particles (contaminants) is
kept within specified limits.

 In industry, cleanrooms are used in the

manufacturing of electronic hardware such as
integrated circuits (ICs) and hard drives.

 In biotechnology and medicine, cleanrooms are

used when it is necessary to ensure an environment free
of bacteria, viruses, or other pathogens.
 HVAC : FUNDAMENTALS OF A CLEAN ROOM
 Contaminants must not be introduced into the
controlled environment from the outside.

 Apparatus or equipment within the controlled

environment must not generate or otherwise give rise to
contaminants (for example as a result of friction,
chemical reactions, or biological processes) .

 Contaminants must not be allowed to accumulate in

the controlled environment .

 Existing contaminants must be eliminated to the

greatest extent possible, and as rapidly as possible.
 CHARACTERISTICS OF AIR-BORNE PARTICLES

Airborne particles are solids suspended in the air. For

our purposes, particles are defined as bodies with:

1) Definite physical boundaries in all directions.

2) Diameters ranging from 0.001 micron to 100
microns*.
3)Liquid or solid phase material characteristics.
•1 micron – 1 millionth of a metre.

•To give a perspective, a human hair is about 75-100

microns in diameter.
•A particle of 0.5 micron (200 times smaller than the
human hair) can cause major disaster in a cleanroom.
 SOURCES OF CONTAMINATION
Contaminants come Five basic sources:
The Walls, floors and ceilings, Paint and coatings,
facilities Construction material (sheet rock, saw dust etc.), Air
conditioning debris, Room air and vapours, Spills and
leaks
People Skin flakes and oil, Cosmetics and perfume, Spittle ,
Clothing debris (lint, fibers etc.), Hair

Tools Friction and wear particles, Lubricants and emissions,

Vibrations, Brooms, mops and dusters

Fluids Particulates floating in air, Bacteria, organics and

moisture , Floor finishes or coatings, Cleaning chemicals,
Plasticizers (out-gasses), Deionized water

Manufactu Silicon chips, Quartz flakes, Cleanroom debris,

ring Aluminium particles
process
 HVAC & CONTROLLED ENVIRONMENT
The integrity of the cleanroom environment is created
by the pressure differential compared with adjacent
areas through HVAC. The HVAC system requirements
include:

Supplying airflow in sufficient volume and cleanliness to

support the cleanliness rating of the room.
Introducing air in a manner to prevent stagnant areas where
particles could accumulate.
Filtering the outside and re-circulated air across high efficiency
filters.
Conditioning the air to meet the cleanroom temperature and
humidity requirements.
Ensuring enough conditioned makeup air to maintain the
specified positive pressurization.
 CONVENTIONAL HVAC & CLEAN ROOM
Increased Air Supply:
Whereas comfort air conditioning would require about 2-10
air changes/hr, a typical cleanroom would typically require 20 -
60 air changes and could be as high as 600 for absolute
cleanliness.

 The large air supply is mainly provided to eliminate the

settling of the particulate and dilute contamination produced in
the room to an acceptable concentration level.

The use of high efficiency filters:

The use of high efficiency particulate air (HEPA) filters having
filtration efficiency of 99.97% down to 0.3 microns is another
distinguishing feature of cleanrooms.

The HEPA filters for stringent cleanrooms are normally

located at the terminal end and in most cases provide 100%
 FILTERS
FILTERS:

All air entering a cleanroom must be treated by one or more

filters. High-efficiency particulate air (HEPA) and ultra-low
penetration air (ULPA) filters are the most common filters used
in cleanroom applications.

 HEPA filters are capable of removing 99.97% of contaminant

particles 0.3 μm in diameter. Most standards also specify that
HEPA filters must feature minimal pressure drop and maximum
airflow when in operation.

ULPA filters are closely related to HEPA filters but are even
more efficient. ULPA filters are specified to remove 99.999% of
contaminants 0.12 μm or larger in diameter.
FILTERS
 AIRFLOW PATTERN
THREE TYPES OF FLOW:
(1)Unidirectional (Laminar) Airflow System Designs:
Stringent cleanrooms with classification rating 100 and below
are almost invariably designed for unidirectional airflow.

A Laminar airflow system contains three basic elements - a

blower, a high efficiency air filter, and a plenum. There may be
variations on this idea - many blowers, many filters, and very
large plenums, but all have the same basics.
AIRFLOW PATTERN
 AIRFLOW PATTERN

Non-Unidirectional (Laminar) Airflow System Designs:

Stringent cleanrooms with classification rating 100 and below
are almost invariably designed for unidirectional airflow.

A Laminar airflow system contains three basic elements - a

blower, a high efficiency air filter, and a plenum. There may
be variations on this idea - many blowers, many filters, and
very large plenums, but all have the same basics.
 ARCHITECURAL FEATURES OF A CLEAN ROOM
Rooms should be constructed using smooth, monolithic,
cleanable, chip resistant materials with a minimum of joints and
seams, and no crevices or moldings.

Sheet vinyl and plastic- or epoxy-coated products shall be used.

All doors, panels, etc. should be flush mounted or use sloped

tops.

Contamination control flooring may have a tacky finish to trap

dust and other debris from wheels and shoes.

Access flooring consists of solid or perforated panels or raised

pedestals. Air can flow through perforated panels and can be
exhausted in a sub floor area.
 ARCHITECURAL FEATURES OF A CLEAN ROOM
Sheet Vinyl is most common in clean rooms of higher control.
Homogenous material, which is solid vinyl, is preferred. Basically
this material is supplied in rolls and serves to reduce the joints,
cracks and crevices.

Frameworks of parallel and perpendicular bars used to house

filter and light fixtures in clean room ceilings.
ARCHITECURAL FEATURES OF A CLEAN ROOM