Tce Dsign Guide PDF

TCE.
M6-ME-811-319
TATA CONSULTING ENGINEERS LIMITED
SECTION:TITLE
DESIGN GUIDE FOR HVAC SYSTEM
FOR GREEN BUILDINGS
SHEET i OF iv

REV. NO. R0
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CHD. BY PRJ Sd
APD. BY GSK Sd
DATE 24.06.2010
FILE NAME: F020R4.DOC TCE FORM NO. 020 R4


FOR GREEN BUILDINGS

FILE NAME:M6ME319R0

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CONTENTS

SL.
NO.
TITLE
SH.
NO.
1.0 INTRODUCTION 1
2.0 SCOPE 1
3.0 DESIGN REQUIREMENTS 1
4.0 REFERENCES 16

APPENDICES

APPENDIX
NO.
TITLE
SH.
NO.
1 REFRIGERANT IMPACT CALCULATION 17
2 A BUILDING ENVELOPE REQUIREMENTS AS PER ECBC-2007 19
2 B
BUILDING ENVELOPE REQUIREMENTS AS PER ASHRAE
90.1.2007
20
3
ASSEMBLY U FACTORS & SHGC FOR UNLABELED
VERTICAL FENESTRATION & SKYLIGHTS
21
4 EQUIPMENT EFFICIENCIES AS PER ECBC-2007 22
5 EQUIPMENT EFFICIENCIES AS PER ASHRAE 90.1.2007 23
5 A AIR CONDITIONERS & CONDENSING UNITS 23
5 B WATER CHILLING PACKAGES 25
5 C PACKAGE UNITS 26
5 D HEAT REJECTION EQUIPMENTS 28
5 E NON-STANDARD CENTRIFUGAL CHILLERS UPTO 150 TR 29
5 F
NON-STANDARD CENTRIFUGAL CHILLERS FROM 151 TR
TO 300 TR
30
5 G NON-STANDARD CENTRIFUGAL CHILLERS BEYOND 301 TR 31

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6 PSYCHROMETRIC CHART (FREE COOLING SYSTEM) 32
7 FAN POWER LIMITATION PRESSURE DROP ADJUSTMENT 33
8 DUCT INSULATION 34
9 PIPING INSULATION 35
10 MINIMUM DUCT SEAL LEVEL 36
11 OUTDOOR AIR FLOW CALCULATION 37
12 A MINIMUM VENTILATION RATES 38
12 B MINIMUM EXHAUST RATES 40
12 C ZONE AIR DISTRIBUTION EFFECTIVENESS 41
12 D SYSTEM VENTILATION EFFICIENCY 42
13 MINIMUM SEPARATION DISTANCE 43
14 LIGHTING POWER DENSITIES 44
15 VOC LIMITS 47
16 VENTILATION RATE PROCEDURE (VRP) CALCULATION 48

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REVISION STATUS

REVISION
NO.
DATE DESCRIPTION
R0 24.06.2010 First issue

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FILE NAME: F120R3.DOC
1.0 INTRODUCTION
The built environment has a profound impact on our natural environment,
economy, health, and productivity. Breakthroughs in building science,
technology, and operations are now available to designers, builders,
operators, and owners who want to build green and maximize both economic
and environmental performance.
The green building movement offers an unprecedented opportunity to
respond to the most important challenges of our time, including global climate
change, dependence on non sustainable and expensive sources of energy,
and threats to human health.
Green building is the practice of increasing the efficiency with which buildings
use resources -- energy, water, and materials while reducing building
impacts on human health and the environment during the building's lifecycle.
2.0 SCOPE
This document gives guidelines for design of HVAC system for Green
Buildings.
3.0 DESIGN REQUIREMENTS
Following requirements should be met for the HVAC system for Green
Buildings to acquire various prerequisites & credits as per LEED (Leadership
in Energy and Environmental Design) rating system:
3.1 REFRIGERANTS
3.1.1 Minimum requirement: Zero use of CFC based refrigerants in new building
HVAC & R systems. In case of renovations or using existing HVAC & R
equipments, identify existing equipments that uses CFC refrigerants &
schedule for replacement of these refrigerants.
3.1.2 As per Indian Green Building Council (IGBC)-LEED rating system, equipment
that do not contain HCFCs should be used for getting additional credits.
Whereas as per LEED-USGBC HVAC&R equipment must comply with the
following formula, which sets a maximum threshold for the combined
contributions to ozone depletion and global warming potential:
LCGWP + LCODP x 10
5
100
Where
LCODP = [ODP
r
x (L
r
x Life +M
r
) x R
c
] / Life
LCGWP = [GWP
r
x (L
r
x Life + M
r
) x R
c
] / Life
LCODP : Lifecycle Ozone Depletion Potential (lb CFC 11/Ton-Year)
LCGWP : Lifecycle Direct Global Warming Potential (lb CO
2
/Ton-Year)
GWP
r
: Global Warming Potential of Refrigerant (0 to 12,000 lb
CO
2
/lbr)
ODP
r
: Ozone Depletion Potential of Refrigerant (0 to 0.2 lb CFC
11/lbr)
L
r
: Refrigerant Leakage Rate (0.5% to 2.0%; default of 2%
unless otherwise demonstrated)

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M
r
: End-of-life Refrigerant Loss (2% to 10%; default of 10%
R
c
: Refrigerant Charge (0.5 to 5.0 lbs of refrigerant per ton of
gross ARI rated cooling capacity)
Life : Equipment Life (10 years; default based on equipment type,

In case of multiple type of equipment average of all equipment must be
calculated using following formula :

(LCGWP + LCODP x 10
5
) x Q
unit
100
Q
Total

Where
Q
unit
: ARI rated cooling capacity of individual refrigeration / HVAC
unit (TR)
Q
Total
: Total ARI rated cooling capacity of all refrigeration / HVAC
unit (TR)
Sample Calculation for the same is shown in APPENDIX 1.
3.1.3 Select HVAC&R equipment with reduced refrigerant charge and increased
equipment life. Maintain equipment to prevent leakage of refrigerant to the
atmosphere.
3.2 BUILDING ENVELOPE
3.2.1 The exterior building envelope shall be designed with either Residential or
Non-residential requirements in APPENDIX 2, Building Envelope
Requirements, (excerpts from American Society of Heating, Refrigerating and
Air-Conditioning Engineers (ASHRAE) 90.1.2007 & Energy Conservation
Building Code (ECBC)). As per green building requirements stringent
requirements of the above (ASHRAE or ECBC) shall be followed.
For all opaque surfaces, compliance to standard shall be demonstrated by
either Minimum rated R values of insulation or Maximum U factor.
3.2.2 The total vertical fenestration area shall be less than 40% (as per ASHRAE
90.1.2007) of the gross wall area. In ECBC vertical fenestration area limit is
up to 60% of the gross wall area. The total skylight area shall be less than 5%
of the gross roof area as per ASHRAE 90.1.2007 and ECBC.
3.2.3 Design building envelope so that space conditions are maintained within the
range specified in ASHRAE standard 55-2004, Thermal comfort Conditions
for Human Occupancy. Documentation shall be as under (Excerpts from
ASHRAE standard 55-2004, Section 6.1.1)
(i) The design criteria of the system in terms of indoor temperature, humidity,
including any tolerance based on stated design outdoor ambient
conditions and total indoor loads should be stated.

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(ii) The system input or output capacities necessary to attain the design
indoor conditions at design outdoor ambient conditions should be stated
along with system supplied and installed capacities.
(iii) The limitations of the system to control the environment of the zone(s)
should be stated.
(iv) The overall space supplied by the system should be shown in a plan view
layout, with all individual zones within it identified. All terminal units should
be shown with type and flow.
(v) Items affecting indoor comfort (such as decor, significant structural items)
should be shown. Notes should be provided to identify areas and location
within space relative to grilles, diffuser, sensors which should not be
obstructed.
(vi) Areas within any zone that lie outside the comfort area, where people
should not be permanently located, should be identified.
(vii) Location of all occupant adjustable controls should be identified and each
should be provided with a legend describing which zone(s) and function it
controls, how it is to be adjusted, the range of effect it can have and
recommended setting for various times of day, season or occupancy load.
(viii) A block diagram control schematic should be provided with sensors,
controls and actuators identified for each zone.
(ix) The general maintenance, operation and performance of the building
systems should be state, followed by more specific comments on
maintenance and operation of automatic controls and manually adjustable
controls and the response of the system to each. Where necessary,
specific seasonal settings of manual controls should be stated and major
system changeovers that are required to be performed by a professional
service agency should be identified.
(x) Specific limits in the adjustment of manual controls should be stated.
Recommendations for seasonal settings on these controls should be
stated. A maintenance and inspection schedule for all thermal
environmental related systems should be provided.
(xi) Assumed electrical load for lighting and equipment in occupied spaces
(including diversity considerations) used in HVAC load calculations
should be documented along with any other significant thermal and
moisture loads assumed in HVAC load calculations and any other
assumptions based upon which HVAC and control design is based.
3.2.4 Fenestration and Doors
Where fenestration and doors are used in the building envelope, it shall
comply with following requirements:

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3.2.4.1 The U factor, SHGC & air leakage rate shall be determined by a laboratory
accredited by a nationally recognized accreditation organization such as
National Fenestration Rating Council (NFRC).
3.2.4.2 U factors & SHGC for the overall fenestration product shall be determined in
accordance with ISO 15099 as per ECBC or NFRC 100 & NFRC 200
respectively as per ASHRAE 90.1.2007. Or alternatively U factors & SHGC
from APPENDIX 3, Assembly U factors & SHGC for unlabeled vertical
fenestration & skylights, are acceptable.
3.2.4.3 U factors for unlabeled opaque doors shall be as under
(a) Un-insulated single layer metal swinging or non-swinging doors, including
single layer un-insulated access hatches : 1.45 Btu/hr ft
2
f
(b) Un-insulated double layer metal swinging or non-swinging doors, including
double layer un-insulated access hatches : 0.75 Btu/hr ft
2
f
(c) Insulated metal swinging doors including fire rated doors, insulated
access hatches : 0.50 Btu/hr ft
2
f
(d) Wood doors , minimum nominal thickness of 1.75 including panel doors
with minimum panel thickness of 1.125 , solid core flush doors, & hollow
core flush doors :0.50 Btu/hr ft
2
f
(e) Any other wood door : 0.60 Btu/hr ft
2
f
3.2.4.4 The U factor & the air leakage rate shall be identified on a permanent
nameplate installed on the product by the manufacturer.
3.2.5 Air Leakage Rates
3.2.5.1 All openings in the building envelope such as joints around doors &
fenestrations, corners, utility services penetrations, openings shall be sealed,
gasketed or weather stripped to minimise air leakage.
3.2.5.2 Air leakage shall not exceed 1 cfm/ft2 for glazed swinging entrance doors &
0.4 cfm/ft2 for all other products.
3.2.6 Insulation
Where insulation is used in the building envelope it shall comply with following
requirements:
3.2.6.1 The rated R value of the insulation shall be clearly identified by the
manufacturer on each piece of building envelope insulation
3.2.6.2 Insulation material shall be installed as per manufacturers recommendation,
in substantial contact with inside surface & in such a manner so as to achieve
the rated R value of the insulation.

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3.2.6.3 Roof insulation shall not be installed on a suspended ceiling with removable
ceiling panels.
3.2.6.4 Loose fill insulation shall not be used in attic roof spaces when slope of the
ceiling is more than 3:12
3.2.6.5 Insulation material in ground contact shall have water absorption rate no
greater than 3%when tested in accordance with ASTM C272
3.2.6.6 Flexible bat insulation installed in floor cavities shall be supported in a
permanent manner by supports no greater than 24 on centre.
3.2.6.7 Any equipment, fixtures shall not be recessed in such a manner as to affect
the insulation thickness.
3.2.6.8 Exterior insulation shall be covered with protective material to prevent
damage from moisture, sunlight, wind, maintenance.
3.2.6.9 Insulation shall extend over the full component area to the required rated R
value of insulation.
3.3 HVAC EQUIPMENTS
3.3.1 Equipment Efficiencies
3.3.1.1 HVAC equipments shall have minimum performance as per APPENDIX 4,
Minimum Equipment Efficiency requirements as per ECBC-2007 or
APPENDIX 5, Minimum Efficiency requirements as per Ashrae 90.1.2007,
whichever is stringent, at specified rating conditions when tested in
accordance with specified test procedure. Where multiple rating conditions or
performance requirements are provided, the equipment shall satisfy all rated
conditions. APPENDIX details are as under :
APPENDIX 4 Minimum Efficiency Requirement As per ECBC
APPENDIX 5 Minimum Efficiency Requirement as
per ASHRAE 90.1.2007 as under
APPENDIX 5 A Air Conditioners & Condensing Units
APPENDIX 5 B Water Chilling Packages
APPENDIX 5 C Package Units
APPENDIX 5 D Heat Rejection Equipments
Water cooled Centrifugal Chillers that are not designed for operation at ARI
standard 550/590 test conditions shall have performance requirements (full
load COP & NPLV) as per following APPENDICES:
APPENDIX 5 E Chiller Capacity < 150 TR

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APPENDIX 5 F 150 TR Chiller Capacity < 300 TR
APPENDIX 5 G Chiller Capacity 300 TR
The table values are applicable over the following full load design range :
Leaving Chilled water temperature :40F to 48F
Entering Condenser water temperature :75F to 85F
Condenser water temperature rise :5F to 15F
3.3.1.2 Equipment efficiencies information provided by the manufacturer shall be
verified by certified programme & data furnished by manufacturer
3.3.1.3 Equipments shall carry a permanent label installed by manufacturer stating
that the equipment complies with the requirements of ASHRAE standard 90.1
3.3.2 Air and Water Economizers
3.3.2.1 Each individual cooling fan system that has a design supply capacity over
2500 cfm and a total mechanical cooling capacity over 6.3 TR shall include
either air side or water side economizer(as per para 5.3.1 of ECBC). Projects
in Hot dry and Warm humid climate zones are exempt and individual ceiling
mounted fan systems (<6500 cfm) are exempt.
3.3.2.2 Free Cooling: When the enthalpy of the outside air is less than the enthalpy of
the mixing air (outside air + return air), conditioning the outside air is more
energy efficient than conditioning mixing air. Air economizer can be used to
implement the scheme. Air economizer consists of modulating outdoor air
damper, return air damper, exhaust air dampers and control system to
operate them. Operating characteristic of the economizer system is illustrated
below for different conditions (Case I, Case II & Case III). Also refer attached
psychrometric chart, APPENDIX 6.
Case I - When the enthalpy of outside air (h
os
) is higher than the
mixing air enthalpy (h
mc
), h
os
> h
mc

(i) The outdoor air damper is opened to a minimum position,
taking minimum outdoor air required for ventilation.
(ii) Return air damper is fully open and exhaust air damper is
opened to a minimum position.
(iii) Refrigeration plant is working to cool the mixing air to the
supply air temperature.
Case II - When the enthalpy of outside air is equal to or lower than
the mixing air enthalpy but more than the supply air enthalpy (h
sa
), h
sa

< h
os
h
mc

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(i) The outdoor air damper and exhaust air damper both are fully
open.
(ii) Return air damper is closed.
(iii) Refrigeration plant is working to cool the outdoor air to the
supply air temperature.
Case III - When the enthalpy of outside air is lower than the supply air
enthalpy, h
os
h
sa

(i) The outdoor air damper and Return air damper both are
modulated to achieve the supply air temperature.
(ii) Exhaust air damper is also modulated.
(iii) Refrigeration plant is switched off
Careful analysis is required for designing & implementing the above scheme
considering outside conditions throughout the year.
3.3.3 Each HVAC system having a total fan system motor nameplate hp exceeding
5 hp shall meet the following :
3.3.3.1 Each HVAC system at fan system design conditions shall not exceed the
allowable fan system motor nameplate hp (Option 1) or fan system bhp
(Option 2) as shown below
Limit Constant Volume Variable Volume
Option1 Allowable hp CFM*0.0011 hp CFM*0.0015
nameplate
Motor HP
Option2 Allowable bhp CFM*0.00094+A bhp CFM*0.0013+A
fan system
BHP
where CFM is the maximum design supply air flow rate to conditioned spaces
served by the system in cfm and A is the sum of (PD x CFM (through each
device) / 4131). PD shall be as given in the APPENDIX 7
3.3.3.2 The selected fan motor shall be no larger than the first available motor size
greater than the bhp.
3.3.3.3 Individual VAV fans with motors 10 hp or larger shall meet one of the
following requirement
(a) The fan shall be driven by a mechanical or electrical variable speed
drive
(b) The fan shall be a vane axial fan with variable pitch blades.

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(c) The fan shall have other controls and devices that will result in fan motor
demand of no more than 30% of design wattage at 50% of design air
volume when static pressure set point equals one third of the total
design static pressure based on manufacturers certified fan data.
3.3.4 HVAC hydronic systems having a total pump power exceeding 10 hp shall
meet following provisions
3.3.4.1 HVAC pumping systems that include control valves designed to modulate or
step open and close as a function of load shall be designed for variable fluid
flow and shall be capable of reducing pump flow rates to 50% or less of the
design flow rate. Individual pumps serving variable flow systems having a
pump head in excess of 100 ft and motor exceeding 50 hp shall have controls
and/or devices (such as variable speed control) that will result in pump motor
demand of no more than 30% of design wattage at 50% of design water flow.
The devices shall be controlled as a function of desired flow or to maintain a
minimum required differential pressure. Differential pressure shall be
measured at or near the most remote heat exchanger requiring the greatest
differential pressure.
3.3.4.2 When a chilled water plant includes more than one chiller, provisions shall be
made so that the flow in the respective chiller can be automatically stopped
when a chiller is shut down.
3.3.5 Each fan of heat rejection equipment (whose energy usage is not included in
equipment efficiency tables listed in Sr. No. 3.3.1.1) of motor rating 7.5 hp or
larger shall have the capability to operate at 2/3
rd
of full speed or less and
shall have speed controls to control the leaving fluid or condensing
temperature or pressure of the heat rejection equipment.
3.3.6 Individual fan systems that have both a design supply air capacity of 5000
cfm or greater and have a minimum outdoor air supply of 70% or greater of
the design supply air quantity shall have an energy recovery system with at
least 50% recovery effectiveness (i.e. Change in enthalpy of the outdoor air
supply equal to 50% of the difference between the outdoor air and return air
at design conditions).
3.3.7 Kitchen exhaust hoods larger than 5000 cfm shall be provided with makeup
air sized for at least 50% of exhaust air volume.
3.3.8 Building with fume hood systems having a total exhaust rate greater than
15000 cfm shall include at least one of the following features
3.3.8.1 VAV hood exhaust and room supply systems capable of reducing exhaust
and makeup air volume to 50% or less of design values
3.3.8.2 Direct make up air supply equal to at least 75% of the exhaust rate, cooler to
no cooler than 3F above room set point and heated no warmer than 2F
below room set point, no humidification added, no simultaneous heating and
cooling used for dehumidification control.

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3.3.8.3 Heat recovery system to precondition makeup air from fume hood exhaust in
accordance with Sr. No. 3.3.6
3.3.9 Controls
3.3.9.1 Design the HVAC system (heating & cooling both) to provide individual
comfort controls to allow adjustments to suit individual needs. Also provide
comfort controls for all shared multi-occupant spaces to enable adjustments
that meet group needs. Conditions of thermal comfort shall be as described in
ASHRAE standard 55-2004.
3.3.9.2 Controls for metering the energy used shall be included in the design.
3.3.9.3 Temperature range or dead band for controls shall be 5F except for special
applications
3.3.9.4 When HVAC systems are not intended to operate continuously , HVAC
system shall be designed with controls (i) that shall start and stop the system
under different time schedule , (ii) an occupant sensor that is capable of
shutting the system off when no occupant is sensed for a period of 30
minutes, (iii) a manually operated timer capable of bring adjusted to operate
the system for upto two hours, (iv) an interlock with the security system that
shuts the system off when the security system is activated.
3.3.9.5 Individual HVAC systems having capacity in excess of 10000 cfm shall have
the optimum start control, the control algorithm as a minimum shall be a
function of difference between space temperature and occupant set point and
amount of time prior to scheduled occupancy.
3.3.9.6 HVAC systems serving zones that may operate non simultaneously shall be
divided into isolated areas. Zones shall be grouped so that no individual zone
exceeds 25000 ft2 of conditioned floor area. Controls shall be provided for
automatic shutting off the system in particular zone when system is not in
use.
3.3.9.7 Stair and shaft vents shall be equipped with motorized dampers that are
capable of being automatically closed during normal building operation & are
interlocked to open when required by fire and smoke detection system. All
outdoor supply air and exhaust air systems shall be equipped with motorised
dampers that will automatically shut down when the spaces served are not in
use.
3.3.9.8 Outdoor air supply & exhaust dampers shall have a maximum leakage rate
not more than 4 cfm / ft2 @ 1 SP for motorized dampers & no leakage at 1
SP for non motorized damper. However damper smaller than 24 in either
dimension may have leakage of 40 cfm/ft2
3.3.10 Insulation
3.3.10.1 All supply & return ductwork insulation shall be in accordance with
APPENDIX 8, Duct Insulation

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3.3.10.2 All piping insulation shall be in accordance with APPENDIX 9, Piping
Insulation
3.3.10.3 Insulation exposed to weather shall be protected by aluminium, sheet metal,
painted canvas or plastic cover.
3.3.11 Ductwork and plenum shall be sealed in accordance with APPENDIX 10,
Minimum Duct Seal Level
3.3.12 Ductwork that is designed to operate at static pressures in excess of 3 w.c.
shall be leak tested for 25% of the installed duct area. The maximum
permitted leakage shall be
L
max
= C
L
x P
0.65
where

L
max
=Maximum permissible leakage , cfm / 100 ft
2
duct surface area
C
L
=Duct leakage class, cfm / 100 ft
2
at 1 W.C.
6 for rectangular sheet metal / fibrous & round flexible ducts
3 for round/flat oval sheet metal / fibrous glass duct
P =test pressure (design duct pressure)
3.3.13 Completion Requirements
Following construction documents shall be provided to building owner or
representative within 90 days of acceptance of the system:
(a) As built drawings
(b) Operation & Maintenance Manual
(c) Air & Water balancing reports
3.3.14 HVAC Electrical equipment & cabling
(a) All Motors shall have a minimum acceptable nominal full load motor
efficiency not less than IS 12615 standard for energy efficient motors
(b) Feeder conductors shall be sized for a maximum voltage drop of 2% at
design load. Branch circuit conductors shall be sized for a maximum
voltage drop of 3% at design load
3.4 VENTILATION FOR ACCEPTABLE INDOOR AIR QUALITY
3.4.1 Outdoor Air Quality

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3.4.1.1 Outdoor air quality shall be evaluated for the project site prior to completion of
ventilation system design for checking the outdoor air contamination levels. A
survey of the building site & its immediate surroundings shall be conducted
during hours the building is expected to be normally occupied to identify local
contaminants from surrounding facilities. The observations of the survey shall
be documented (as per ASHRAE 62.1.2004) & discussed with the building
owner or their representatives.
3.4.1.2 If the outdoor air is judged to be unacceptable in accordance with ASHRAE
62.1.2004, ventilation system that provides outdoor air through a supply fan
shall comply with the following :
(a) Air filters having MERV of 6 or higher shall be provided
(b) Air cleaning devices having minimum volumetric ozone removal efficiency
of 40% for ozone shall be provided when outdoor ozone levels are
expected to exceed 0.16 ppm. Air cleaning devices for ozone are not
required when outdoor air intake results in 1.5 ACPH or less
3.4.2 Mechanical Ventilation
3.4.2.1 As a minimum requirement for green buildings, mechanical ventilation
systems shall be designed using the Ventilation Rate Procedure (VRP) or the
applicable local code whichever is more stringent. Refer APPENDIX 11, for
Ventilation Rate Procedure details. Further additional credit points can be
acquired by increasing the ventilation rates to all occupied spaces by at least
30% above minimum rates required by ASHRAE standard 62.1.2004.
Minimum ventilation rates are given in APPENDIX 12 A. One example is
given in APPENDIX 16.
3.4.2.2 Various tables required for calculation in ventilation rate procedure are given
as under :
APPENDIX 12 A - Minimum Ventilation Rates for Breathing Zone
APPENDIX 12 B - Minimum Exhaust Rates
APPENDIX 12 C - Zone Air Distribution Effectiveness
APPENDIX 12 D - System Ventilation Efficiency
3.4.2.3 Demand control ventilation (DCV) is required for spaces larger than 500 ft2
and with design occupancy for ventilation of greater than 40 people per 1000
ft2 of floor area and served by systems with either an air side economizer or
automatic modulating control of the outside air damper or both.

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DCV is a system that adjusts the amount of outside air based on the number
of occupants and the ventilation demands that those occupants create. DCV
systems uses CO
2
-based sensors, which measure the buildup of CO
2
from
the occupants present and control the outside air flow. In this system CO
2

sensors monitor CO
2
levels in the air inside a building or occupied areas, and
an air-handling system uses this data from the sensors to regulate the
amount of ventilation air admitted.
3.4.2.4 Use heat recovery, where appropriate, to minimize the additional energy
consumption associated with higher ventilation rates.
3.4.2.5 Indoor Air Quality (IAQ) procedure can be used as an alternative to VRP
(described at Sr. No. 3.4.2.1) as per Ashrae standard 62.1. IAQ procedure
allows credit to be taken for controls that remove contaminant. It is also used
where the design is intended to attain specific target contaminant
concentrations or levels of acceptability of perceived indoor air quality. Air
purification equipment are used in the HVAC systems enabling a reduction in
ventilation air flow rates from the levels required by VRP.
3.4.2.6 Use of controlled injection of ozone can help reduce the quantity of fresh air.
Ozone is a powerful oxidant, which removes odour, Volatile Organic
Compounds (VOC) and even fungi by oxidation. This reduces the oxygen
requirement in the form of ventilation and air is mainly required for diluting
CO
2
. With ozone generators, ozone is injected into the central air conditioning
system (ducts) & concentration is controlled by sensors activated by excessive
VOC concentrations & turned off by excess ozone concentration sensors.
Ozone concentration is required to be kept below harmful limit (0.05 ppm as
per Ashrae).
3.4.3 Natural Ventilation
3.4.3.1 Naturally ventilated spaces shall be permanently open to and within 8 m of
operable wall or roof openings to the outdoors. Openable area shall be
minimum of 4% of the net occupiable floor area.
3.4.3.2 An engineered natural ventilation system when approved by the authority
having jurisdiction need not meet the above requirement
3.4.3.3 Credits may be acquired by designing natural ventilation system to meet
recommendations set forth in the Chartered Institution of Building Services
Engineers (CIBSE) Application manual 10:2005, follow flow diagram process
shown in figure 2.8 of CIBSE Application Manual 10 OR
3.4.3.4 Follow 8 design steps, as under, described in Carbon Trust Good Practice
Guide 237
(a) Develop design requirements
(b) Plan air flow paths
(c) Identify building uses & features that require special attention

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(d) Determine ventilation requirement
(e) Estimate external driving pressures
(f) Select types of ventilation devices
(g) Size ventilation devices
(h) Analyze the design
OR Use public domain software such as NISTs CONTAM, Multizone
modelling software, along with LoopDA, Natural ventilation sizing tool, to
analytically predict room by room airflows.
3.4.4 Smoking rooms designed to contain, capture & remove environmental
tobacco smoke (ETS) from the building must be directly exhausted to the
outdoors, away from air intakes and building entry paths with no recirculation
of ETS containing air. Exhaust shall be sufficient to create negative pressure
differential with the surrounding spaces of at least an average of 0.02 of
water gauge & minimum of 0.004 of water gauge when doors to smoking
rooms are closed. Corridors common to ETS & ETS free areas shall be
supplied with outdoor air at the rate of 0.1 cfm/ft2. Differential pressure
generally used is 0.05 WC.
3.4.5 Sufficiently exhaust each space where hazardous gases or chemicals may be
present or used to create negative pressure with respect to adjacent spaces
when the doors to the room are closed. Exhaust rate must be at least 0.5 cfm
/ ft2 with no air recirculation. The pressure differential with the surrounding
spaces must be at least an average of 0.02 & minimum of 0.004 when doors
to the rooms are closed. Filters having MERV of 13 or higher must be
provided for mechanically ventilated buildings. This requirement is used to
acquire credit points and is not a mandatory requirement.
3.4.6 Minimum outdoor air intake shall be greater than the design maximum
exhaust airflow when the mechanical air-conditioning are dehumidifying.
3.4.7 ASHRAE Standard 62.1 includes a design requirement intended to limit
relative humidity in zones. To comply with this, designers must analyze the
performance of the proposed air conditioning system at relatively severe
latent load conditions, namely, with outdoor air at dehumidification design
condition (design dew point and mean coincident dry-bulb temperature) and
with no zone sensible-heat gain due to solar load. This analysis tests the
dehumidification capability of the HVAC system configuration and control. It
must show that zone relative humidity does not exceed 65% RH at these
conditions. Some systems in some buildings in some climates can meet this
requirement without direct humidity control, e.g., VAV systems that supply
cool, dry primary air at all conditions. Other systems, however, such as
traditional single-zone constant volume systems, supply warmer, moister air
at part-sensible load and cannot maintain 65% RH or less without some
enhancement. To comply with Standard 62.1, these systems must be
reconfigured, to limit relative humidity indirectly, or using a zone humidistat
and local reheat.

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3.4.8 Location of outdoor air intakes shall be such that the shortest distance from
the intake to any specific potential outdoor contaminant source shall be equal
to or greater than the separation distance listed in APPENDIX 13, Minimum
Separation distance
3.4.9 Outdoor air intakes that are part of the mechanical ventilation system shall be
designed to manage Rain entrainment, Rain intrusion, Snow entrainment in
accordance with the ASHRAE standard 62.1.2004
3.4.10 Air shall be classified and its recirculation shall be limited in accordance with
the following :
(a) Class 1 air : Air with low contaminant concentration, low irritation intensity
and inoffensive odour, may be recirculated or transferred to any space.
(b) Class 2 : Air with moderate contaminant concentration, mild irritation
intensity and mild offensive odour, may be recirculated within the space of
origin or transferred or recirculated to other class 2 or class 3 or class 4
spaces utilized for similar purpose.
(c) Class 3 : Air with significant contaminant concentration, irritation intensity
and offensive odour, may be recirculated within the space of origin. Shall
not be transferred or recirculated to any other space.
(d) Class 4 : Air with highly objectionable fumes or gases & at harmful
concentrations, Shall not be transferred or recirculated to any other space
nor recirculated within space of origin.
Classification of air leaving each space shall be in accordance with
APPENDIX 12 A, Minimum Ventilation Rates for Breathing Zone
3.4.11 Mechanical ventilation systems shall include controls, manual or automatic,
that enable fan system to operate whenever the spaces served are occupied.
The system shall be designed to maintain the minimum outdoor airflow under
any load condition.
3.4.12 The system may be designed to reset the design outdoor air intake flow as
operating conditions change, these conditions include but are not limited to :
3.4.12.1Variation in occupancy or ventilation rate or CO2 levels (DCV as described at
Sr. No. 3.4.2.3) in one or more individual zones.
3.4.12.2 A higher fraction of outdoor air in the supply due to intake of additional
outdoor air for free cooling or exhaust air make up.
3.4.12.3 All air stream surfaces in equipments and ducts shall be designed and
constructed in accordance with ASHRAE standard 62.1.2004, Resistance to
mould growth & erosion
3.5 LIGHTING POWER DENSITIES

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Lighting power densities must not exceed the densities for the classified zone
given in ANNEXURE 12, Lighting Power Densities
3.6 LOW EMITTING MATERIALS
3.6.1 Specifications shall clearly state the VOC limits as given in ANNEXURE 13,
VOC Limits, for coatings, adhesives & paints that may be used in construction
/ installation of HVAC system. All adhesives and sealants must comply with
South Coast Air Quality Management District Rule 1168
3.7 BUILDING PERFORMANCE
As a minimum requirement for Green building, at least one of the following
requirements shall be met.

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

Whereas as per LEED (USGBC) rating system it is required to demonstrate a
10% improvement in the proposed building performance rating for new
buildings, or a 5% improvement in major renovations to existing buildings,
compared with the baseline building performance rating. Baseline building
performance rating is calculated according to the building performance rating
method of ASHRAE Standard 90.1-2007 using a computer simulation model
for the whole building project. Ashrae Standard 90.1-2007 requires that the
energy analysis done for the building performance rating method include all
energy costs associated with the building project.

OR

3.7.2 Comply with the prescriptive measures of ASHRAE Advanced Energy Design
Guide for Small Office Buildings 2004 / Small Retail Buildings 2006 / Small
Warehouses & Self Storage Building 2008 or Core Performance Guide

3.7.3 Further, additional credits may be acquired by improving the performance of
the proposed building (Ref 3.7.1). Credits are available up to 42% (48% as
per LEED USGBC) improvement in performance of proposed building. This
can be achieved by whole building energy simulation (using the Building
Performance Rating Method in Appendix G of the ASHRAE standard 90.1) or
prescriptive compliance path described in 3.7.2 above.

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

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4.0 REFERENCES
4.1 LEED 2009 for New Construction and Major Renovations
4.2 Reference Guide for New Construction and Major Renovations (LEED-India
NC) Version 1.0
4.3 ASHRAE Standard 90.1.2007, Energy Standard for Buildings except Low
Rise Residential Buildings
4.4 ASHRAE Standard 62.1.2004, Ventilation for Acceptable Indoor Air Quality
4.5 Energy Conservation Building Code 2007
4.6 ASHRAE Standard 55-2004, Thermal comfort Conditions for Human
Occupancy

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APPENDIX 1
REFRIGERANT IMPACT CALCULATION
Sample calculation for arriving at the refrigerant impact is given here.
Assumptions made for the calculation are as under
Total no. of systems in complete project :3 (System-1,2 and 3)
Refrigerant for Systems :R-134a for System-1, 2 and 3

CALCULATION TABLE
Description of system System-1 System-2 System-3 Total
Refrigerant R-134a R-134a R-134a
System Capacity TR 1000 1400 1400 3800
GWP
r
1320 1320 1320
ODP
r
0 0 0
R
c
lb 3300 3990 3990
Life years 23 23 23
L
r
% 2 2 2
M
r
% 10 10 10
LCGWP 106059 128235 128235
LCODP 0 0.00 0.00
LCGWP + LCODP x
10
5

106059 128235 128235 362529
Total impact

95.4

Where
LCODP = [ODP
r
x (L
r
x Life +M
r
) x R
c
] / Life
LCGWP = [GWP
r
x (L
r
x Life + M
r
) x R
c
] / Life
LCODP : Lifecycle Ozone Depletion Potential (lb CFC 11/Ton-Year)
LCGWP : Lifecycle Direct Global Warming Potential (lb CO
2
/Ton-Year)
GWP
r
: Global Warming Potential of Refrigerant (0 to 12,000 lb
CO
2
/lbr). Values taken from Refrigerant Reference Guide,
National Refrigerants
ODP
r
: Ozone Depletion Potential of Refrigerant (0 to 0.2 lb CFC
11/lbr). Values taken from Refrigerant Reference Guide,
National Refrigerants

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L
r
: Refrigerant Leakage Rate (0.5% to 2.0%; default of 2%
M
r
: End-of-life Refrigerant Loss (2% to 10%; default of 10%
R
c
: Refrigerant Charge (0.5 to 5.0 lbs of refrigerant per ton of
gross ARI rated cooling capacity). Values taken from
equipment Manufacturer.
Life : Equipment Life, Values taken from
equipment Manufacturer

Total impact (LCGWP + LCODP x 10
5
) x Q
unit
100
Q
Total

Conclusion
1.0 Project satisfies minimum requirement of zero use of CFC refrigerant as
specified in Sr. No. 3.1.1
2.0 Project will get the additional credit as it satisfies the requirement of total
impact less than 100.

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APPENDIX 2 A
BUILDING ENVELOPE REQUIREMENTS AS PER ECBC 2007
Walls & Roofs
Climate
Zones*
Assembly Insulation Assembly Insulation
Max U Min R Value Max Min R Value
Btu/hr ft
2
f hr ft
2
f / Btu Btu/hr ft
2
f hr ft
2
f / Btu
Roofs
Composite 0.0460 R-19.8 0.0715 R-11.9
Hot & Dry 0.0460 R-19.8 0.0715 R-11.9
Warm & Humid 0.0460 R-19.8 0.0715 R-11.9
Moderate 0.0715 R-11.9 0.0715 R-11.9
Cold 0.0460 R-19.8 0.0715 R-11.9
Walls
Composite 0.0775 R-11.9 0.0775 R-11.9
Hot & Dry 0.0775 R-11.9 0.0775 R-11.9
Warm & Humid 0.0775 R-11.9 0.0775 R-11.9
Moderate 0.0759 R-10.2 0.0699 R-11.4
Cold 0.0650 R-12.5 0.0620 R-13.3
Fenestrations
Climate Maximum
Zones* U Factor WWR 40% 40%=WWR 60%
Btu/hr ft
2
f
Vertical Fenestration
Composite 0.58 0.25 0.20
Hot & Dry 0.58 0.25 0.20
Warm & Humid 0.58 0.25 0.20
Moderate 1.22 0.40 0.30
Cold 0.58 0.51 0.51
Skylights
Climate With Curb W/o Curb 0 to 2% SRR 2.1 to 5% SRR
Zones* Btu/hr ft
2
f Btu/hr ft
2
f
Composite 1.98 1.36 0.40 0.25
Hot & Dry 1.98 1.36 0.40 0.25
Warm & Humid 1.98 1.36 0.40 0.25
Moderate 1.98 1.36 0.61 0.40
Cold 1.98 1.36 0.61 0.4
*Climate Zones as per ECBC , Climate Zone Map of India
Definitions :
WWR : Window to Wall Ratio, SRR : Skylight Roof Ratio
Maximum SHGC
Maximum SHGC Maximum U Factor
24 Hour use buildings Daytime use buildings
Hotels, Hospitals etc Other Building Types

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APPENDIX 2 B
BUILDING ENVELOPE REQUIREMENTS* AS PER ASHRAE 90.1.2007
Opaque
Elements Assembly Insulation Assembly Insulation
Max U Min R Value Max Min R Value
Btu/hr ft
2
f hr ft
2
f / Btu Btu/hr ft
2
f hr ft
2
f / Btu
Roofs
Insulation above deck 0.063 R-15 0.048 R-20
Metal Building 0.065 R-19 0.065 R-19
Attic & Other 0.034 R-30 0.027 R-38
Walls, Above grade
Mass 0.58 NR 0.151 R-5.7
Metal Building 0.113 R-13 0.113 R-13
Steel framed 0.124 R-13 0.124 R-13
Wood framed or other 0.089 R-13 0.089 R-13
Walls, Below grade C-1.14 NR C-1.14 NR
Floors
Mass 0.322 NR 0.322 NR
Steel Joist 0.35 NR 0.35 NR
Wood framed & other 0.282 NR 0.282 NR
Fenestration 0 to 40% of wall
Normal framing 1.2 1.2
Metal framing 1.2 1.2
(Curtainwall/Storefront)
*For Climate Zone 1 (A,B) & Prescriptive Building Envelope Option
Notes : (1) Either above U values can be specified / used or alternatively U values for pre-calculated assemblies can be used from APPENDIX A
of ASHRAE 90.1.2007. (2) For Min. R value, specifications listed in APPENDIX A shall be used to determine compliance. For Max. U value , the
values for typical construction assemblies listed in APPENDIX A shall be used to determine compliance. (3) Component U factors for other
assemblies (not listed in APPENDIX A) can be determined in accordance with Section A9 of ASHRAE 90.1.2007
Definitions :
mass wall : a wall with heat capacity exceeding (1) 7 Btu/ft
2
F or (2) 5 Btu/ft
2
F, provided that the wall has a material unit weight not greater
than 120 lb/ft
3
metal building wall : a wall whose structure consists of metal spanning members supprted by steel structural members (i.e., does not include
spandrel glass or metal panels in curtain wall systems)
steel framed wall : a wall with a cavity (insulated or otherwise) whose exterior surfaces are separated by steel framing members (i.e. typical steel
stud walls & curtain walls system)
wood framed & other walls : all other wall types, including wood stud walls.
Non-Residential Residential
SHGC 0.25 all SHGC 0.25 all

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APPENDIX 3
ASSEMBLY U FACTORS & SHGC FOR UNLABELED
VERTICAL FENESTRATION & SKYLIGHTS

(A) FOR VERTICAL FENESTRATION
Frame Glazing
Type Type U Factor SHGC U Factor SHGC
Btu/hr ft
2
f Btu/hr ft
2
f
All frame types Single glazing 1.25 0.82 1.25 0.70
Wood, vinyl or Double glazing 0.60 0.59 0.60 0.42
fibreglass frames
Metal & other frames Double glazing 0.90 0.68 0.90 0.50
Clear Glass Tinted Glass

(B) FOR SKYLIGHTS
To determine the default U factor for unlabeled sloped glazing & skylights without a
curb multiply the values in the above APPENDIX 3 by 1.2
To determine the default U factor for unlabeled sloped glazing & skylights on a curb
multiply the values in the above APPENDIX 3 by 1.6

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APPENDIX 4
MINIMUM EQUIPMENT EFFICIENCY REQUIREMENT AS PER ECBC 2007
Sr. no. Equipment Class Minimum Minimum Test
COP IPLV Standard
1 Air Cooled Chillers < 530 kW 2.9 3.16 ARI 550 / 590
(<150 TR) 1998
2 Air Cooled Chillers > = 530 kW 3.05 3.32 ARI 550 / 590
(> = 150 TR) 1998
3 Centrifugal Water Cooled Chiller < 530 kW 5.8 6.09 ARI 550 / 590
(<150 TR) 1998
4 Centrifugal Water Cooled Chiller > = 530 kW & <1050 kW 5.8 6.17 ARI 550 / 590
(> = 150 TR & < 300 TR) 1998
5 Centrifugal Water Cooled Chiller >= 1050 kW 6.3 6.61 ARI 550 / 590
(> = 300 TR) 1998
6 Reciprocating Compressors, Water Cooled Chillers all sizes 4.2 5.05 ARI 550 / 590
1998
7 Rotary Screw & Scroll Compressor, Water Cooled Chillers 4.7 5.49 ARI 550 / 590
< 530 kW (< 150 TR) 1998
8 Rotary Screw & Scroll Water Cooled Chiller > = 530 kW 5.4 6.17 ARI 550 / 590
& <1050 kW ( > = 150 TR & < 300 TR) 1998
9 Rotary Screw & Scroll Water Cooled Chiller >= 1050 kW 5.75 6.43 ARI 550 / 590
(> = 300 TR) 1998
Notes: Heating & Cooling equipment not listed here shall comply with Ashrae 90.1 standard.
Unitary Air conditioner shall meet IS 1391 Part 1
Split conditioner shall meet IS 1391 Part 2
Packaged air conditioner shall meet IS 8148

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APPENDIX 5 A
EQUIPMENT EFFICIENCIES AIR CONDITIONERS
AND CONDENSING UNITS (ASHRAE 90.1.2007)

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APPENDIX 5 B
EQUIPMENT EFFICIENCIES
WATER CHILLING PACKAGES

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APPENDIX 5 C
EQUIPMENT EFFICIENCIES PACKAGE UNITS

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APPENDIX 5 D
HEAT REJECTION EQUIPMENTS
Equipment Rating Performance Test
Type Conditions Required
a,b
Procedure
Propeller or axial 95F entering water
fan cooling towers 85F leaving water CTI ATC-105
c
&
75F wb outdoor air CTI STD-201
d
Centrifugal fan 95F entering water CTI ATC-105 &
cooling towers 85F leaving water CTI STD-201
75F wb outdoor air
Air cooled 125F condensing temp.
condensers R-22 test fluid ARI 460
190F entering gas temp
15F subcooling
95F entering db
a
Cooling tower performance is defined as the maximum flow rating of the tower divided by the fan nameplate rated motor power
b
Air cooled condenser performance is defined as the heat rejected from the refrigerant divided by the fan nameplate rated motor power
c
Cooling Technology Institute , Acceptance Test Code for Water Cooling Towers
d
Cooling Technology Institute , Stndard for Certification of Water Cooling Towers Thermal Performance
= 38.2 gpm / hp
= 20 gpm / hp
= 1,76,000 Btu/hr.hp

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APPENDIX 5 E
NON-STANDARD CENTRIFUGAL CHILLERS UPTO 150 TR

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APPENDIX 5 F
NON-STANDARD CENTRIFUGAL CHILLERS FROM 151 TR TO 300 TR

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APPENDIX 5 G
NON-STANDARD CENTRIFUGAL CHILLERS BEYOND 301 TR

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APPENDIX 6
PSYCHROMETRIC CHART (FREE COOLING SYSTEM)

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APPENDIX 7
FAN POWER LIMITATION PRESSURE DROP ADJUSTMENT

Device Adjustment
Fully ducted return and/or exhaust air systems 0.5" WC
Return and/or exhaust air flow control devices 0.5" WC
Exhaust filters, scrubbers, or other exhaust Pressure drop (PD) calculated at
treatment fan system design condition
Particulate filtration credit MERV 9 through 12 0.5" WC
Particulate filtration credit MERV 13 through 15 0.9" WC
Particulate filtration credit MERV 16 and greater PD calculated at 2xclean filter PD
and electronically enhanced filter at fan system design condition
Carbon and other gas phase air cleaners Clean filter PD at fan system
design condition
Heat recovery device PD of device at fan system
design condition
Evaporative humidifier / cooler in series with PD of device at fan system
another cooling coil design condition
Sound attenuation section 0.15 WC

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APPENDIX 8
DUCT INSULATION

Duct
Location Supply Duct Return Duct Supply Duct Return Duct
hr ft
2
f / Btu hr ft
2
f / Btu hr ft
2
f / Btu hr ft
2
f / Btu
Exterior R-7.9 R-3.4 R-6 R-3.5
Ventilated Attic R-7.9 R-3.4 R-7 R-3.5
Unventilated Attic w/o Roof
Insulation
R-7.9 R-3.4 R-8 R-3.5
Unventilated Attic with Roof
Insulation
R-3.4 No Requirement R-3.5 No Requirement
Unconditioned Space R-3.4 No Requirement R-3.5 No Requirement
Indirectly Conditioned Space No Requirement No Requirement No Requirement No Requirement
Buried R-3.4 No Requirement R-3.5 No Requirement
a
Insulation R value is measured on a horizontal plane in acoordance with ASTM C518 at a mean temperature of 75F at installed thk.
Required Insulation

As Per ASHRAE 90.1 Required Insulation
a
As Per ECBC

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APPENDIX 9
PIPING INSULATION

Design Required Insulation
Operating Temperature R-Value
hr ft
2
f / Btu
Temp > = 140F (Heating Systems) R-4
139F >= Temp > 104F (Heating Systems) R-2
59F >= Temp. > 40 (Cooling Systems) R-2

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APPENDIX 10
MINIMUM DUCT SEAL LEVEL

Seal Sealing Requirements
Level
A
All transverse joints, longitudinal seams and duct wall
penetrations. Pressure sensitive tape shall not be used
as primary sealant, unless it has been certified to comply
with UL-181A or B by an independent testing laboratory
B
All transverse joints, longitudinal seams. Pressure
sensitive tape shall not be used as primary sealant,
unless it has been certified to comply with UL-181A or B
by an independent testing laboratory
C Transverse joints only
Table 1 - Duct Seal Levels

Duct Return Exhaust
Location Upto 2" w.c. > 2" w.c. Duct Duct
Static Pressure Static Pressure
Outdoor A A A C
Unconditioned Spaces B A B C
Conditioned Spaces C B C B
a
Refer Table-1 for description of seal level
Supply Duct
Table 2 - Minimum Duct Seal Level
a

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OUTDOOR AIR FLOW CALCULATION

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APPENDIX 12 A
MINIMUM VENTILATION RATES
cfm/person cfm/ft2 #1000ft2 cfm/person
Cell 5 0.12 25 10 2
Day Room 5 0.06 30 7 1
Guard Stations 5 0.06 15 9 1
Booking/Waiting 7.5 0.06 50 9 2
Daycare(through age 4) 10 0.18 25 17 2
Classrooms(ages 5-8) 10 0.12 25 15 1
Classrooms(age 9 plus) 10 0.12 35 13 1
Lecture Classroom 7.5 0.06 65 8 1
Lecture hall (fixed seats) 7.5 0.06 150 8 1
Art classroom 10 0.18 20 19 2
Science Laboratories 10 0.18 E 25 17 -
Wood/Metal shop 10 0.18 20 19 2
Computer Lab 10 0.12 25 15 1
Media Center 10 0.12 A 25 15 1
Music/Theater/Dance 10 0.06 35 12 1
Multi-use assembly 7.5 0.06 100 8 1
Restaurant Dining Rooms 7.5 0.18 70 10 2
Cafeteria/fast food dining 7.5 0.18 100 9 2
Bars, cocktail lounges 7.5 0.18 100 9 2
Conference/Meetings 5 0.06 50 6 1
Corridors - 0.06 - 1
Storage Rooms - 0.12 B - 1
Bedroom/Living Room 5 0.06 10 11 1
Barracks sleeping areas 5 0.06 20 8 1
Lobbies/prefunction 7.5 0.06 30 10 1
Multi-purpose assembly 5 0.06 120 6 1
Office Space 5 0.06 5 17 1
Reception areas 5 0.06 30 7 1
Telephone/Data entry 5 0.06 60 6 1
Main entry lobbies 5 0.06 10 11 1
Bank vaults/Safe deposit 5 0.06 5 17 2
Computer(not printing) 5 0.06 4 20 1
Pharmacy(prep. Area) 5 0.18 10 23 2
Photo Studios 5 0.12 10 17 1
People
Outdoor Air
Rate
Area
Outdoor Air
Rate
Occupancy Category Air Class Notes
Default Values
Occupant
Density
Combined
Outdoor Air
Rate
Correctional Facilities
Educational Facilities
Food and Beverage Service
General
Hotels, Motels, Resorts, Dormitories
Office Buildings
Miscellaneous Spaces

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Shipping/Receiving - 0.12 B - 1
Transportation waiting 7.5 0.06 100 8 1
Warehouses - 0.06 B - 2
Auditorium seating area 5 0.06 150 5 1
Places of religious workshop 5 0.06 120 6 1
Courtrooms 5 0.06 70 6 1
Legislative chambers 5 0.06 50 6 1
Libraries 5 0.12 10 17 1
Lobbies 5 0.06 150 5 1
Museums (Childrens) 7.5 0.12 40 11 1
Museums/gallaries 7.5 0.06 40 9 1
Sales (except as below) 7.5 0.12 15 16 2
Mall common areas 7.5 0.06 40 9 1
Barber shop 7.5 0.06 25 10 2
Beauty and nail salons 20 0.12 25 25 2
Pet shops (animal areas) 7.5 0.18 10 26 2
Supermarket 7.5 0.06 8 15 1
Coin-operated Laundries 7.5 0.06 20 11 2
Sports area(play area) - 0.3 - 1
Gym, stadium (play area) - 0.3 30 2
Spectator areas 7.5 0.06 150 8 1
Swimming (pool and deck) - 0.48 C - 2
Disco/dance floors 20 0.06 100 21 1
Health club/aerobics room 20 0.06 40 22 2
Health club/weight rooms 20 0.06 10 26 2
Bowling alley(seating) 10 0.12 40 13 1
Gambling casinos 7.5 0.18 120 9 1
Game arcaes 7.5 0.18 20 17 1
Stages, studios 10 0.06 D 70 11 1
GENERAL NOTES FOR TABLE 6.1
1 Related Requirements: The rate in this table are based on all other applicable requirements of this standard being met.
2 Smoking: This table applies to non-smoking areas. Rates for smoking permitted spaces must be determined using other
methods. See section 6.2.9 of Ashrae 62.1.2007 for ventilation requirement in smoking areas.
3 Air density: Volumetric airflow rates are based on an air density of 1.2 Kg/m3 which corresponds to dry air at a barometric
pressure of 1 atm (101.3 kPa) and an air temperature of 21 deg C. Rates may be adjusted for actual density but such
adjustment is not required for compliance with this standard.
4 Default Occupant Density: The default occupant density shall be used when actual occupant density is not known.
5 Default Combined Outdoor Air Rate (per person): This rate is based on default occupant density.
6 Unlisted Occupancies: If the occupancy category for a proposed space or zone is not listed, the requirement for the listed
occupancy category that is most similar in terms of occupant density, activities and building construction shall be used.
7 Healthcare facilities : Rates shall be determined in accordance with Appendix E.
ITEM-SPECIFIC NOTES
A For high school and college libraries, use values shown for public spaces , library.
B Rates may not be sufficient when stored materials include those having potentially harmful emissions.
C Rates does not allow for humidity control. Additional ventilation or dehumidification may be required to remove moisture
D Rate does not include special exhaust for stage effects, e.g. dry ice vapors, smoke.
E No class of air has been established for this occupancy category.
Retail
Sports and Entertainment
Public Assembly Spaces

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APPENDIX 12 B
MINIMUM EXHAUST RATES
Occupancy Category Exhaust Notes Air Class
Air Rate cfm/ft2
Arenas 0.5 B 1
Art Classrooms 0.7 2
Auto repair rooms 1.5 A 2
Barber shops 0.5 2
Beauty & nail Salons 0.6 2
Cells with toilets 1 2
Copy, printing rooms 0.5 2
Darkrooms, Educational Science Labs 1 2
Janitor closets, trash rooms, recycling 1 3
Kitchenettes 0.3 2
Kitchens - Commercial 0.7 2
Locker/dressing rooms 0.25 2
Locker rooms 0.5 2
Paint spray booths -- F 4
Parking garages 0.75 C 2
Pet shops (animal areas) 0.9 2
Refrigerating machinery rooms -- F 3
Residential Kitchens 50 / 100 per unit G 2
Soiled laundry storage rooms 1 F 3
Storage rooms, chemical 1.5 F 4
Toilets - private 25 / 50 per unit E 2
Toilets - public 50 / 70 per unit D 2
Woodwork shop/classroom 0.5 2
Notes : A Stands where engines are run shall have exhaust systems that directly connect to the
engine exhaust & prevent escape of fumes
B When combustion equipment is intended to be used on the playing surface additional dilution
ventilation and/or source control shall be provided
C Exhaust not required if two or more sides comprise walls that are atleast 50% open to the outside
D Rates are per water closet and / or urinal. Provide higher rates where periods of heavy use are
expected, such as toilets in theatres, schools , sports facilities etc
E Rates is for toilet room intended to be occupied by one person at a time. For continuous system
operation during normal hours of use, the lower rate may be used, otherwise use higher rate.
F See other applicable standard for exhaust rate.
G For continuous system operation, the lower rate may be used. Otherwise use higher rate.

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APPENDIX 12 C
ZONE AIR DISTRIBUTION EFFECTIVENESS
Air Distribution Configuration E
z
Ceiling supply of cool air 1
Ceiling supply of warm air & floor return 1
Ceiling supply of warm air 15F or more 0.8
above space temperature
Floor supply of cool air and ceiling return 1
provided that the 150 fpm supply jet
reaches 4.5 ft or more above floor (Note:
most underfloor air distribution systems)
Floor supply of warm air & ceiling return 0.7
Make up supply drawn in on the opposite 0.8
side of the room from the exhaust and /
or return
Make up supply drawn in near to the 0.5
exhaust and / or return location
E
z
= Zone air distribution effectiveness

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APPENDIX 12 D
SYSTEM VENTILATION EFFICIENCY

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APPENDIX 13
AIR INTAKE MINIMUM SEPARATION DISTANCE
Object
Minimum
Distance (ft)
Significantly contaminated exhaust 15
Noxious or dangerous exhaust (Note 1) 30
Vents, chimneys & flues from combustion appliances & equipments 15
Garage entry, automobile loading area, or drive in queue (Note 2) 15
Truck loading area or dock, bus parking / idling area (Note 2) 25
Driveway, street or parking place (Note 2) 5
Thoughroughfare with high traffic volume 25
Roof, landscaped grade,or other surface directly below intake (Note3) 1
Garbage storage / pickup area 15
Cooling tower intake or basin 15
Cooling tower exhaust 25
Note 1 : Laboratory fume hood exhaust air outlets shall be in compliance with NFPA 45 & ANSI std
Note 2 : Distance measured to closest place that vehicle exhaust is likely to be located.
Note 3 : No min. separation distance applies to surfaces that are sloped more than 45 degrees from horizontal or that are less
than 1" wide. Where snow accumulation is expected, distance listed shall be increased by expected avergae snow depth.

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APPENDIX 14
LIGHTING POWER DENSITIES
Table- 1 Building Area Method
Building area type W/ft
2
Automotive faciltiy 0.9
Convention Center 1.2
Courthouse 1.2
Dining : bar lounge/leisure 1.3
Dining : family 1.6
Dormitory 1.0
Exercise Center 1.0
Gymnasium 1.1
Health care clinic 1
Hospital 1.2
Hotel 1
Library 1.3
Manufacturing facility 1.3
Motel 1
Motion picture theater 1.2
Multifamily 0.7
Museum 1.1
Office 1
Parking Garage 0.3
Penitentiary 1
Performing arts theater 1.6
Police/Fire station 1.0
Post Office 1.1
Religious Building 1.3
Retail 1.5
School / University 1.2
Sports arena 1.1
Town hall 1.1
Transportation 1
Warehouse 0.8
Workshop 1.4

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Table- 2 Space by Space Method
Common space types W/ft2 Building specific space types W/ft2
Office 1.1 Gym / Exercise center
Conference / Meeting / Multipurpose 1.3 Playing area 1.4
Classroom / Lecture / Training 1.4 Exercise area 0.9
Lobby 1.3 Courthouse/Police Station
For Hotel 1.1 Courtroom 1.9
For Performing Art Theater 3.3 Confinement Cells 0.9
For Motion Picture Theater 1.1 Judges Chambers 1.3
Audience / Seating area 0.9 Fire Stations
For Gymnasium 0.4 Engine room 0.8
For Exercise center 0.3 Sleeping quarters 0.3
For Convention center, Penitentiary 0.7 Post Office - Sorting area 1.2
For Religious building 1.7 Convention center-Exhibit space 1.3
For Sports arena 0.4 Library
For Performing Art Theater 2.6 Card file & cataloging 1.1
For Motion Picture Theater 1.2 Stacks 1.7
For Transportation 0.5 Reading area 1.2
Atrium - First Three floors 0.6 Hospital
Atrium - each additional floor 0.2 Emergency 2.7
Lounge / Recreation 1.2 Recovery 0.8
For Hospital 0.8 Nurses station 1.0
Dining area 0.9 Exam / Treatment 1.5
For Hotel, Penitentiary 1.3 Pharmacy 1.2
For Motel 1.2 Patient room 0.7
For Bar Lounge / Leisure dining 1.4 Operating room 2.2
For Family dining 2.1 Nursery 0.6
Food preperation 1.2 Medical supply 1.4
Laboratory 1.4 Physical Therapy 0.9
Restrooms 0.9 Radiology 0.4
Dressing / locker / fitting room 0.6 Laundry-washing 0.6
Corridor / Transition 0.5 Automotive-Service repair 0.7
For Hospital 1.0 Manufacturing
For Manufacturing facility 0.5 Low bay (<25ft ht) 1.2
Stairs - Active 0.6 High bay (=25ft ht) 1.7
Active storage 0.8 Detailed manufacturing 2.1
For Hospital 0.9 Equipment room 1.2
Inactive storage 0.3 Control room 0.5
For Museum 0.8 Hotel/Motel Guest rooms 1.1
Electrical / Mechanical 1.5 Dormitory-Living quarters 1.1
Workshop 1.9 Museum
Sales area (except accent lighting) 1.7 General exhibition 1.0
Restoration 1.7
Bank office-Banking activity area 1.5

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Religious Buildings
Worship pulpit, choir 2.4
Fellowship hall 0.9
Retail
Sales area (except accent lighting) 1.7
Mall concourse 1.7
Sports arena
Ring sports area 2.7
Court sports area 2.3
Indoor playing field area 1.4
Warehouse
Fine material storage 1.4
Medium/Bulky material storage 0.9
Parking Garage 0.2
Transportation
Airport concourse 0.6
Air/Train/Bus-Baggage area 1.0
Terminal-Ticket counter 1.5

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

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APPENDIX 15
VOC LIMITS

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

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APPENDIX 16
VENTILATION RATE PROCEDURE (VRP) CALCULATION
Sample calculation for arriving at ventilation rate is given here.
Assumptions made for the calculation are as under
Two restaurants with lift lobby at intermediate floor of multi-storey commercial
complex are considered for this outdoor air flow rate calculation. It is assumed that
this area is served by one common air handler.
CALCULATION TABLE

Conclusion
1.0 Project satisfies minimum requirement of mechanical ventilation system
design using VRP.
2.0 Project will get the additional credit as V
oal
is selected as out door air quantity
which is 30% more than minimum requirement.
Note
(1) Similar calculations need to be performed for all air handlers in the project.

TCE CONSULTING ENGINEERS LIMITED
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TCE.M1-ME-127-201
BASIC STUDY GUIDE FOR
COOLING TOWER MAKE-UP SYSTEM
SHEET i OF iii
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PPD.BY TSR Sd/- SDP Sd/- SDP
CHD.BY TSR Sd/- TSR Sd/- TSR R2
APD.BY KG Sd/- RL Sd/- RL
DATE 92.03.31 98.07.24 01.07.16
TCE FORM NO. 020R2
FLOPPY NO. : TCE.00000-ME-FP-139
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TCE.M1-ME-127-201
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PPD.BY TSR Sd/- SDP Sd/- SDP
CHD.BY TSR Sd/- TSR Sd/- TSR R2
APD.BY KG Sd/- RL Sd/- RL
DATE 92.03.31 98.07.24 01.07.16
TCE FORM NO. 020R2
FILE NAME : M1ME201R2.DOC
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CONTENTS
SL.NO. TITLE SH. NO.
1.0 SCOPE 1
2.0 INTRODUCTION 1
3.0 SYSTEMS 1
4.0 INPUT DATA 2
5.0 DESCRIPTION 2
APPENDIX 1 SCHEMATIC DIAGRAMS FOR 9
COOLING WATER SYSTEMS
APPENDIX 2 FACTOR A FOR TOTAL 10
DISSOLVED SOLIDS (TDS)
APPENDIX 3 FACTOR B FOR HOT WATER 11
TEMPERATURE
APPENDIX 4 FACTOR C FOR CALCIUM HARDNESS 12
(AS CaCO
3
)
APPENDIX 5 FACTOR D FOR TOTAL ALKALINITY 13
(AS CaCO
3
)
APPENDIX 6 EQUILIBRIUM pH VALUE DETERMINED 14
FROM TOTAL ALKALINITY
(AS CaCO
3
)
APPENDIX 7 SCALING SEVERITY KEYED TO PSI 15
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REVISION STATUS
REV.NO. DATE DESCRIPTION
R0 92.03.31 --
R1 98.07.24 Generally revised.
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1.0 SCOPE
This basic study guide outlines various methods adopted for the Cooling Tower
Make-Up System.
2.0 INTRODUCTION
The water chemistry, treatments and operational control methods discussed in this
guide apply specifically to open re-circulating cooling water systems containing
cooling towers. The air-water contact in the cooling towers affects, both directly and
indirectly, the system water chemistry. Air borne dust is scrubbed from air ,
increasing suspended solids concentration of the cooling water, and the water is
continuously inoculated with air borne micro-organisms. Evaporation of water in the
cooling tower causes the dissolved and suspended matter in the make-up water to
be concentrated in the recirculating water. These processes influence the corrosion,
scaling, deposition and micro-biological fouling potential of the system. The
objective of this guide is to give general overview of recirculating cooling water
operations, guidelines for calculating make-up water quantity and chemical
treatment. For format, structure and other guidelines for preparation of basic study
refer TCE.M9-PCS-25.
3.0 SYSTEMS
3.1 The following are the various cooling water systems adopted in chemical, industrial
and power plants etc. : (Refer Appendix 1)
(a) Once-through system
(b) Open or cooling tower re-circulating system
(c) Closed loop system
(d) Recirculation system using spray ponds
3.2 In the case of once-through system, make-up water is not required. Hence this
system is not considered further, in this study. Requirements of items (b) and
(c) are studied hereunder. Requirement of (d) is not covered as same is not used
now-a-days because of space constraints.
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4.0 INPUT DATA
Following data needs to be collected :
(a) Analysis of the water which is to be used as make-up. Refer TCE.M1-ME-
612-202 Basic Study Guide For Water Treatment System. Analysis shall
contain values of Total Dissolved Solids (TDS) in mg/l, total alkalinity in
mg/l as CaCO
3
, calcium hardness in mg/l as CaCO
3.
Due to seasonal
variation for ground water, total hardness may be more in summer. Hence
total hardness and alkalinity of summer shall be considered.
(b) Maximum cooling water return temperature,
(c) Materials of construction of process plant equipment using the cooling
water,
(d) Range of cooling in cooling tower
(e) Availability of make-up water and
(f) Cooling water quality if given by process collaborator or equipment supplier
5.0 DESCRIPTION
5.1 COOLING TOWER CIRCULATING SYSTEM (CT SYSTEM)
Cooling water is pumped through a point of heat exchange or heat transfer
equipment, increasing the temperature of the cooling water from recooled water
temperature to hot water temperature. The hot water flows through the recirculating
lines to the cooling tower deck , from which the water falls by gravity through the
tower packing to the tower basin. Heat is rejected to the atmosphere by means of
evaporation as cooling water droplets are broken up in the packing. Air passes
upward by means of mechanical or natural draft. The rejection of heat in the
recirculating water by evaporation (E) restores the cooling water temperature T1 at
which the cooling cycle begins again.
In the operation of cooling tower, water is continuously evaporated and replaced
with fresh make-up water. This results in an increase in the concentration of
dissolved solids in the recirculating water. The ratio of the total dissolved solids in
the recirculating water to the total dissolved solids in the make-up water
(TDSR/TDSM) is called Cycles of Concentration (COC). Increase in COC
results in formation of scale. To prevent the formation of scale, a portion of the
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concentrated recirculating water is blown down or bled from the system and
replaced with make-up water. In addition to blowdown some water droplets
containing concentrated dissolved solids are carried through the evaporation
equipment in the cooling tower and lost to the atmosphere. This windage or drift
loss(D) may vary from one cooling tower to another.
Thus, the following contribute to the loss of water from the cooling water system of
cooling tower :
(a) Evaporation,
(b) Drift (physical carry-over of the water particles),
(c) Blowdown adopted to control concentration of dissolved solids in the circuit
and
(d) Miscellaneous losses like pump gland leakage etc.
5.2 CLOSED LOOP SYSTEM
Closed loop cooling water system is also called as primary circuit. Cooling of
primary circuit water is through heat exchanger. Elements of loss i.e. evaporation
and drift are not present. Loss due to occasional blowdown and pump gland
leakage etc. is minimal and hence make-up for the system is very low. Since closed
loop system is adopted due to process requirement and also since the make-up
quantity is small, normally Demineralised (DM) water or soft water or municipal
water is used for make-up depending upon process requirements. Also corrosion-
cum-scale inhibitors are dosed to prevent corrosion. Make-up water quantity shall
be generally 1.5% to 5% of total circulating flow.
5.3 QUALITY OF WATER USED FOR CT SYSTEM
Quality of water in cooling water circuit shall be such that it does not have tendency
to form any scale on heat transfer surfaces or elsewhere. Scale forming
characteristics of the circulating water can be predicted by calculating the Puckorius
Scaling Index (PSI). It is also called Predictable Scaling Index. PSI is worked out
for various COC based on :
(a) Total dissolved solids (TDS) X COC - Factor A
(b) Hot water temperature - Factor B
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(c) Calcium hardness X COC - Factor C
(d) Alkalinity X COC - Factor D
Factors A, B, C and D are derived from the appendices 2, 3, 4 and 5 respectively.
If soft water is used, normally calcium hardness of 5 mg/l is to be considered.
Calcium carbonate saturation index (pHs) and PSI are worked out as follows :
(a) pHs = 9.3 + A + B - (C + D)
(b) PSI = 2 pHs pHeq
pHeq is taken from the Appendix 6.
If the PSI is less than 6.0, the water has scale forming tendency. Characteristics of
water versus PSI can be read from Appendix 7. While designing the system, PSI
shall be around 6.5.
5.4 QUANTITY OF MAKE-UP WATER FOR CT SYSTEM
5.4.1 For Chemical Plants, Industrial Plants and Oil Fired Power Plants
(a) If as per 5.3, the untreated raw water for COC upto 1.3 has scale forming
characteristic, soft water shall be used as make-up to the system. In the
case of both raw water and/or softened water, used as make-up, highest
cycle of concentration is selected, after calculation of PSI with cycles of
concentration 1.5, 2.0, 2.5 etc. on trial basis such that the characteristics of
circulation water remains non-scale forming. COC is generally limited to 3.0
to 3.5 as beyond this make-up quantity changes marginally.
(b) Cycles of concentration is related to blowdown by the following formula
E + B + D
COC = , where
B + D
COC = Cycles of concentration
E = Evaporation - taken as 1% of circulation flow rate for
every 5.56
0
C (10
0
F) temperature range across
cooling tower - M
3
/Hr.
B = Blowdown - M
3
/Hr.
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D = Drift taken as 0.1% of circulation water flow rate -
M
3
/Hr.
Make-up water to cooling tower system is the sum of E + B + D in M
3
/Hr. A
margin of 10% is considered for design purposes.
5.4.2 For Coal Fired Power Plant
The blowdown from the system is governed by the end use of the blowdown. For
instance, in case of coal fired power plants, blowdown is utilised for ash handling
system. Hence, depending upon the water requirement for ash handling system, the
blowdown shall be determined and for this blowdown, concentration ratio shall be
calculated and with this concentration ratio the PSI shall be determined to ascertain
need or otherwise of the treatment.
Following two (2) alternatives may be considered.
(a) If, for example, the concentration ratio with the blowdown as above is 1.8
and this results in slight scaling, a lower concentration ratio of upto 1.3 may
be considered and if this concentration ratio does not call for any treatment,
same may be adopted, provided adequate quantity of make-up water is
available to meet the increased blowdown.
(b) If lower concentration ratio as suggested in (a) above cannot be adopted
due to non-availability of water or even the lower concentration results in
scaling, adopt make-up water treatment. Once the type of treatment is
decided, adopt as high a concentration ratio as permissible which leads to
minimum blowdown. Additional water (over this blowdown) required for
the ash handling system shall be supplied from other source.
5.4.3 While selecting the maximum concentration ratio, care shall be taken to ensure that
the silica, chloride and sulphate values of circulating water do not exceed the limits
given in IS 8188.
5.4.4 Normally, cooling tower blowdown is led to effluent treatment plant. Any treatment
and/or dilution to meet the pollution standard criteria at the final disposal point shall
be carried out in effluent treatment plant.
5.5 POINTS OF CONSIDERATION FOR CT SYSTEM
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5.5.1 Based on PSI, if raw water without treatment is used, it is advisable to use filtered
water for make-up especially for chemical plants (considering small quantity of
make-up).
5.5.2 In other process plants and power plants with splash type fill for cooling tower and
where large quantity of make-up is required, raw water without treatment is used as
make-up based on PSI. In process and power plants where film type fill is used for
cooling tower, clarified water shall be used. Side stream filtration may be adopted
for both the above cases. (Appendix 1)
5.5.3 Cooling water system is dynamic system, due to variation in make-up water
analysis, temperatures and possible contamination from process and atmosphere
etc. Hence in order to make sure that the system remains non- scaling and non-
corrosive, scaling and corrosion inhibitors may be required to be dosed. These
inhibitors are of proprietory nature and manufacturer shall be consulted for dosage
etc. Manufacturer invariably carries out actual tests at site to finalise the dosage,
etc.
5.5.4 In case good quality water is available in adequate quantity in or nearby the plant ,
this water can be used directly or after some treatment instead of using raw water.
For example, if clarified water is to be used for process requirement, this can be
used instead of raw water.
5.6 SCALE INHIBITORS
Based on PSI if raw water is to be treated, for controlling scaling, the following
methods are available :
(a) External side stream or full flow treatment of the circulating water,
(b) Chemical treatment
The optimum scale control programme developed for any specific system must
depend upon the make-up water composition and its availablity, operating
parameters in the cooling system , the number of COC to be carried in the
circulating system and sometimes on effluent considerations.
SECTION: WRITE-UP
TCE.M1-ME-127-201
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(a) External Pre-Treatment of the Make-Up Water
This can be through ion-exchange, de-alklisation or cold lime clarifier
methods. Ion-exchange method removes all the hardness and minimises
scaling. However, the use of very low or zero hardness make-up is
generally not desirable as the treated water tends to be corrosive and may
need corrosion inhibitor. However, for small to medium cooling water
systems, this can be blended with raw water.
Cold lime clarifier involves large reaction vessel and hence high initial cost.
This removes most of bicarbonate hardness, which is the aim of treatment
for cooling tower make-up and reduces turbidity and suspended solids also.
The treated water is high in pH and may need pH control. Hence this
method is normally adopted for very large cooling water systems only.
For medium and large systems, where the water contains very high
bicarbonate hardness, de-alkalisation may be adopted. This is a form of
external acid dosing, and consists of cation exchanger or cation-cum-
softener combination and a decarbonator. A suitable corrosion inhibitor and
pH conditioning equipment is needed.
(b) Chemical Treatment
In this method bicarbonate content of water is converted to sulphate form,
by dosing sulphuric acid. Use of corrosion inhibitor is a must. In this
method number of COC in cooling tower circuit is decided based on
solubility limit of calcium sulphate. It is necessary to incorporate
sophisticated pH control equipment with automation and skilled operational
staff. This method is generally not considered since handling of sulphuric
acid is difficult. Hence it is advisable to adopt this method only for medium
to large systems.
Scale suppressant can be used without softening with due care that very high
concentration of hardness and pH does not occur. In this system poly
phosphates, with or without acid dosing for reduction of alkalinity, or
synthetic organic material like phosphonates may be used.
5.7 CORROSION INHIBITORS
SECTION: WRITE-UP
TCE.M1-ME-127-201
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Corrosion inhibitors are almost universally used to control deterioration of carbon
steel and other alloys in cooling systems. Various corrosion inhibitors
such as polyphosphates, orthophosphates, chromate, zinc, organic phosphorous
compounds, molybdate are generally employed as corrosion inhibitors for cooling
tower system. Mixture of corrosion inhibitors are often synergistic and provide
excellent protection at costs far lower than would be required for individual
components. Selection of a specific corrosion inhibitor must be based on
compatibility of the inhibitor with other chemicals in the system, materials of
construction, operating conditions in the system and formulation considerations in
preparing the complete inhibitor package. Many of these products are protected by
patents.
5.8 MICRO-BIOLOGICAL GROWTH CONTROL
Chlorine is generally used for micro-biological growth control. It is effective for the
control of bacteria, algae and fungi. Chlorine may be purchased as a compressed
gas, solid calcium hypochlorite or sodium hypochlorite soluion.
Refer following design guides for further details :
(a) Design Guide for Water Treatment Plant TCE.M6-ME-612-203
(b) Design Guide for Bulk Chemicals Storage TCE.M6-ME-612-205
and Handling
5.9 OTHER RECENT CONCEPTS
Pollution control regulations and shortage of water has prompted industries to adopt
zero blowdown concept and recycling of water for reuse and near zero drift of
cooling towers.
Recycling is done on case to case basis, by segregation of various waste water
streams including cooling tower blowdown and further treatment such as
clarification, reverse osmosis etc.
Zero blowdown concept is further step to the recycling i.e. not only water is
recovered for reuse but the concentrated stream is totally converted to water for
reuse and solid waste. This results in zero waste water from the plant.
SECTION: APPENDIX
TCE.M1-ME-127-201
COOLING WATER MAKE-UP SYSTEM
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APPENDIX 1 SCHEMATIC DIAGRAMS FOR
COOLING WATER SYSTEMS
COOLING WATER-OUT
TO DRAIN OR
LARGE WATER BODY
ONCE THROUGH SYSTEM
COOLING TOWER (CT)
CT SUMP
OPEN OR COOLING TOWER RE-CIRCULATING SYSTEM
COOLING TOWER
C T SUMP
CLOSED LOOP SYSTEM
PROCESS
EQUIPMENT
LIKE
CONDENSER
ETC.
PROCESS
EQUIPMENT
HEAT
EXCHANGER
PROCESS
EQUIPMENT
SIDE
STREAM
FILTER
SYSTEM
SECTION: APPENDIX
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APPENDIX 2
FACTOR A FOR TOTAL DISSOLVED SOLIDS (TDS)
TDS, mg/l VALUE OF A
50 0.07
75 0.08
100 0.10
150 0.11
200 0.13
300 0.14
400 0.16
600 0.18
800 0.19
1000 0.20
1500 0.21
2000 0.22
2500 0.23
3000 0.24
4000 0.25
5000 0.26

SECTION: APPENDIX
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APPENDIX 3
FACTOR B FOR HOT WATER TEMPERATURE
SECTION: APPENDIX
TCE.M1-ME-127-201
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APPENDIX 4
FACTOR C FOR CALCIUM HARDNESS (AS CaCO
3
)
mg/l VALUE OF FACTOR C
tens 0 1 2 3 4 5 6 7 8 9
0 - - - 0.08 0.20 0.30 0.38 0.45 0.51 0.56
10 0.60 0.64 0.68 0.72 0.75 0.78 0.81 0.83 0.86 0.88
20 0.90 0.92 0.94 0.95 0.98 1.01 1.02 1.03 1.05 1.06
30 1.06 1.09 1.11 1.12 1.13 1.15 1.16 1.17 1.18 1.19
40 1.20 1.21 1.23 1.25 1.25 1.25 1.26 1.27 1.28 1.29
50 1.30 1.31 1.32 1.33 1.34 1.34 1.35 1.36 1.37 1.37
60 1.38 1.39 1.39 1.40 1.41 1.42 1.42 1.43 1.43 1.44
70 1.45 1.45 1.46 1.47 1.48 1.48 1.49 1.49 1.49 1.50
80 1.51 1.51 1.52 1.53 1.53 1.53 1.54 1.54 1.55 1.55
90 1.56 1.56 1.57 1.57 1.58 1.58 1.58 1.59 1.59 1.60
100 1.60 1.61 1.61 1.61 1.62 1.62 1.63 1.63 1.64 1.64
110 1.64 1.65 1.65 1.65 1.65 1.66 1.67 1.67 1.67 1.68
120 1.68 1.68 1.69 1.70 1.70 1.70 1.70 1.71 1.71 1.71
130 1.72 1.72 1.72 1.73 1.73 1.73 1.74 1.74 1.74 1.75
140 1.75 1.75 1.75 1.76 1.76 1.77 1.77 1.77 1.77 1.78
150 1.78 1.78 1.80 1.80 1.80 1.80 1.80 1.80 1.80 1.80
160 1.81 1.81 1.81 1.81 1.82 1.82 1.82 1.82 1.83 1.83
170 1.83 1.84 1.84 1.84 1.84 1.85 1.85 1.85 1.85 1.85
180 1.86 1.86 1.86 1.86 1.87 1.87 1.87 1.87 1.88 1.88
190 1.88 1.88 1.89 1.89 1.89 1.89 1.89 1.90 1.90 1.90
200 1.90 1.91 1.91 1.91 1.91 1.91 1.92 1.92 1.92 1.92
mg/l VALUE OF FACTOR C
hundreds 0 10 20 30 40 50 60 70 80 90
200 1.90 1.92 1.94 .196 1.98 2.00 2.02 2.03 2.05 2.06
300 2.08 2.09 2.11 2.12 2.13 2.15 2.16 2.17 2.18 2.19
400 2.20 2.21 2.23 2.25 2.25 2.26 2.26 2.27 2.29 2.29
500 2.30 2.31 2.32 2.33 2.34 2.34 2.35 2.36 2.37 2.37
600 2.38 2.39 2.39 2.40 2.41 2.42 2.42 2.43 2.43 2.44
700 2.45 2.45 2.45 2.47 2.47 2.48 2.48 2.49 2.49 2.50
800 2.51 2.51 2.52 2.52 2.53 2.53 2.54 2.54 2.55 2.55
900 2.56 2.56 2.56 2.57 2.57 2.58 2.58 2.59 2.59 2.60
Example : For 144 mg/l calcium hardness as CaCO3, C= 1.76.
SECTION: APPENDIX
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APPENDIX 5
FACTOR D FOR TOTAL ALKALINITY (TA) ( AS CaCO
3
)
mg/l VALUE OF FACTOR D
tens 0 1 2 3 4 5 6 7 8 9
0 - 0.00 0.30 0.45 0.60 0.70 0.78 0.85 0.90 0.95
10 1.00 1.04 1.08 1.11 1.15 1.18 1.20 1.23 1.26 1.29
20 1.30 1.32 1.34 1.36 1.38 1.40 1.42 1.43 1.45 1.46
30 1.48 1.49 1.51 1.52 1.53 1.54 1.56 1.57 1.58 1.59
40 1.60 1.61 1.62 1.63 1.64 1.65 1.67 1.67 1.68 1.69
50 1.70 1.71 1.72 1.72 1.73 1.74 1.75 1.76 1.76 1.77
60 1.78 1.79 1.80 1.81 1.81 1.82 1.83 1.83 1.83 1.84
70 1.85 1.85 1.86 1.86 1.87 1.88 1.88 1.89 1.89 1.90
80 1.90 1.91 1.91 1.92 1.92 1.93 1.93 1.94 1.94 1.95
90 1.95 1.96 1.96 1.97 1.97 1.98 1.98 1.99 1.99 2.00
100 2.00 2.00 2.01 2.01 2.02 2.02 2.03 2.03 2.03 2.04
110 2.04 2.05 2.05 2.05 2.05 2.06 2.06 2.07 2.07 2.08
120 2.08 2.08 2.09 2.09 2.09 2.10 2.10 2.10 2.11 2.11
130 2.11 2.12 2.12 2.12 2.13 2.13 2.13 2.14 2.14 2.14
140 2.14 2.15 2.15 2.16 2.16 2.16 2.16 2.17 2.17 2.17
150 2.18 2.18 2.18 2.18 2.19 2.19 2.19 2.20 2.20 2.20
160 2.20 2.21 2.21 2.21 2.21 2.22 2.22 2.23 2.23 2.23
170 2.23 2.23 2.23 2.23 2.23 2.24 2.24 2.25 2.25 2.26
180 2.26 2.26 2.26 2.26 2.26 2.27 2.27 2.27 2.27 2.28
190 2.28 2.28 2.28 2.29 2.29 2.29 2.29 2.29 2.30 2.30
200 2.30 2.30 2.30 2.31 2.31 2.31 2.31 2.32 2.32 2.32
mg/l VALUE OF FACTOR D
hundreds 0 10 20 30 40 50 60 70 80 90
200 2.32 2.32 2.34 2.36 2.38 2.40 2.42 2.43 2.45 2.45
300 2.48 2.49 2.51 2.52 2.53 2.54 2.56 2.57 2.58 2.59
400 2.60 2.61 2.62 2.63 2.64 2.65 2.66 2.67 2.68 2.69
500 2.70 2.71 2.72 2.72 2.73 2.74 2.75 2.76 2.76 2.77
600 2.78 2.79 2.80 2.81 2.81 2.81 2.82 2.83 2.83 2.84
700 2.85 2.85 2.86 2.86 2.87 2.88 2.88 2.89 2.89 2.90
SECTION: APPENDIX
TCE.M1-ME-127-201
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800 2.90 2.91 2.91 2.92 2.92 2.93 2.93 2.94 2.94 2.95
APPENDIX 6
EQUILIBRIUM pH VALUE (pH eq) DETERMINED FROM
TOTAL ALKALINITY (TA) (AS CaCO
3
)
alkalinity,
mg/l
VALUE OF pHeq
hundreds 0 10 20 30 40 50 60 70 80 908
0 - 6.00 6.45 6.70 6.89 7.03 7.14 7.24 7.33 7.40
100 7.47 7.53 7.59 7.64 7.68 7.73 7.77 7.81 7.84 7.88
200 7.91 7.94 7.97 8.00 8.03 8.05 8.08 8.10 8.15 8.15
300 8.17 8.19 8.21 8.23 8.25 8.27 8.29 8.30 8.32 8.34
400 8.35 8.37 8.38 8.40 8.41 8.43 8.44 8.46 8.47 8.48
500 8.49 8.51 8.52 8.53 8.54 8.56 8.57 8.58 8.59 8.60
600 8.61 8.62 8.63 8.64 8.65 8.66 8.67 8.67 8.68 8.70
700 8.71 8.72 8.73 8.74 8.74 8.75 8.76 8.77 8.78 8.79
800 8.79 8.80 8.81 8.82 8.82 8.83 8.84 8.85 8.85 8.86
900 8.87 8.88 8.88 8.89 8.90 8.90 8.91 8.92 8.92 8.93
pH eq = 1.465 log TA + 4.54 where TA denotes total alkalinity.
SECTION: APPENDIX
TCE.M1-ME-127-201
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APPENDIX 7
SCALING SEVERITY KEYED TO PSI
PSI CONDITION
3.0 EXTREMELY SEVERE
4.0 VERY SEVERE
5.0 SEVERE
5.5 MODERATE
5.8 SLIGHT
6.0 STABLE WATER , NO SCALING , NO
TENDENCY TO DISSOLVE SCALE
6.5 NO SCALING, VERY SLIGHT
7.0 NO SCALING, SLIGHT TENDENCY
TO DISSOLVE SCALE
8.0 NO SCALING, MODERATE
9.0 NO SCALING, STRONG TENDENCY
TO DISSOLVE SCALE
10.0 NO SCALING, VERY STRONG
TCE CONSULTING ENGINEERS LIMITED SECTION: TITLE
TCE.M1-ME-811-301
AIR-CONDITIONING SYSTEM
SHEET i OF iv
REV. NO. R2 R3 R4 R5
ISSUE
PPD. BY HRK Sd/- HRK Sd/- HRK Sd/- IYM
CHD. BY PRJ Sd/- PRJ Sd/- PRJ Sd/- PRJ
APD. BY RL Sd/- RL Sd/- RL Sd/- RL
DATE 27.09.1999 06.04.2001 15.01.2003 22.08.2003
R5
TCE FORM NO. 020R2
TCE.M1-ME-811-301
SHEET i OF iv
ISSUE
PPD. BY HRK Sd/- HRK Sd/- HRK Sd/- IYM
CHD. BY PRJ Sd/- PRJ Sd/- PRJ Sd/- PRJ
APD. BY RL Sd/- RL Sd/- RL Sd/- RL
DATE 27.09.1999 06.04.2001 15.01.2003 22.08.2003
R5
TCE FORM NO. 020R2
FILE NAME: M1ME301R5.DOC
TCE CONSULTING ENGINEERS LIMITED SECTION: CONTENTS
TCE.M1-ME-811-301
SHEET ii OF iv
ISSUE
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TCE FORM NO. 120 R1
CONTENTS
SL. NO. TITLE SH. NO.
1.0 SCOPE 1
2.0 INPUT DATA 1
3.0 SYSTEM DESIGN AND SELECTION 2
4.0 ENTHALPY CONTROL SYSTEM 10
5.0 HEAT RECOVERY SYSTEM 12
6.0 OPERATION AND CONTROL SCHEME 13
7.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS 13
8.0 EQUIPMENT AND ELECTRICAL LOAD LIST 14
9.0 UTILITY AND SPACE REQUIREMENTS 15
10.0 PROCUREMENT STRATEGY 15
APPENDICES
1. OUTSIDE DESIGN CONDITIONS OF IMPORTANT CITIES OF
INDIA
16
2. RECOMMENDED INSIDE DESIGN CONDITIONS- SUMMER
AND WINTER
21
3. HEAT GAIN FROM PEOPLE 22
4. DEFAULT VALUES FOR SOME DESIGN PARAMETERS 24
5. COMPARISON BETWEEN RECIPROCATING, SCREW,
CENTRIFUGAL CHILLING UNITS AND VAMs
27
6. CHILLED WATER/BRINE CLOSED LOOP SINGLE PUMPING
SYSTEM-(ALTERNATIVE 1)
30
TCE.M1-ME-811-301
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TCE FORM NO. 120 R1
7. CHILLED WATER/BRINE CLOSED LOOP SINGLE PUMPING
31
CONTENTS (CONTD.)
8. CHILLED WATER/BRINE OPEN LOOP SINGLE PUMPING
32
9. CHILLED WATER/BRINE OPEN LOOP SINGLE PUMPING
33
10. CHILLED WATER/BRINE OPEN LOOP DOUBLE PUMPING
SYSTEM
34
11. COMPARISON BETWEEN CLOSED, OPEN LOOP SINGLE AND
DOUBLE PUMPING SYSTEMS
35
TCE CONSULTING ENGINEERS LIMITED SECTION: REV. STATUS
TCE.M1-ME-811-301
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REVISION STATUS
REV. NO. DATE DESCRIPTION
R0 29.12.1980 ----------------
R1 11.05.1994 Contents sheet and sheet number 4 revised.
R2 27.09.1999 Completely revised.
R3 06.04.2001 Para 5.0 added.
R4 15.01.2003 Paras 4.0 and 5.0 added.
R5 22.08.2003 Para 7.0 revised.
TCE CONSULTING ENGINEERS LIMITED SECTION: WRITE-UP
TCE.M1-ME-811-301
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1.0 SCOPE
This document gives guidelines for carrying out a basic study for air-conditioning system for
chemical, industrial, power plants and high-rise buildings. For format, structure and other
guidelines refer TCE.M9-PCS-25. The basic study shall form the basis for procurement
and detailed engineering of the air- conditioning system.
2.0 INPUT DATA
Following input data shall be collected from various sources like client, process
collaborator, other groups in the mechanical department, other departments, bidders and
vendors.
2.1 Location of the site
2.2 Latitude and altitude of the site
2.3 Names of areas to be air-conditioned
2.4 Equipment layout drawings of the areas to be air-conditioned
2.5 Architectural drawings and civil Reinforced Cement Concrete (RCC) or structural
steel drawings of the areas to be air-conditioned
2.6 Outside design conditions like Dry Bulb Temperature (DBT), Wet Bulb
Temperature (WBT) and Relative Humidity (RH) for summer, monsoon and winter and
daily temperature range
2.7 Inside design conditions for each of the areas to be air-conditioned
(a) DBT range
(b) RH range
(c) Lighting loads
(d) Sensible and latent equipment heat loads, of heat sources within and adjacent to
the air-conditioned areas with specific periodic loading patterns, if any
(e) Occupancy
(f) Fresh air and exhaust air requirements, if any
(g) Filtration and cleanliness requirements, if any
(h) Pressurisation requirements, if any
(i) Air flow pattern requirements, if any
(j) Acceptable noise and vibration levels
(k) Hazardous area classification
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2.8 Duration of air-conditioning for each of the areas to be air-conditioned
2.9 Availability of cooling water, make-up water, quality of water, inlet and outlet
pressures and temperatures
2.10 Electrical power supply voltage levels
2.11 Specific requirements like future expansion plans and provisions required to be
incorporated at present
Some of the input data indicated above may not be readily available at the time of the
preparation of the basic study. Appendices 1 to 4 of this document give guidelines for
assuming such data. These appendices are based on published literature and experience
gained over the years.
3.0 SYSTEM DESIGN AND SELECTION
3.1 Based on the input data collected or assumed as per guidelines given in appendices 1 to 4,
the cooling loads, the dehumidified air flow rate, Apparatus Dew Point (ADP) and heating
loads, if any, shall be calculated as per TCE.M6-ME-811-301 Design Guide for Air-
Conditioning Cooling Load Calculations for each of the areas to be air-conditioned.
3.2 Cooling load, dehumidified air flow rate, ADP and heating loads, if any, for each of the
area shall be tabulated. Table shall be made in such a way that areas which have similar
inside design conditions of DBT and RH and which are location-wise close to each other
are clubbed together. A typical format is given below:
INSIDE
DESIGN
CONDITIONS
COOLING
LOAD
DEHUMI-
DIFIED
AIR
FLOW
RATE
ADP HEATING
LOAD
DURATION
OF
OPERATION
DBT RH FROM TO
SL.
NO.
NAME
OF
AREA
O
C %
TR M
3
/HR
O
C KW
Hrs Hrs
R
E
M
A
R
K
S
3.3 The above table will enable grouping of the air-conditioned areas, selection of air-
conditioning system e.g. selecting the number of units for the total system, combining the
units for areas which are located in the proximity of each other and which are to be
maintained at similar inside design conditions etc. The table will also help in determining
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requirements and distribution of utilities like cooling water, chilled water, chilled brine,
instrument air and power etc.
3.4 AIR DISTRIBUTION DIAGRAMS
3.4.1 An air distribution diagram in the form of a single line diagram shall be prepared for supply
and return air circuits for each of the air-conditioned areas, which are grouped together.
This diagram is an internal document and not part of the basic study which is circulated to
other departments for review or submitted to client for review and approval. This air
distribution diagram shall include all the elements like Air Handling Units (AHUs), supply
air ducting with air outlets, return air ducting with return air inlets, supply or return air
plenums, volume control dampers in supply and return air ducting for unit isolation and air
flow adjustment. Elements like filters, cooling coils, heating coils, supply and return air fans
located within the AHU shall also be indicated in the air distribution diagram.
3.4.2 Typically, an air-conditioning air circuit is a closed loop system with air being routed from
the AHU to the air-conditioned area by supply air ducting and then routed back to the
AHU inlet by return air ducting. Supply air and return air ducting is generally routed to and
from the air-conditioned areas, above a false ceiling provided for aesthetic reasons. When
a false ceiling is provided, return air may be routed back to the AHU between the ceiling
or roof and false ceiling. In such cases the return air ducting may be eliminated.
The air-conditioned area is generally maintained at an over-pressure, i.e. a pressure slightly
above the ambient. As a result of this over-pressure, air will leak out of the air-conditioned
area through cracks and gaps between door and window frames and minimise outdoor or
un-conditioned air ingress into the area. Fresh air is taken into the system in the return air
path at the AHU inlet and this completes the circuit.
The most optimum design of an air-conditioning system attempts to minimise the loss of the
conditioned air from the room.
3.4.3 The air distribution diagram shall also indicate local exhaust or return air collection points.
Local air collections points may be provided for the following typical cases:
(a) Local Exhausts from Equipment
Such air collection points are provided to minimise the exhaust air so as to minimise
the loss of conditioned air from the room and consequently the cooling load.
(b) Local Return from Equipment
For equipment having high or concentrated heat dissipation loads, local return air
collection points are provided. These local return air collection points allow a higher
return air temperature than the room temperature. While this does not reduce the
total heat dissipation from the equipment, the heat dissipation to the room from the
equipment will reduce. Consequently the supply air flow rate required to be
supplied to the room will be lower.
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The measures described above will reduce equipment size and therefore the cost of the
system.
3.4.4 Based on the air distribution diagram, an air pressure diagram shall be prepared indicating
the air pressure at the inlet and outlet of each of the element in the air circuit as given
below.
(a) Start from the air-conditioned area for which the room over-pressure is defined as
per the input data collected or as per appendix 4.
(b) Proceed upstream along the air circuit towards the AHU. The pressure shall
increase progressively as the pressure drops in the individual elements in the air
path. Indicate the air pressure at the inlet and outlet of each of the elements in the air
path. The procedure shall be continued until the air circuit is completed. The
pressure drops to be considered in each of the elements are listed below. These
pressure drops are preliminary and shall be reconfirmed during further engineering,
with firm data from bidders and vendors. The pressure drop across the plenum
being negligible, may be ignored for the purpose of preliminary estimation.
(i) Volume control dampers : 3 mm WG
(ii) Filters in clogged condition
Pre-filters* : 12 mm WG
Fine filters* : 18 mm WG
HEPA filters* : 75 mm WG
(iii) Cooling coils* : 20 mm WG
(iv) Heating coils* : 10 mm WG
(v) Supply and return air ducting : 0.084 mm WG
per metre of duct length
(vi) Supply air outlets : 3 mm WG
(vii) Return air inlets : 2 mm WG
(viii) Pressure in area to be air-conditioned : 1 mm WG
(ix) Pressure in AHU room or at AHU inlet : (-) 3 mm WG
The differential pressure across the AHU inlet and outlet is the External Static Pressure
(ESP) for the AHU.
* Filters, cooling coils and heating coils are normally located within the AHU. Hence
pressure drops in these elements shall be considered for estimation of fan total static
pressure and motor rating. Pressure drops across these elements shall not be considered
for estimation of ESP for the AHU.
3.5 The guidelines for selection of suitable air-conditioning system for a particular
requirement or duty are given in the following paragraphs:
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3.5.1 Window Air-Conditioners
Window air-conditioning units are available in capacities of 0.75, 1.0, 1.5, 2.0 and 2.5TR.
Window units are generally preferred for comfort air-conditioning applications where
control on temperature within () 2
0
C is acceptable and no RH and dust control are
required. The units require access to an external wall for the air-cooled condenser cooling
and therefore for proper air distribution to be achieved, the units have to be located such
that a uniform distribution of air can be achieved in the room. Multiple units may be used
for larger rooms. These units are designed to provide a throw of about 8 metres when
mounted at an elevation of about 3 metres, which normally is the bottom of beam elevation
for buildings. Considering this limitation window units may be recommended for installation
where the room widths are restricted to 8 metres with one external wall or with about 16
metres with units mounted on external walls on opposite sides.
3.5.2 Split Air-Conditioners
Split air-conditioning units are available in capacities of 1.0, 1.5, 2.0, 2.5, 3.0, 4.0, 5.0,
7.5 and 8.5 TR. These units are air-cooled and are available as ductable or non-ductable
units. These units may be recommended for installation where the temperature control
between () 2
0
C is acceptable. The ductable units generally have dehumidified air blower
with ESP of 15 to 20 mmWG and their use for applications requiring fine filter installation,
which require higher ESP of about 35 to 40 mm WG, is not recommended. The non-
ductable units are available as decorative floor mounted or decorative or non-decorative
ceiling suspended or wall mounted units. These have in-built pre-filters and cannot be used
for applications requiring fine filters. Sufficient care shall be taken in selecting these units
and their installation to limit the refrigerant piping lengths to about 15 metres and ensuring
proper drainage of cooling coil condensate from the air-conditioned areas. To prevent
condensation on its surface, the condensate drain pipe shall be thermally insulated.
3.5.3 Packaged Air-Conditioners
Packaged air-conditioning units are available in nominal capacities of 5.0, 7.5, 10 and 15
TR. Nominal capacity is the Net Total Cooling Effect of a unit at temperature conditions
defined in IS 8148. These are ductable units and are available as water-cooled or air-
cooled units. Water-cooled units may be selected in case cooling water is available.
Alternatively, if cooling water is not available but make-up water is available, a dedicated
cooling water system comprising of cooling tower, cooling water pumps and inter-
connecting cooling water piping, may be selected. In case water is not available, air-cooled
units shall be selected. Refer relevant guides for the selection of the cooling tower and
cooling water pumps for the system.
These units may be used for applications having inside design conditions of temperature
between 22
0
C and 28
0
C with a tolerance of () 2
0
C and RH control between 50% to
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70% with tolerance of () 5%. These units are not suitable for temperature below 22
0
C
and RH below 50%.
Indigenous units available are generally for a dehumidified air blower ESP of about 25
mmWG. If specifically asked for, an ESP of 35 to 40 mmWG may also be available.
Considering this limitation, these units may be considered for applications requiring fine
filter installation, where duct lengths are restricted to match the available unit ESP. Special
imported precision type units are available with higher dehumidified air flow per TR than
those for standard applications. These units are intended for high sensible load applications,
e.g. computer and control rooms requiring stringent temperature and RH control. These
units are either in top or bottom discharge configuration. Special units are available for
capacities up to 25 TR and are equipped with in-built electric heaters and steam
humidifiers. Soft water is to be made available to the units for the steam humidifier.
The units are of standard construction, factory assembled and tested, mass-manufactured
and have shorter delivery periods, making them suitable for projects having short
schedules. The unit installation is relatively simple as skilled personnel are not required.
Packaged units are also available with in-built micro-processor based control panels which
display and monitor parameters such as current drawn, power consumption, temperature,
RH etc.
Multiple packaged units installation may be considered for cooling requirements up to 100
TR. Higher cooling capacity requirements may result in large number of units and
consequent higher installation and operating costs.
3.5.4 Central Direct Expansion (DX) Plant
DX plants comprise of a skid mounted compressor with drive motor, condenser
interconnected by refrigerant piping with an Air Handling Unit (AHU) located near the area
to be air-conditioned. The primary refrigerant expanding in the cooling coil, cools the air
which is supplied to the area to be air-conditioned, hence the name Direct Expansion
(DX).
These systems may be either water-cooled or air-cooled and may be used wherever the
cooling capacity requirements are beyond the range of packaged units with respect to
DBT, RH and ESP. The capacity of the condensing units ranges between 7 and 100 TR
for indigenously available equipment having single refrigerant circuit. The units may be
installed for low temperature applications like cold storage etc., with room temperatures of
about (-) 25
0
C. High ESP is generally not a limitation with these units as these units are
specially assembled for a specific application.
Multiple unit installations though technically possible may be avoided due to maintenance
and operation difficulties. The units along with the AHUs are generally assembled at site.
Special care has to be taken during design and installation of the refrigerant circuit so as to
ensure proper distribution to each of the units (AHUs or DX units) installed in parallel.
Unless proper suction and oil pressure equalisation is ensured, oil and refrigerant suction
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gas flooding or starving of the individual DX unit compressors of oil and refrigerant suction
gas may lead to major damage to the compressors.
3.5.5 Central Chilled Water or Brine Systems
The plant comprises of the water or brine chilling unit (hereafter referred as chillers), chilled
water or brine pumps, and chilled water or brine piping inter-connecting the chilled water
or brine AHUs. The AHUs may be located adjacent or near the area to be air-conditioned
while the chillers may be installed in the plant room located conveniently in the utility area
for ease of maintenance and operation. Two categories of chillers are commercially
available as described below:
(a) Vapour Compression Chillers
These systems comprise of compressor, condenser, evaporator and inter-connecting
refrigerant piping. The chillers with evaporator having water or brine on the shell side
is called a DX chiller, whereas those with water or brine on the tube side is called a
flooded chiller. These chillers use primary refrigerants like R22, R134a, R123 or
R717 (ammonia), to chill a relatively cheaper and dispensable secondary refrigerant
like water which is circulated to the cooling coils in the AHUs to cool the air supplied
to the air-conditioned area. Refrigerants R11 and R12 which were commonly used
and are still in operation, are Chloro-Fluoro-Carbons (CFCs) and their use is being
restricted as per Montreal Protocol.
These chillers are available in capacities of 5 TR and higher. However, it is preferred
to recommend these units for cooling loads of 100 TR and higher or where the loads
are distributed over a number of areas requiring individual air- conditioning units.
Vapour compression chillers are available with the following types of compressors:
(i) Reciprocating compressors
(ii) Screw compressors
(iii) Centrifugal compressors
Reciprocating compressors for a capacity range of 5 to 150 TR, screw compressors
from 100 to 500 TR and centrifugal compressors from about 100 to 2,500 TR are
indigenously available. These chillers are available in water-cooled or air-cooled
construction.
Centrifugal chillers are not recommended for installation where load fluctuations
cause low loads below 40% for extended periods. These chillers reach the surge
limit at about 40% of the rated capacity unless a hot gas bypass arrangement is
provided. This arrangement provides an artificial load on the chillers, limiting the
lowering of load on the chiller to about 40%. This method is not energy efficient and
may be avoided as far as possible.
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The units are available in open type or in hermetic construction i.e. a hermetic motor
drives the compressor. In case the temperature to be maintained in the air-
conditioned areas requires a secondary refrigerant at a temperature lower than 5
0
C a
pure liquid having a low freezing point or solution of water and brine is used as a
secondary refrigerant.
Screw chillers with lower specific power consumption at part loads as compared to
reciprocating or centrifugal chillers are available. However, these chillers may be
more expensive and the economics have to be studied before recommending for
installation.
(b) Vapour Absorption Chillers
Vapour absorption chillers or Vapour Absorption Machines (VAM) as they are
commonly known, are available between a capacity of 100 to 2,500 TR. VAM may
be steam, hot water or direct-fired machines operating on fuel oil or fuel gas. Steam
fired VAMs are available in double effect, requiring saturated steam at pressures of 3
to 8 Kg/cm
2
(g), or in single effect construction requiring steam pressures in the range
of 0.5 to 3 Kg/cm
2
(g). Direct oil fired chillers are available for capacities ranging
between 30 to 500 TR.
(c) A comparison of the various types of compressors available in these categories is
given in appendix 5.
(d) Types of Brines
Various types of brines normally used are given in the following table.
MAXIMUM
CONCENTRATION
LOWEST OPERATING
TEMPERATURE
SL.
NO.
NAME OF BRINE
% BY WEIGHT
0
C
REMARKS
1. Sodium chloride 23.00 (-) 25.0
2. Calcium chloride 29.87 (-) 50.0
3. Aqueous ethylene glycol 60.00 (-) 43.0
4. Aqueous propylene glycol 60.00 (-) 45.0
5. Methylene chloride Used as pure liquid (-) 96.7
6. Trichloroethylene Used as pure liquid (-) 86.1
7. Polydimethylsiloxane Used as pure liquid (-) 73.3
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8. d-limonene Used as pure liquid (-) 96.7
The operating temperatures for sodium chloride brine, calcium chloride brine,
aqueous ethylene glycol and aqueous propylene glycol are 5
0
C higher than their
freezing points. For concentrations exceeding 60% aqueous propylene glycol does
not have a freezing point but forms a glass (being an amorphous, under-cooled liquid
of extremely high viscosity having all the appearances of a solid). For further details
of the brines refer ASHRAE Handbook, Fundamentals may be referred.
The selection of brine shall be optimised wherever possible considering the process
requirements and the installation and operating costs. It is recommended that nitrogen
blanketing is provided for methylene chloride and trichloroethylene. Any other
specific requirements shall be examined and clearly indicated in the basic study.
(e) Various configurations of chilled water or brine systems are indicated in appendices
6 to 10. The relative merits of these configurations are given in appendix 11. The
configuration of the system shall indicate the number of pumps, their flow and head,
tanks and piping. The selection of the configuration shall be based on the relative
merits for the particular application.
3.6 Based on guidelines given in para 3.5 above, select a suitable system for the various areas.
The number of units may be selected considering the continuous minimum cooling load
available and also the economy of providing a standby unit. If more than one system could
be considered, carry out a brief economic analysis. Some of the features which may be
examined in the economic study to minimise installation and operating costs are as follows:
(a) Minimisation of the air-conditioning and refrigeration cooling load by use of better
insulation materials or building materials of construction, energy efficient lighting
systems etc.
(b) Optimum sizing of the equipment considering the maximum continuous total load on
the system rather than the total of peak individual loads which may not be
simultaneous. The optimum sizing of equipment may also be effected by use of
chemical dehumidifiers (for low RH applications so as to reduce the latent cooling
loads on the cooling coils), thermal storage systems like ice banks or chilled water or
brine storage tanks, to meet peak loads in a 24-hour cycle, etc. The thermal storage
arrangement is especially effective in case electrical tariffs are different during day
and night.
(c) Optimum selection of equipment considering the utilities available for the total project
configuration, so as to match the project philosophy. e.g. sizing of chillers so as to
restrict the motor rating within limits of 415 Volts power supply. This has to done in
consultation with the project electrical engineer.
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(d) Use of enthalpy control systems, which utilise the low outdoor air conditions
(temperature and enthalpy of air) to meet the refrigeration loads
(e) Use of heat-recovery systems, e.g. heat recovery wheels, variable speed drives to
minimise operating loads
A clear recommendation shall be made highlighting technical and commercial advantages of the
system proposed.
4.0 ENTHALPY CONTROL SYSTEM
4.1 The cooling load of an area to be air-conditioned is decided by the dimensions of the
building, its orientation, materials of construction and the internal heat loads etc. This
cooling load is imposed on the refrigeration system. The enthalpy control system utilises the
ambient air condition variation to minimise the cooling load of the area to be air-
conditioned. This system has been used very successfully for applications where the
internal loads are relatively high and the Effective Sensible Heat Factor (ESHF) is higher
than 0.9. The system operates in three (3) modes as described below:
(a) Mode 1
In this mode, the system draws fresh air at its design minimum requirement. This
could be the fresh air requirement for the maintenance of building pressurisation or
air quality in the area or by process requirements. The system operates in this
mode when the enthalpy of the outdoor air is at its maximum and is higher than the
room leaving air enthalpy. The load on the refrigeration system is at its maximum
during this mode.
(b) Mode 2
In this mode the system draws 100% fresh air. This mode operates when the
outdoor air enthalpy lies between the enthalpy of the air between the supply air
enthalpy and the room air enthalpy. The load on the refrigeration system varies
from close to the peak load to zero.
(c) Mode 3
In this mode, the system draws fresh air in a proportion varying from 100%
downwards to a value depending upon the ambient air enthalpy. This mode of
operation is primarily in the winter conditions when outdoor air enthalpy is lower
than the supply air enthalpy.
4.2 The proportion of the fresh air drawn is modulated, using automatic dampers, so as to have
a mixed air enthalpy equal to the supply air enthalpy. In Indian conditions it has been found
that the lowest fresh air intake in Mode 3 is still well above the minimum design fresh air
intake. In cases where the ambient air winter conditions are low and fresh air proportion to
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obtain mixed air enthalpy equal to supply air enthalpy, is lower than the minimum fresh air
requirement, the minimum fresh air may be drawn, re-heated and then passed through an air
washer to arrive at the supply air conditions. The operation of this system necessitates the
use of an air washer.
4.3 For the operation of the enthalpy control system, the supply air, return air and outdoor air
enthalpies are measured. Based on these measurements the controller calculates and
compares the air enthalpies and controls the position of fresh air, exhaust air and re-
circulation air automatic dampers to operate the system in each of the modes described
above.
4.4 The enthalpy control system has been used extensively for the air-conditioning systems for
synthetic fibre plants and can be used effectively for air conditioning systems for other
applications also, provided the economic study for the application permits the same.
4.5 Schematic diagram given below illustrates the process.
ZONE 1
ZONE 2
ZONE 3
ROOM
CONDITIONS
SUPPLY AIR
CONDITIONS
OUTDOOR
SUMMER/
MONSOON
CONDITIONS
OUTDOOR
WINTER
CONDITIONS
CONSTANT
ENTHALPY
LINE
DRY BULB TEMPERATURE
H
U
M
I
D
I
T
Y

R
A
T
I
O
AIR MIXTURE
CONDITIONS
SUMMER/
MONSOON
LOAD ON
COOLING
COIL
AIR MIXTURE
CONDITIONS
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5.0 HEAT RECOVERY SYSTEM
5.1 Another possible avenue for reduction of energy consumption is the effective use of heat
internal to the system. Heat recovery systems are being used for various applications in
HVAC systems, e.g. full fresh air systems and synthetic fibre plants etc. A typical case
study for such systems is discussed below:
5.2 For synthetic fibre plants the typical supply air conditions to the quench chamber and take-
up are typically as follows:
Quench air : 18C DB1C , 14C Dew point
Take-up : 20C DB 1C, 14C Dew point
The air supply for both quench and take-up require to be provided with reheat. The return
air from quench (which is collected in the spinning area) and take-up are generally
combined together to form a common return air. Typically, the return air temperature is
about 33 to 34C DB due to the high equipment load dissipation from the spinning
machinery.
The heat recovery system, installed in the plants, collects the sensible heat in the return air
and supplies it to the quench and take-up supply air, reducing the return air temperature to
about 28 to 29C. This is achieved by circulating a heat recovery medium, e.g. water at a
supply temperature of 26
0
C to quench and take-up supply air reheat coil. The water cools
to a temperature of about 23
0
C and is circulated to a heat recovery coil in the return air
path. The return air is cooled to about 29
0
C and the water heated to 26C. This water is
now re-circulated back to the quench and take-up heating coils completing the circuit. This
system has been used effectively for synthetic fibre plants. Schematic diagram given below
illustrates the process.
5.3
29C
RETURN AIR
26C
AIR-
WASHER
CHILLED
WATER
COOLING
COIL
20C
18C
23C
FILTER
FILTER
14C
SPINNING
AREA
QUENCH
AREA
TAKE-UP
AREA
RETUR
N AIR
RE-
CIRCULATION
EXHAUST DAMPER
SUPPLY AIR
FANS
SUPPLY
DAMPE
HEAT
RECOVERY
COILS
RE-CIRCULATION
PUMP
34C
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The use of heat recovery system for full fresh air air-conditioning applications has been
advocated and installed with satisfactory results.
6.0 OPERATION AND CONTROL SCHEME
Brief description of operation and control scheme of the proposed system shall be included
in the basic study. Project instrument engineer may be consulted, if necessary.
7.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS
As per National Building Code (NBC), a building having height more than 15 metres
above the surrounding ground level is called a High Rise Building. Following
requirements need to be incorporated while designing air-conditioning system for such a
building. While these requirements are mandatory for High Rise buildings, it is advisable
to follow these for any building.
7.1 Air-conditioning equipment except for window and split air-conditioners shall be
interlocked with fire detection and alarm system such that in case of fire, air-conditioning
equipment shall stop automatically.
7.2 For distribution of air, metallic ducts shall be provided.
7.3 Preferably, metallic ducts shall be provided for return air also, instead of using the space
above the false ceiling.
7.4 Non-combustible and fire retardant materials shall be used for the false ceiling and all
fixtures, if space above the false ceiling is used for return air.
7.5 Non-combustible and fire retardant materials shall be used for the acoustic and thermal
insulation of ducts and plenums.
7.6 Return air from areas like staircases and lift lobbies etc. shall not be taken to Air
Handling Units (AHUs) or AHU rooms.
7.7 If the air-conditioning duct passes through fire walls or floors, the open space around the
duct shall be sealed with fire resistant materials like asbestos rope or vermiculite
concrete etc.
7.8 Air-conditioning duct serving the main floor areas shall not be routed through the
staircase enclosure.
7.9 Preferably, separate AHUs and ducts shall be provided for each floor. Ducts for two
different floors shall not be interconnected.
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7.10 In case one AHU serves more than one floor, automatic fire dampers shall be provided
in both supply and return air ducts for isolation of ducts at every floor from the main riser
or downcomer.
7.11 Automatic fire dampers shall be provided in both supply and return air ducts at fire
separation walls
7.12 AHU fan shall be interlocked with automatic fire alarm system so that in case of fire, the
respective AHU fan is switched off automatically unless AHU is designed to exhaust the
smoke from the fire. In such a case, the AHU shall remain in operation in exhaust mode.
7.13 Non-combustible and fire retardant filter media shall be provided for air filters use in the
AHUs.
7.14 AHU room shall not be used for storage of any combustible material.
7.15 At appropriate locations, access doors shall be provided in the ducting to facilitate
maintenance of fire dampers.
7.16 If AHU room is located in the core of the building, the vertical shaft for the fresh air shall
be in masonry construction.
7.17 Each AHU shall serve maximum floor area of 750 square metres.
8.0 EQUIPMENT AND ELECTRICAL LOAD LIST
An appendix covering all equipment like window units, split units, packaged units, chillers,
AHUs, pumps, fans, blowers, tanks and vessels etc. with equipment tag numbers,
name/title/designation, major parameters, materials of construction and estimated ratings of
motor and other electric equipment shall be furnished in tabular form. Motor ratings may be
calculated as per the relevant design guides.
The motor rating would reflect the selected capacity of the equipment. While finalising per
unit capacity of equipment, available supply voltage is to be given due consideration. For
instance, while sizing the capacity for a water chilling unit of total requirement of 400TR,
considerations of heat load and recommended minimum reserve capacity may permit two
(2) alternatives namely:
(a) 2 X 400 TR capacity
centrifugal chillers
including 1 standby
- Calling for 325 KW motor rating with 15%
margin on BKW @ 0.7KW/TR
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(b) 4 X 135 TR capacity
reciprocating chillers
including 1 standby
- Calling for 150 KW motor rating with 15%
margin on BKW @ 0.9KW/TR
If power supply is available only at 415V, alternative (b) would be the preferred choice, as
motor rating is within the permitted 165KW limit for 415V supply voltage. The above shall
be decided in consultation with the project electrical engineer.
9.0 UTILITY AND SPACE REQUIREMENTS
Requirement of utilities like steam, cooling water, make-up water and instrument air with
the design parameters like flow rates, pressure, temperature and quality required at the
battery limit of the system shall be indicated in tabular form.
The space requirements and clear height for air-conditioning equipment plant rooms, and
for routing of ducting and piping etc. shall be indicated. Requirements of hoists, cranes and
monorails shall also be included. Preferably, a sketch giving the plant room layout shall be
included.
Bare bus-bars, conductors and electrical equipment shall not be located in areas where
there is a possibility of condensation of moisture and consequent malfunction.
10.0 PROCUREMENT STRATEGY
Proposed procurement strategy with number of enquiries and the scope for each shall be
clearly indicated.
TCE CONSULTING ENGINEERS LIMITED SECTION: APPENDIX
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APPENDIX 1
OUTSIDE DESIGN CONDITIONS OF IMPORTANT CITIES OF INDIA
(SOURCE: DB, WB And LAT. from Voltas Air-Conditioning and Refrigeration Engineers Handbook-I, 1995 Edition. RH (%)
read from ASHRAE Psychrometric Chart No. 1. Daily Range and Altitude from ISHRAE HVAC Handbook 1997.
Part I
SUMMER MONSOON WINTER
CITY
DAILY
RANGE
DB WB RH% DB WB RH% DB WB RH%
LAT(
0
N)
ALT.
FROM
MSL (M)
Agra
0
F
0
C
26
14.44
108
42.2
75
23.9
May
22 96
35.6
83
28.3
Jul
58 48
8.9
43
6.1
Jan
67 27.10
169
Ahmedabad
0
F
0
C
26
14.44
110
43.3
78
25.6
May
24 90
32.2
85
29.4
Jul
82 60
15.6
51
10.6
Dec
54 23.02
55
Ahmednagar
0
F
0
C
29
16.11
108
42.2
75
23.9
May
22 101
38.3
88
31.1
Jun
60 50
10
43
6.1
Jan
55 19.05
657
Ajmer
0
F
0
C
22
12.22
108
42.2
74
23.3
May
20 93
33.9
81
27.2
Aug
60 45
7.2
39
3.9
Jan
59 26.27
486
Aligarh
0
F
0
C
26
14.44
108
42.2
75
23.9
May
22 96
35.6
83
28.3
Jul
58 48
8.9
43
6.1
Jan
67 27.53
169
Allahabad
0
F
0
C
26
14.44
110
43.3
76
24.4
May
21 96
35.6
83
28.3
Jul
58 48
8.9
46
7.8
Jan
87 25.27
98
Ambala
0
F
0
C
29
16.11
110
43.3
75
23.9
Jun
20 95
35.0
80
26.7
Jul
52 45
7.2
41
5.0
Jan
70 30.23
272
Asansol
0
F
0
C
23
12.78
108
42.2
78
25.6
May
26 90
32.2
86
30.0
Jul
85 52
11.1
44
6.7
Jan
52 23.41
126
Aurangabad
0
F
0
C
27
15.00
104
40.0
76
24.4
May
29 90
32.2
80
26.7
Jul
65 55
12.8
48
8.9
Dec
60 19.53
581
Bangalore
0
F
0
C
22
12.22
96
35.6
78
25.6
Apr
45 82
27.8
78
25.6
Sep
82 58
14.4
54
12.2
Jan
78 12.58
921
Belgaum
0
F
0
C
29
16.11
100
37.8
77
25.0
Apr
35 82
27.8
77
25.0
Jul
80 58
14.4
53
11.7
Jan
71 15.51
753
Bellary
0
F
0
C
23
12.78
105
40.6
77
25.0
May
28 94
34.4
78
25.6
Sep
50 65
18.3
59
15.0
Dec
70 15.09
449
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Bhopal
0
F
0
C
26
14.44
106
41.1
73
22.8
May
20 92
33.3
83
28.3
Jul
69 45
7.2
38
3.3
Jan
50 23.16
523
APPENDIX 1 (CONTD.)
CITY
DAILY
RANGE
LAT(
0
N)
ALT
FROM
MSL (M)
Bhubaneshwar
0
F
0
C
20
11.11
100
37.8
82
27.8
May
46 90
32.2
86
30.0
Aug
85 56
13.3
48
8.9
Jan
55 20.15
27
Calcutta
0
F
0
C
20
11.11
100
37.8
83
28.3
May
49 90
32.2
86
30.0
Jul
85 56
13.3
48
8.9
Dec
55 22.32
6
Calicut
0
F
0
C
96
35.6
82
27.8
May
55 85
29.4
82
27.8
Jul
88 72
22.2
65
18.3
Jan
69 11.15
Chanda
0
F
0
C
26
14.44
115
46.1
75
23.9
May
15 88
31.1
80
26.7
Jul
70 55
12.8
49
9.4
Dec
65 19.58
193
Chennai
0
F
0
C
18
10.00
103
39.4
82
27.8
May
41 83
28.3
80
26.7
Nov
88 65
18.3
57
13.9
Jan
60 13.04
16
Cochin
0
F
0
C
10
5.56
95
35.0
82
27.8
Apr
58 85
29.4
82
27.8
Jul
88 72
22.2
65
18.3
Jan
69 9.58
3
Coimbatore
0
F
0
C
23
12.78
98
36.7
76
24.4
May
37 82
27.8
75
23.9
Oct
72 65
18.3
57
13.9
Dec
60 11.00
409
Cuttack
0
F
0
C
21
11.67
105
40.6
82
27.8
May
37 90
32.2
86
30.0
Aug
85 56
13.3
48
8.9
Jan
55 20.29
27
Dehradun
0
F
0
C
26
14.44
105
40.6
75
23.9
Jun
25 90
32.2
80
26.7
Aug
65 42
5.6
38
3.3
Jan
70 30.19
682
Dibrugarh
0
F
0
C
11
6.11
90
32.2
78
25.6
Jun
59 82
27.8
78
25.6
Jul
84 52
11.1
51
10.6
Jan
95 27.28
106
Durgapur
0
F
0
C
23
12.78
108
42.2
78
25.6
May
26 90
32.2
86
30.0
Jul
85 52
11.1
44
6.7
Jan
52 23.14
100
Gaya
0
F
0
C
25
13.89
110
43.3
74
23.3
May
18 90
32.2
84
28.9
Aug
78 50
10.0
44
6.7
Jan
62 24.49
116
TCE.M1-ME-811-301
SHEET 18 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 1 (CONTD.)
CITY
DAILY
RANGE
LAT(
0
N)
ALT
FROM
MSL (M)
Goa
0
F
0
C
9
5.00
90
32.2
82
27.8
Apr
70 84
28.9
81
27.2
Jun
88 65
18.3
60
15.6
Jan
76 15.25
62
Guwahati
0
F
0
C
11
6.11
90
32.2
78
25.6
Apr
59 88
31.1
82
27.8
Jul
78 52
11.1
47
8.3
Jan
70 26.11
55
Hyderabad
0
F
0
C
14
7.78
106
41.1
78
25.6
May
28 85
29.4
81
27.2
Sep
82 55
12.8
48
8.9
Dec
60 17.86
545
Indore
0
F
0
C
30
16.67
106
41.1
77
25.0
May
27 90
32.2
82
27.8
Jul
70 50
10.0
45
7.2
Jan
69 22.43
567
Jabalpur
0
F
0
C
29
16.11
108
42.2
75
23.9
May
25 93
33.9
84
28.9
Jul
69 45
7.2
41
5.0
Dec
70 23.16
393
Jaipur
0
F
0
C
27
15.00
110
43.3
75
23.9
May
20 95
35.0
78
25.6
Aug
48 46
7.8
41
5.0
Jan
65 26.27
390
Jamnagar
0
F
0
C
20
11.11
100
37.8
80
26.7
May
43 85
29.4
81
27.2
Jul
84 55
12.8
49
9.4
Dec
65 22.29
23
Jamshedpur
0
F
0
C
27
15.00
110
43.3
78
25.6
May
24 90
32.2
84
28.9
Aug
78 50
10.0
46
7.8
Dec
75 22.49
129
Jhansi
0
F
0
C
26
14.44
111
43.9
76
24.4
May
20 97
36.1
84
28.9
Jul
58 48
8.9
45
7.2
Jan
80 25.27
251
Jodhpur
0
F
0
C
29
16.11
110
43.3
77
25.0
May
23 95
35.0
80
26.7
Aug
52 46
7.8
39
3.9
Jan
52 26.18
224
Kakinada
0
F
0
C
18
10.00
103
39.4
82
27.8
May
41 83
28.3
80
26.7
Oct
88 65
18.3
57
13.9
Jan
60 16.57
8
Kalyan
0
F
0
C
15
8.33
100
37.8
82
27.8
Apr
47 86
30.0
83
28.3
Jul
86 65
18.3
58
14.4
Jan
65 18.54
10
Kanpur
0
F
0
C
29
16.11
109
42.8
77
25.0
May
23 97
36.1
84
28.9
Jul
58 45
7.2
42
5.6
Jan
75 26.26
126
Kathmandu
0
F
0
C
31
17.22
85
29.4
75
23.9
May
63 76
24.4
71
21.7
Jul
79 45
7.2
42
5.6
Jan
78 27.42
1324
TCE.M1-ME-811-301
SHEET 19 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 1 (CONTD.)
CITY
DAILY
RANGE
LAT(
0
N)
ALT
FROM
MSL (M)
Kota
0
F
0
C
27
15.00
113
45.0
75
23.9
May
17 99
37.2
80
26.7
Jul
44 45
7.2
41
5.0
Jan
70 25.11
257
Kurnool
0
F
0
C
23
12.78
108
42.2
80
26.7
May
30 93
33.9
81
27.2
Sep
60 60
15.6
53
11.7
Dec
62 15.50
281
Lucknow
0
F
0
C
30
16.67
109
42.8
79
26.1
May
26 94
34.4
83
28.3
Aug
64 48
8.9
43
6.1
Jan
67 26.52
111
Madurai
0
F
0
C
20
11.11
101
38.3
78
25.6
May
36 94
34.4
78
25.6
Oct
49 68
20.0
62
16.7
Jan
72 9.55
133
Mangalore
0
F
0
C
11
6.11
96
35.6
82
27.8
May
55 85
29.4
82
27.8
Jul
88 70
21.1
64
17.8
Jan
72 12.52
22
Meerut
0
F
0
C
110
43.3
75
23.9
May
20 95
35.0
83
28.3
Aug
60 45
7.2
41
5.0
Jan
70 28.35
Mumbai
0
F
0
C
12
6.67
95
35.0
83
28.3
Apr
60 85
29.4
82
27.8
Jul
88 65
18.3
58
14.4
Jan
65 18.54
11
Mysore
0
F
0
C
21
11.67
100
37.8
78
25.6
Apr
38 85
29.4
77
25.0
Oct
69 66
18.9
60
15.6
Dec
70 12.18
767
Nagpur
0
F
0
C
26
14.44
112
44.4
76
24.4
May
18 85
29.4
81
27.2
Jul
82 60
15.6
52
11.1
Dec
58 21.09
310
Nellore
0
F
0
C
22
12.22
108
42.2
83
28.3
May
35 94
34.4
82
27.8
Nov
60 65
18.3
57
13.9
Jan
61 14.27
20
New Delhi
0
F
0
C
25
13.89
110
43.3
75
23.9
May
20 95
35.0
83
28.3
Aug
60 45
7.2
41
5.0
Jan
70 28.35
216
Ootacamund
0
F
0
C
22
12.22
73
22.8
60
15.6
May
48 66
18.9
Jul -
58
14.4
Oct
62 38
3.3
33
0.6
Dec
60 11.24
2249
Patna
0
F
0
C
26
14.44
108
42.2
78
25.6
May
26 90
32.2
84
28.9
Aug
78 50
10.0
44
6.7
Jan
62 25.37
53
TCE.M1-ME-811-301
SHEET 20 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 1 (CONTD.)
CITY
DAILY
RANGE
LAT(
0
N)
ALT
FROM
MSL (M)
Pune
0
F
0
C
31
17.22
104
40.0
76
24.4
Apr
28 83
28.3
79
26.1
Jul
82 50
10.0
42
5.6
Dec
50 18.32
559
Raichur
0
F
0
C
107
41.7
79
26.1
May
29 93
33.9
82
27.8
Sep
62 60
15.6
54
12.2
Dec
69 16.12
Raipur
0
F
0
C
25
13.89
110
43.3
77
25.0
May
22 92
33.3
83
28.3
Jul
68 50
10.0
45
7.2
Dec
70 21.14
298
Ranchi
0
F
0
C
27
15.00
100
37.8
82
27.8
May
46 84
28.9
78
25.6
Jul
76 48
8.9
42
5.6
Jan
60 23.23
655
Rentachintala
0
F
0
C
110
43.3
83
28.3
May
32 94
34.4
82
27.8
Oct
60 55
12.8
49
9.4
Dec
65 16.33
Rourkela
0
F
0
C
28
15.56
110
43.3
78
25.6
May
25 87
30.6
82
27.8
Jul
81 54
12.2
44
6.7
Dec
41 21.28
148
Salem
0
F
0
C
18
10.00
103
39.4
80
26.7
May
38 93
33.9
77
25.0
Oct
49 65
18.3
59
15.0
Jan
70 11.39
278
Sambalpur
0
F
0
C
28
15.56
110
43.3
78
25.6
May
25 87
30.6
82
27.8
Jul
81 54
12.2
44
6.7
Dec
41 21.28
148
Shillong
0
F
0
C
14
7.78
85
29.4
71
21.7
Apr
50 74
23.3
70
21.1
Jun
82 38
3.3
32
0.0
Jan
50 25.34
1500
Sholapur
0
F
0
C
27
15.00
108
42.2
77
25.0
May
25 92
33.3
82
27.8
Sep
65 55
12.8
47
8.3
Jan
55 17.40
479
Thane
0
F
0
C
15
8.33
100
37.8
82
27.8
Apr
47 86
30.0
83
28.3
Jul
86 65
18.3
58
14.4
Jan
65 18.54
10
Thiruchirapalli
0
F
0
C
20
11.11
104
40.0
81
27.2
May
38 95
35.0
81
27.2
Oct
55 70
21.1
64
17.8
Jan
72 10.49
88
Thiruvanan-
thapuram
0
F
0
C
15
8.33
92
33.3
80
26.7
Mar
59 85
29.4
80
26.7
Jun
80 72
22.2
65
18.3
Jan
69 8.29
64
Vadodara
0
F
0
C
26
14.44
110
43.3
78
25.6
May
24 88
31.1
79
26.1
Jul
68 50
10.0
43
6.1
Jan
55 22.18
34
TCE.M1-ME-811-301
SHEET 21 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 1 (CONTD.)
CITY
DAILY
RANGE
LAT(
0
N)
ALT
FROM
MSL (M)
Varanasi
0
F
0
C
29
16.11
109
42.8
76
24.4
May
25 94
34.4
83
28.3
Aug
64 50
10.0
47
8.3
Jan
80 25.18
76
Vijaywada
0
F
0
C
24
13.33
110
43.3
83
28.3
May
32 94
34.4
82
27.8
Oct
60 55
12.8
49
9.4
Dec
65 16.33
106
Visakhapatnam
0
F
0
C
11
6.11
92
33.3
82
27.8
May
65 87
30.6
82
27.8
Oct
81 65
18.3
57
13.9
Jan
60 17.42
3
TCE.M1-ME-811-301
SHEET 22 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
W
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TCE.M1-ME-811-301
SHEET 23 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
ISSUE
R5
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TCE.M1-ME-811-301
SHEET 24 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
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TCE.M1-ME-811-301
SHEET 25 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 4
DEFAULT VALUES FOR SOME DESIGN PARAMETERS
1.0 LIGHTING LOADS
DESCRIPTION OF THE AREA Watts/M
2
Office areas 15
Control rooms, Laboratories 20
Manufacturing areas :
Pharmaceutical areas 30
Machine, Assembly, Press shops 20
Commercial areas, Show rooms 50
Computer rooms 30
2.0 OCCUPANCY
DESCRIPTION OF THE AREA M
2
/PERSON
Office areas 5
Auditorium 2
Conference rooms 2.5
Manufacturing areas 10
3.0 FRESH AIR AND EXHAUST AIR REQUIREMENTS
DESCRIPTION OF THE AREA NUMBER OF AIR
CHANGES PER HOUR
M
3
/Hr PER
PERSON
Control rooms 1 -
Office areas 1 34
Pharmaceutical areas 4.5 to 6 -
Commercial areas, Show rooms,
Public areas
2 air changes per hour or 25 M
3
/Hr per
person whichever is higher
Auditoriums 2 air changes per hour or 25 M
3
/Hr per
Conference rooms 2 air changes per hour or 42.5 M
3
/Hr per
NOTES
1. The fresh air requirement for pharmaceutical areas which require to be over-
pressurised is dictated by the pressurisation requirements and is to be calculated
from the air flow leakage through the door and window cracks and openings.
TCE.M1-ME-811-301
SHEET 26 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 4 (CONTD.)
4.0 FILTRATION AND CLEANLINESS
4.1 Control rooms and Laboratories
(a) Pre-filters with filtering efficiency of 90% down to a particle size of 20 microns as
per IS 7613 test dust G2.
(b) Fine filters with filtering efficiency of 99% down to a particle size of 5 microns as
per IS 7613 test dust G3.
4.2 Office areas and areas air-conditioned for comfort Pre-filters as per para 4.1(a).
5.0 OVER-PRESSURE
5.1 Comfort Air-Conditioning
Pressurisation to correspond to that achieved by the amount of fresh air taken into the
system.
5.2 Industrial Air-Conditioning
5.2.1 Pharmaceutical : 1 mmWG differential pressure between adjacent areas.
5.2.2 In certain areas negative differential pressure may be required to be maintained with
respect to the adjacent areas to ensure against cross contamination.
5.2.3 Synthetic Fibre Plants
(a) Quench air : 30 to 80 mmWG
(b) Spinning areas : 1.5 to 2 mmWG
5.3 Control Rooms and Laboratories : 1 mmWG
6.0 CIVIL CONSTRUCTION DETAILS
6.1 External walls out of 230 mm thick ordinary brick with 20 mm and 15 mm thick sand
cement plaster on outer and inner wall surfaces respectively.
6.2 Internal walls out of 115 mm thick ordinary brick with 15 mm thick sand cement plaster
on both sides of the wall.
6.3 Floor slab out of 100 mm thick RCC of density 2,500 Kg/M
3
with 25 mm thick sand
cement mortar and 25 mm thick ceramic tile on the top. No plaster shall be considered
for the bottom surface of the floor slab.
TCE.M1-ME-811-301
SHEET 27 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 4 (CONTD.)
6.4 Roof slab out of 100 mm thick RCC of density 2,500 Kg/M
3
with asphalt roll water
proofing on top. No plaster shall be considered for the bottom of the roof slab.
Underdeck insulation out of 50 mm thick expanded polystyrene with thermal conductivity
of 0.034 W/M
0
C.
6.5 Glass for doors and windows shall be considered to be out of ordinary single glass pane.
For windows venetian blinds shall be considered.
6.6 False ceiling out of aluminium panels size 610 mm x 610 mm size. The false ceiling grid
shall be located centrally in the room.
TCE.M1-ME-811-301
SHEET 28 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
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TCE.M1-ME-811-301
SHEET 29 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
V
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TCE.M1-ME-811-301
SHEET 30 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 5 (CONTD.)
NOTES
1. Vapour compression chillers and VAMs are suitable only for water chilling duty down to a
temperature of 5
0
C. It is possible theoretically to design water chilling units for a chilled
water outlet temperature of 4
0
C. During operation of the chiller the refrigerant suction
pressure and consequently the refrigerant evaporating pressure in the evaporator may vary
considerably with the variation in the cooling load on the chiller. At low load conditions
the evaporating pressure may drop well below the freezing point of water in the chiller. If
this manner of the operation is persisted for an extended period, it may cause icing and
severe damage to the evaporator due to rupture of tubes because of the expansion of ice
trapped within the tube spaces for DX chillers or within the tubes in case of flooded
chillers. Therefore for temperatures below 5
0
C, brine reciprocating or screw compressor
chilling units are recommended.
2. The cooling water flow rate and power consumption for the chillers are indicated for
cooling water inlet and outlet temperature 32 and 35.7
0
C and chilled water inlet and outlet
temperatures of 6 and 11
0
C respectively. For air-cooled chillers the power consumption
for Mumbai outdoor design conditions i.e. 35
0
C DBT, would be 15 to 20% higher than
that for water-cooled chillers. The power consumption for air-cooled chillers for ambient
DBT other than 35
0
C shall be estimated from vendor data or from the Molier diagram for
the refrigerant used for the chiller.
TCE.M1-ME-811-301
SHEET 31 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 6
CHILLED WATER/BRINE CLOSED LOOP
SINGLE PUMPING SYSTEM
(ALTERNATIVE 1)
CHILLER
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
E

R
E
T
U
R
N

H
E
A
D
E
R
CHILLED WATER/BRINE PUMP
CHILLED WATER/BRINE EXPANSION TANK
LOCATED ABOVE THE ELEVATION OF
HIGHEST CONSUMER
MAKE-UP AND
QUICK FILL LINE
CONSUMER
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
E

S
U
P
P
L
Y

H
E
A
D
E
R
CONSUMER
TCE.M1-ME-811-301
SHEET 32 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 7
CHILLED WATER/BRINE CLOSED LOOP
(ALTERNATIVE 2)

CHILLER
CONSUMER
CHILLED WATER/BRINE PUMPS
CONSUMER
CONSUMER
CONSUMER CONSUMER
CONSUMER
CHILLED WATER/BRINE EXPANSION TANK
LOCATED ABOVE THE ELEVATION OF
HIGHEST CONSUMER
MAKE-UP AND
QUICK FILL LINE
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
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R
E
T
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R
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A
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I
N
E

S
U
P
P
L
Y

H
E
A
D
E
R
TCE.M1-ME-811-301
SHEET 33 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 8
CHILLED WATER/BRINE OPEN LOOP
(ALTERNATIVE 1)
CHILLER
CONSUMER
CHILLED WATER/BRINE PUMP
MAKE-UP
AND
QUICK FILL
CHILLED WATER/
BRINE STORAGE TANK
CONSUMER
CONSUMER
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
E

S
U
P
P
L
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H
E
A
D
E
R
C
H
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L
L
E
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W
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E
R
/
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I
N
E

R
E
T
U
R
N

H
E
A
D
E
R
TCE.M1-ME-811-301
SHEET 34 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 9
(ALTERNATIVE 2)

CHILLER
CONSUMER
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
E

R
E
T
U
R
N

H
E
A
D
E
R
CHILLED WATER/BRINE PUMPS
CONSUMER
CONSUMER
CONSUMER CONSUMER
CONSUMER
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
E

S
U
P
P
L
Y

H
E
A
D
E
R
MAKE-UP AND
QUICK FILL LINE
CHILLED WATER/BRINE
STORAGE TANK
TCE.M1-ME-811-301
SHEET 35 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
APPENDIX 10
DOUBLE PUMPING SYSTEM

OVERFLOW
COLD WELL HOT WELL

CHILLER
CONSUMER
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
E

R
E
T
U
R
N

H
E
A
D
E
R

(
T
Y
P
)
CHILLED WATER/BRINE
PRIMARY PUMPS
CONSUMER
CONSUMER
CONSUMER CONSUMER
CONSUMER
MAKE-UP AND
QUICK FILL LINE
CHILLED WATER/BRINE
STORAGE TANK
CHILLED WATER/BRINE
SECONDARY PUMPS
C
H
I
L
L
E
D

W
A
T
E
R
/
B
R
I
N
E

S
U
P
P
L
Y

H
E
A
D
E
R

(
T
Y
P
)
TCE.M1-ME-811-301
SHEET 36 OF 35
TCE FORM NO. 120 R1
ISSUE
R5
R
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TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET i OF iii
ISSUE
PPD. BY RMM Sd/- HRK Sd/- IYM Sd/- IYM
CHD. BY SCM/SJB Sd/-/Sd/- PRJ Sd/- PRJ Sd/- PRJ
APD. BY DHNR Sd/- RL Sd/- RL Sd/- RL
DATE 29.12.1980 12.10.1999 19.04.2001 22.08.2003
R3
TCE FORM NO. 020R2
VENTILATION SYSTEM
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET i OF iii
ISSUE
PPD. BY RMM Sd/- HRK Sd/- IYM Sd/- IYM
CHD. BY SCM/SJB Sd/-/Sd/- PRJ Sd/- PRJ Sd/- PRJ
DATE 29.12.1980 12.10.1999 19.04.2001 22.08.2003
R3
TCE FORM NO. 020R2
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET ii OF iii
TCE FORM NO. 120R1
ISSUE
R3
CONTENTS
1.0 SCOPE 1
2.0 INPUT DATA 1
3.0 SYSTEM DESIGN AND SELECTION 2
4.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS 9
5.0 OPERATION AND CONTROL SCHEME 10
6.0 EQUIPMENT AND ELECTRICAL LOAD LIST 10
7.0 UTILITY AND SPACE REQUIREMENTS 11
8.0 PROCUREMENT STRATEGY 11
APPENDICES
1. LIST OF AREAS NORMALLY VENTILATED 12
2. OUTSIDE DESIGN CONDITIONS OF IMPORTANT CITIES OF
INDIA
13
3. DEFAULT VALUES FOR SOME DESIGN PARAMETERS 18
TCE.M1-ME-811-302
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REVISION STATUS
R0 29.12.1980 ----------------
R2 19.04.2001 Paras 3.4.1 and 3.11 modified. Appendix 4 added.
R3 22.08.2003 Para 4.0 added. Para 3.11 of R2 issue merged with Para 4.0
of R3 issue. Paras 3.4.1 and 3.10.1 of write-up and para 4.4
of Appendix 3 revised. Appendix 4 deleted.
TCE.M1-ME-811-302
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1.0 SCOPE
This document gives guidelines for carrying out a basic study for ventilation system for
chemical, industrial and power plants. For format, structure and other guidelines refer
TCE.M9-PCS-25. The basic study shall form the basis for procurement and detailed
engineering of the ventilation system.
2.0 INPUT DATA
collaborator, other groups in the mechanical department, other departments, bidders and
vendors.
2.1 Location of the site
2.3 Names of areas to be ventilated
2.4 Equipment layout drawings of the areas to be ventilated
2.5 Architectural drawings and civil Reinforced Cement Concrete (RCC) or structural steel
drawings of the areas to be ventilated
2.6 Outside design conditions like Dry Bulb Temperature (DBT), Wet Bulb Temperature
(WBT) and Relative Humidity (RH) for summer, monsoon and winter and daily
temperature range
2.7 The prevailing wind direction and speed for most time of the year
2.8 Inside design conditions indicating the DBT and RH for each of the areas to be ventilated
2.9 Lighting loads
2.10 Sensible and latent equipment heat loads, of heat sources within and adjacent to the
ventilated areas with specific periodic loading patterns, if any. The local concentration of
these loads, if any, is particularly important and shall be obtained.
2.11 Occupancy in the ventilated areas and the type of human activity envisaged
2.12 Supply air and exhaust air requirements, if any
2.13 Filtration and cleanliness requirements, if any
2.14 Pressurisation requirements, if any
2.15 Air flow pattern requirements, if any
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2.16 Acceptable noise and vibration levels
2.17 Hazardous area classification
2.18 Duration of working of the ventilation system for each of the areas
2.19 Availability of soft or filtered water, make-up water, quality of water, inlet and outlet
Some of the input data indicated above may not be readily available at the time of the
preparation of the basic study. Appendices of this document give guidelines for assuming
such data. These appendices are based on published literature and experience gained
over the years.
3.0 SYSTEM DESIGN AND SELECTION
3.1 Ventilation is required to be provided for:
(a) Removing heat from the working areas so as to maintain the temperature within
acceptable limits
(b) Removing toxic vapour generated by process equipment or components so as to
maintain their concentration within acceptable limits
(c) Removing hazardous vapour emitted or leaking from process equipment or
components so as to maintain their concentration within acceptable limits
(d) Removing obnoxious fumes, vapour, odour etc. from process equipment or
components so as to maintain their concentration within acceptable limits
Recovery of recyclable volatile substances or powders either leaking from or
emitted by process equipment or components. The details of these systems are not
covered in this basic study guide.
For details of recyclable powders refer Industrial Ventilation - A Manual of
Recommended Practice - 1980 edition.
The selection of type of recovery system for recyclable volatile substances shall be
studied and decided on a case to case basis considering the requirements of the
process and properties of the substances.
3.2 Ventilation load calculations shall be carried out as per TCE.M6-ME-811-309 Design
Guide for Ventilation Heat Load Calculations. The air flow requirements and any special
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requirements for the ventilated area shall be indicated by the load calculations. Following
paragraphs describe various types of ventilation systems.
3.3 NATURAL VENTILATION
This can be achieved by providing adequate wall openings, windows and doors so as to
allow free air movement and cross ventilation due to wind pressures. Natural ventilation is
also possible where the height of the buildings is sufficiently large with a temperature
difference adequate to provide the driving force for the air movement. Refer TCE.M6-
ME-811-317 Design Guide for Natural Ventilation for details.
3.4 FORCED VENTILATION
These systems comprise of fans, air distribution system, filters etc. Various types of
systems are described in para 3.6. The types of fans used in ventilation systems are
described in the following sub-paras and estimation of fan static pressure is covered in
para 3.5.
3.4.1 Propeller fans
These fans are generally mounted on the wall and are designed for low static pressures
upto 12.5 mmWG. Propeller fans are not suitable where the air is required to be
distributed by an air distribution system consisting of filters, ducting, supply or return air
grills, volume control dampers etc. These fans are available in the capacity range from 500
to about 23,500 M
3
/Hr. The capacity of 23,500 M
3
/Hr is at a static pressure 2.5 mm
WG. The fan impeller sizes generally range from 200 to 900 mm in diameter.
3.4.2 Tube-Axial Fans
These fans are axial flow fans, which can generate static pressures up to 40 mm WG.
Special fans with variable pitch angle for the blades and variable speed can be designed
for higher static pressures and air flow control, but these are more expensive and
economical only for large capacities of the order of 2,00,000 M
3
/Hr and larger. Tube
axial fans are generally specified for pressurised ventilation systems where the ventilated
area is to be supplied with filtered air to maintain a dust-free environment. Tube axial fans
are available in the capacity range from about 3,000 to 1,50,000 M
3
/Hr, with a static
pressure of 5 to 110 mm WG. The impeller diameters for these capacities range from 300
to 2,000 mm or more. The fan selection shall ensure that fan motor synchronous speeds
do not exceed 1,500 RPM for impeller diameters up to 450 mm and 1,000 RPM for
impeller diameters greater than 450 mm.
Tube axial fans are generally noisier than propeller or centrifugal fans. These fans shall be
selected for operating speeds within the speed limits given above so as to ensure that
noise levels are maintained within acceptable limits. The efficiency of tube axial fans is
generally lower than that of centrifugal fans and considering that the noise level also is
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generally much higher, it is recommended that tube axial fan static pressures be limited to
40 mm WG.
A variation of this fan configuration is the roof extractor, which is primarily a tube axial fan
provided with a hood for protection from the rain or sunshine. Roof extractors are
available in the capacity range of 5,000 to 45,000 M
3
/Hr with static pressure upto 7 mm
WG.
3.4.3 Centrifugal Fans
These fans are used for applications requiring fan static pressures of 40 mmWG and
higher. The impellers for these fans may be of the following types:
(a) Airfoil Backward Curved Vanes
These fans have non-over loading characteristics and have the highest efficiency of
all types of centrifugal impeller types.
(b) Backward Curved or Inclined Vanes
These impellers like airfoil backward curved vanes have non-overloading
characteristics and efficiencies only slightly lower than airfoil vanes. These fans are
relatively cheaper than airfoil impeller fans and are generally preferred over other
types of impellers.
(c) Forward Curved or Inclined Vanes
These fans are generally used for smaller capacities upto about 1,000 M
3
/Hr or for
static pressures of 75 mm WG or less. These fans are also used for AHUs. The
motor rating shall be at least 15% above the power requirement at duty point or
10% higher than the maximum power requirement at selected speed whichever is
higher, considering that the power consumption rises continuously from shut-off to
free delivery.
(d) Radial Vanes
These fans are generally used in material handling applications or for applications
requiring high static pressure of around 1,000 mm WG, e.g. fans for vacuum
cleaning system. These fans are generally not used for ventilation applications.
Centrifugal fans can be Single Inlet-Single Width (SISW) or Double Inlet- Double Width
(DIDW). These fans are generally belt driven by an electric motor drive.
SISW fans have a single impeller with air intake from one side of the fan casing with the
fan drive arrangement located on the other side of the casing. The process gas or air
handled may be ducted to the inlet of the fan; i.e. the fan may be used for systems where
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the process gas or air to or from the process or ventilated area is ducted to the fan
suction. This is advantageous, as the drive motor for this fan is completely external to the
fan gas circuit and can be approached for routine maintenance without exposure to the
gas. The single impeller of the SISW fan necessitates a thrust bearing to take care of the
thrust generated by the one-sided air intake.
DIDW fans are provided with a double impeller placed back-to-back, allowing air intake
from both sides of the fan casing. As a result of this configuration, the process air or gas
cannot be ducted to the DIDW fan inlet due to the drive arrangement being located on
either of sides of the casing. The DIDW fans along with the belt drive and motor
necessarily have to be located within the process gas or ventilated air stream. Due to the
air intake from both sides of the casing, DIDW fans are balanced as compared to SISW
fans, obviating the need for thrust bearings and resulting in relatively lower maintenance.
For a given air flow and static pressure the impeller diameter for DIDW fans is smaller,
having a smaller height but larger floor space as compared to SISW fans. For
commercially available fans, SISW fans generally have an efficiency about 5% to 20%
higher than that for DIDW fans, depending upon the capacity and static pressure and
outlet velocity selected for the fan. As compared to SISW fans, which are ducted at the
intake, for DIDW fans, the fan heat gain to the process air or gas may be as much as 18%
higher than the fan brake power. The break-up of this heat gain is given in the table at the
end of this para.
The type of fan whether SISW or DIDW may be selected considering the above and the
requirements of the particular application.
Centrifugal fans are available for a capacity range from 500 to 400,000 M
3
/Hr or higher,
with static pressures ranging from 40 to 4,000 mm WG.
SL. NO. ITEM
HEAT GAIN (%
OF FAN BKW)
REMARKS
1. Fan efficiency 5* * Assumed for the purpose of this
table
2. Belt drive loss to
process air
3 For DIDW fans the belt drive
package, i.e. the belts, pulleys etc.,
and the fan motor are located in the air
or gas stream.
3. Motor heat loss 10 Heat loss from motor corresponds to
a motor efficiency of about 90 %
Total heat gain 18 -
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3.5 FAN STATIC PRESSURE
An air circuit diagram shall be prepared in line with the anticipated ducting layout
configuration of the ventilated area, indicating the air pressure at the inlet and outlet of
each of the elements like fans, louvers with bird screen, ducting, supply and exhaust air
grills, volume control dampers, plenums etc., in the air circuit as follows:
(a) Start from the ventilated area for which the room over-pressure is defined as per
the data collected or as per appendix 3 of this guide.
(b) Proceed upstream along the air circuit towards the fan. The pressure will increase
progressively as the pressure drops in the individual elements in the air path.
Indicate the air pressure at the inlet and outlet of each of the elements in the air
path. The procedure shall be continued until the air circuit is completed by either
reaching the starting point or point of air intake from the atmosphere.
The pressure drops to be considered in each of the elements are listed
below. These pressure drops are preliminary and shall be reconfirmed during
further engineering, with firm data from bidders and vendors. The pressure drop
across the plenum being negligible may be ignored for the purpose of preliminary
estimation.
(i) Volume control dampers : 3 mm WG
(ii) Filters in clogged condition
Pre-filters : 12 mm WG
Fine filters : 18 mm WG
HEPA filters : 75 mm WG
(iii) Supply and exhaust air ducting : 0.067 mm WG per metre
of duct length
(iv) Supply air outlets : 3 mm WG
(v) Exhaust air inlets or louvers with : 2 mm WG
bird screen
(vi) Pressure in area to be ventilated
Pressurised ventilation : 1 mm WG
Exhaust ventilation : (-) 1 mm WG
(vii) Pressure in ventilation plant room : (-) 3 mm WG
or at fan inlet
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The differential static pressure across the fan inlet and outlet is the Static Pressure for the
fan.
3.6 TYPES OF VENTILATION SYSTEMS
Various types of ventilation systems are briefly described in the following paragraphs.
Combinations of these systems, or if required by the specific application, variations of the
systems described also may be adopted.
3.6.1 Dry Exhaust Ventilation System
This system essentially comprises of exhaust fans provided for the ventilated area. The
fans may be wall mounted propeller type or roof mounted roof extractors. The location of
wall mounted exhaust fans and air inlets shall be decided so that air flow is not against
wind direction as far as possible. Suitably located wall openings or doors shall be
provided to allow the infiltration of air to replace this exhausted air.
In these systems, the ventilated area is generally at ambient or slightly lower pressure than
the ambient pressure. In areas having large widths (greater than about 15 metres), or
where a specific overall air flow pattern is required, suitably located wall mounted supply
fans may be provided in addition to the wall mounted exhaust fans.
In cases where the dimensions of the ventilated area exceed 15 metres in width and where
roof extractors cannot be installed, it may be necessary to provide exhaust air ducting.
This is to ensure uniform air exhaust over the ventilated area, especially where heat
dissipation loads from equipment are likely to cause local hot spots.
For ducted systems tube axial fans may be used for static pressure requirements of up to
40 mmWG. For higher static pressure requirements centrifugal fans shall be used. For
wall mounted fans of air flow capacities exceeding 8,000 M
3
/Hr, it is recommended that
tube axial fans be used instead of propeller fans so as to limit the size of the fan.
3.6.2 Dry Pressurised Ventilation System
This system is generally provided where the inside design temperature is not critical and
the area is required to be provided with a dust-free environment. A dust-free environment
implies the specification of the type of filtration system. Generally pre-filters with a filtering
efficiency of 80 % down to a particle size of 20 microns as per IS 7613 - test dust G2,
are adequate for ventilation applications like switch-gear rooms or manufacturing areas.
The system essentially comprises of fans, filters and air distribution system.
3.6.3 Evaporative Air Cooling Ventilation System
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In areas with outdoor conditions having a WB depression, i.e. difference between DBT
and WBT, of higher than 8
0
C in summer and ambient DBT above 35
0
C, wet ventilation
system may be considered. This system is also called evaporative cooling ventilation
system. A temperature lower than the ambient can be achieved by evaporative cooling
ventilation system.
This system comprises of supply air fan, air intake louvers with bird screen, filters, air
washer, spray water pumps, spray water piping and air distribution system. The fans for
the system are selected as described earlier in this guide. The air washer comprises of a
spray chamber in either masonry construction or sheet metal construction, with necessary
internals i.e. spray headers and standpipes, spray nozzles. Air washers are installed with
one, two or three spray banks (spray header with standpipes and spray nozzles
constitutes a spray bank) having air humidifying efficiencies of up to 90%.
3.7 EXHAUST HOOD REQUIREMENTS
In areas where there is a major equipment load and the temperature rise is to be limited,
or in areas where fumes or dusts are generated, it may be required to provide local
exhaust hood in addition to providing a supply to area. In case exhaust hoods are
provided, a part of the total equipment heat load only is to be considered for the
estimation of the ventilation air flow rates. The ventilation hood design shall be carried out
as per the guidelines given in the Industrial Ventilation A Manual of Recommended
Practice - 1980 edition.
3.8 HEATING REQUIREMENTS
In case of ventilated areas in locations where winter ambient conditions are lower than the
design lowest temperature it may be necessary to provide heating by use of steam or
electric heating coils. These heaters shall be incorporated into the system so as to provide
the maximum benefit by suitable air distribution.
3.9 NUMBER OF EQUIPMENT / STANDBY ETC.
The local ventilation load distribution may dictate the air distribution requirements, which
in turn will dictate the configuration, i.e. the number and capacities of the ventilation fans,
filters, heaters etc. The configuration of the ventilation system also has to consider the air
movement in the ventilated area to ensure relative comfort conditions in working area. The
economics of providing a standby for the equipment shall be examined while selecting the
system components.
3.10 NOISE AND VIBRATION
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3.10.1 Noise
The noise levels for the equipment e.g. skid-mounted chiller, compressor, fan and base
frame with motor, AHU, pump with base frame and motor etc. may be checked from
vendor catalogues. The allowable noise levels for various areas are given in Table 34,
Chapter 47, ASHRAE HandbookHVAC Applications, 2003-Edition. Necessary sound
attenuators or acoustic lining of ducting and plant room shall be specified, if necessary, to
meet the above criteria.
3.10.2 Vibration
The acceptable vibration level of all major equipment shall be specified in the respective
enquiry document. Unless specified otherwise by client or the process collaborator, the
vibration level of an equipment shall be specified as B as per ISO 10816-1. Vibration
isolators having an isolation efficiency of at least 70% shall be specified for the equipment
wherever required for the system design.
4.0 FIRE SAFETY REQUIREMENTS FOR BUILDINGS
As per National Building Code (NBC), a building having height more than 15 metres
above the surrounding ground level is called a High Rise Building. Following requirements
need to be incorporated while designing ventilation system for such a building. While these
requirements are mandatory for High Rise buildings, it is advisable to follow these for any
building.
4.1 Ventilation system fans except propeller type wall mounted exhaust fans shall be
interlocked with fire detection and alarm system such that in case of fire, ventilation fans
shall stop automatically. In case of fire, exhaust fans shall continue to operate, if designed
to exhaust the smoke from fire into the atmosphere.
4.2 Wherever the ventilation system duct pass through fire wall or floor, the opening around
the ducts shall be sealed with fire resisting materials such as asbestos rope, vermiculite
concrete or other suitable materials.
4.3 Wherever the ventilation system duct pass through fire wall or floor, fire damper shall be
provided in the ducting. The fire damper actuators may be fusible link, pneumatically
operated, electric motor or solenoid operated. Solenoid operated dampers being
economical are generally preferred due to their reliability and facility for interlocking with
fire detection and alarm system, so as to shut the damper in case of fire.
4.4 Staircases shall be ventilated to the atmosphere at each landing i.e. at each floor level and
at the topmost level. Minimum free area of 0.5 M
2
shall be provided in the external wall at
each landing i.e. at each floor and at the topmost level.
4.5 If the staircase can not be ventilated to the atmosphere, because of the location or other
TCE.M1-ME-811-302
VENTILATION SYSTEM
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TCE FORM NO. 120R1
ISSUE
R3
reasons like internal staircase within the building, forced ventilation shall be provided.
Positive pressure of 5 mm WG shall be maintained inside the staircase. The mechanism of
pressurising the staircase shall operate automatically with the fire alarm. It shall also be
possible to manually operate the pressurisation.
4.6 Doors for the staircases or stairwells shall be of auto-shut type and shall have 2 hour fire
resistance.
4.7 If the lift shaft and the lift lobby are in the core of the building, a positive pressure of 2.5 to
3 mm WG shall be maintained in the lobby and 5 mmWG in the lift shaft. The mechanism
of pressurising shall operate automatically with the fire alarm. It shall also be possible to
manually operate the pressurisation.
4.8 Each basement floor shall have independent ventilation system. Exhaust from each
basement floor shall be vented to atmosphere and shall not be connected to exhaust of
any other area.
4.9 For multi-storey basements natural fresh air or common fan with ducts may be provided
for supply air. However, exhaust system for each basement floor shall be independent.
4.10 For exhaust ventilation of internal toilets a minimum of 4 M
2
shaft shall be provided. This
shaft shall be open to atmosphere at the topmost level.
5.0 OPERATION AND CONTROL SCHEME
Brief description of operation and control scheme of the proposed system shall be
included in the basic study. Project instrument engineer may be consulted, if necessary.
6.0 EQUIPMENT AND ELECTRICAL LOAD LIST
An appendix covering all equipment like fans, filters, air washers, pumps etc., with
equipment tag numbers, name/title/designation, major parameters, materials of
construction and estimated ratings of motor and other electric equipment shall be furnished
in tabular form. Requirements such as fume resistant and anti-corrosive paint for fans,
motors, panels, equipment or structure in battery or chlorination rooms or areas where
corrosive fumes are expected, shall be specifically indicated in the equipment list. Motor
ratings may be calculated as per the relevant design guides.
7.0 UTILITY AND SPACE REQUIREMENTS
TCE.M1-ME-811-302
VENTILATION SYSTEM
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TCE FORM NO. 120R1
ISSUE
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7.1 Requirement of utilities like steam, soft or filtered make-up water and instrument air with
the design parameters like flow rates, pressure, temperature and quality required at the
battery limit of the system shall be indicated in tabular form.
7.2 The space requirements and clear height for ventilation equipment plant rooms, and for
routing of ducting and piping etc. shall be indicated. The space requirements shall
consider the operations and maintenance space for fans e.g. space requirements at fan
inlet as per AMCA, filters, air-washers and pumps etc. Requirements of hoists, cranes
and monorails shall also be included. Preferably, a sketch giving the plant room layout
shall be included.
8.0 PROCUREMENT STRATEGY
Proposed procurement strategy with number of enquiries and the scope for each shall be
clearly indicated.
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 12 OF 20
TCE FORM NO. 120R1
ISSUE
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APPENDIX 1
LIST OF AREAS NORMALLY VENTILATED
1. Operating areas like main station building, tripper floor, TG area etc.
2. Electrical sub-station building, switch-gear room and cable vault
3. Areas having high equipment load such as fuel oil heater sheds, manufacturing areas,
welding booths, foundries, boiler houses, kitchens, diesel generator room etc.
4. Water treatment plant areas inclusive of DM water plant, chlorination room etc.
5. All control rooms including those for electrostatic precipitator, switchyard, ash
handling, coal yard etc. (These areas are sometimes air-conditioned.)
6. Areas where contaminants like fumes or dust are present or are generated, like
battery rooms, coal conveyor tunnels, machine shops, weld shops, etc.
7. All pump houses
8. All machine or equipment rooms like elevator machine room, compressor room, air-
conditioning plant room, hydrogen generation station, electrostatic precipitator
rectifier room etc.
9. Service building inclusive of office areas, workshop, welding and smithy, instrument
maintenance, stores, warehouses, locker rooms, canteen etc.
10. Toilets
NOTES
1. Some of the areas mentioned above may be located in one building or house.
2. For power plants evaporative cooling is normally provided for the main station
building and electrostatic precipitator rectifying room.
3. Each project shall be reviewed individually and ventilation for the areas decided
accordingly.
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 13 OF 20
TCE FORM NO. 120R1
ISSUE
R3
APPENDIX 2
OUTSIDE DESIGN CONDITIONS OF IMPORTANT CITIES OF INDIA
(SOURCE: DB, WB And LAT. from Voltas Air-Conditioning and Refrigeration Engineers Handbook-I, 1995 Edition. RH
(%) read from ASHRAE Psychrometric Chart No. 1. Daily Range and Altitude from ISHRAE HVAC
Handbook 1997 Part I
LAT(
0
N
)
CITY
DAILY
RANGE
DB WB RH% DB WB RH
%
DB WB RH%
ALT.
FROM
MSL (M)
Agra
0
F
0
C
26
14.44
108
42.2
75
23.9
May
22 96
35.6
83
28.3
Jul
58 48
8.9
43
6.1
Jan
67 27.10
169
Ahmedabad
0
F
0
C
26
14.44
110
43.3
78
25.6
May
24 90
32.2
85
29.4
Jul
82 60
15.6
51
10.6
Dec
54 23.02
55
Ahmednagar
0
F
0
C
29
16.11
108
42.2
75
23.9
May
22 101
38.3
88
31.1
Jun
60 50
10
43
6.1
Jan
55 19.05
657
Ajmer
0
F
0
C
22
12.22
108
42.2
74
23.3
May
20 93
33.9
81
27.2
Aug
60 45
7.2
39
3.9
Jan
59 26.27
486
Aligarh
0
F
0
C
26
14.44
108
42.2
75
23.9
May
22 96
35.6
83
28.3
Jul
58 48
8.9
43
6.1
Jan
67 27.53
169
Allahabad
0
F
0
C
26
14.44
110
43.3
76
24.4
May
21 96
35.6
83
28.3
Jul
58 48
8.9
46
7.8
Jan
87 25.27
98
Ambala
0
F
0
C
29
16.11
110
43.3
75
23.9
Jun
20 95
35.0
80
26.7
Jul
52 45
7.2
41
5.0
Jan
70 30.23
272
Asansol
0
F
0
C
23
12.78
108
42.2
78
25.6
May
26 90
32.2
86
30.0
Jul
85 52
11.1
44
6.7
Jan
52 23.41
126
Aurangabad
0
F
0
C
27
15.00
104
40.0
76
24.4
May
29 90
32.2
80
26.7
Jul
65 55
12.8
48
8.9
Dec
60 19.53
581
Bangalore
0
F
0
C
22
12.22
96
35.6
78
25.6
Apr
45 82
27.8
78
25.6
Sep
82 58
14.4
54
12.2
Jan
78 12.58
921
Belgaum
0
F
0
C
29
16.11
100
37.8
77
25.0
Apr
35 82
27.8
77
25.0
Jul
80 58
14.4
53
11.7
Jan
71 15.51
753
Bellary
0
F
0
C
23
12.78
105
40.6
77
25.0
May
28 94
34.4
78
25.6
Sep
50 65
18.3
59
15.0
Dec
70 15.09
449
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 14 OF 20
TCE FORM NO. 120R1
ISSUE
R3
Bhopal
0
F
0
C
26
14.44
106
41.1
73
22.8
May
20 92
33.3
83
28.3
Jul
69 45
7.2
38
3.3
Jan
50 23.16
523
APPENDIX 2 (CONTD.)
LAT(
0
N
)
CITY
DAILY
RANGE
DB WB RH% DB WB RH
%
DB WB RH%
ALT
FROM
MSL (M)
Bhubaneshwar
0
F
0
C
20
11.11
100
37.8
82
27.8
May
46 90
32.2
86
30.0
Aug
85 56
13.3
48
8.9
Jan
55 20.15
27
Calcutta
0
F
0
C
20
11.11
100
37.8
83
28.3
May
49 90
32.2
86
30.0
Jul
85 56
13.3
48
8.9
Dec
55 22.32
6
Calicut
0
F
0
C
96
35.6
82
27.8
May
55 85
29.4
82
27.8
Jul
88 72
22.2
65
18.3
Jan
69 11.15
Chanda
0
F
0
C
26
14.44
115
46.1
75
23.9
May
15 88
31.1
80
26.7
Jul
70 55
12.8
49
9.4
Dec
65 19.58
193
Chennai
0
F
0
C
18
10.00
103
39.4
82
27.8
May
41 83
28.3
80
26.7
Nov
88 65
18.3
57
13.9
Jan
60 13.04
16
Cochin
0
F
0
C
10
5.56
95
35.0
82
27.8
Apr
58 85
29.4
82
27.8
Jul
88 72
22.2
65
18.3
Jan
69 9.58
3
Coimbatore
0
F
0
C
23
12.78
98
36.7
76
24.4
May
37 82
27.8
75
23.9
Oct
72 65
18.3
57
13.9
Dec
60 11.00
409
Cuttack
0
F
0
C
21
11.67
105
40.6
82
27.8
May
37 90
32.2
86
30.0
Aug
85 56
13.3
48
8.9
Jan
55 20.29
27
Dehradun
0
F
0
C
26
14.44
105
40.6
75
23.9
Jun
25 90
32.2
80
26.7
Aug
65 42
5.6
38
3.3
Jan
70 30.19
682
Dibrugarh
0
F
0
C
11
6.11
90
32.2
78
25.6
Jun
59 82
27.8
78
25.6
Jul
84 52
11.1
51
10.6
Jan
95 27.28
106
Durgapur
0
F
0
C
23
12.78
108
42.2
78
25.6
May
26 90
32.2
86
30.0
Jul
85 52
11.1
44
6.7
Jan
52 23.14
100
Gaya
0
F
0
C
25
13.89
110
43.3
74
23.3
May
18 90
32.2
84
28.9
Aug
78 50
10.0
44
6.7
Jan
62 24.49
116
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 15 OF 20
TCE FORM NO. 120R1
ISSUE
R3
Goa
0
F
0
C
9
5.00
90
32.2
82
27.8
Apr
70 84
28.9
81
27.2
Jun
88 65
18.3
60
15.6
Jan
76 15.25
62
Guwahati
0
F
0
C
11
6.11
90
32.2
78
25.6
Apr
59 88
31.1
82
27.8
Jul
78 52
11.1
47
8.3
Jan
70 26.11
55
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 16 OF 20
TCE FORM NO. 120R1
ISSUE
R3
APPENDIX 2 (CONTD.)
LAT(
0
N
)
CITY
DAILY
RANGE
DB WB RH% DB WB RH
%
DB WB RH%
ALT
FROM
MSL (M)
Hyderabad
0
F
0
C
14
7.78
106
41.1
78
25.6
May
28 85
29.4
81
27.2
Sep
82 55
12.8
48
8.9
Dec
60 17.86
545
Indore
0
F
0
C
30
16.67
106
41.1
77
25.0
May
27 90
32.2
82
27.8
Jul
70 50
10.0
45
7.2
Jan
69 22.43
567
Jabalpur
0
F
0
C
29
16.11
108
42.2
75
23.9
May
25 93
33.9
84
28.9
Jul
69 45
7.2
41
5.0
Dec
70 23.16
393
Jaipur
0
F
0
C
27
15.00
110
43.3
75
23.9
May
20 95
35.0
78
25.6
Aug
48 46
7.8
41
5.0
Jan
65 26.27
390
Jamnagar
0
F
0
C
20
11.11
100
37.8
80
26.7
May
43 85
29.4
81
27.2
Jul
84 55
12.8
49
9.4
Dec
65 22.29
23
Jamshedpur
0
F
0
C
27
15.00
110
43.3
78
25.6
May
24 90
32.2
84
28.9
Aug
78 50
10.0
46
7.8
Dec
75 22.49
129
Jhansi
0
F
0
C
26
14.44
111
43.9
76
24.4
May
20 97
36.1
84
28.9
Jul
58 48
8.9
45
7.2
Jan
80 25.27
251
Jodhpur
0
F
0
C
29
16.11
110
43.3
77
25.0
May
23 95
35.0
80
26.7
Aug
52 46
7.8
39
3.9
Jan
52 26.18
224
Kakinada
0
F
0
C
18
10.00
103
39.4
82
27.8
May
41 83
28.3
80
26.7
Oct
88 65
18.3
57
13.9
Jan
60 16.57
8
Kalyan
0
F
0
C
15
8.33
100
37.8
82
27.8
Apr
47 86
30.0
83
28.3
Jul
86 65
18.3
58
14.4
Jan
65 18.54
10
Kanpur
0
F
0
C
29
16.11
109
42.8
77
25.0
May
23 97
36.1
84
28.9
Jul
58 45
7.2
42
5.6
Jan
75 26.26
126
Kathmandu
0
F
0
C
31
17.22
85
29.4
75
23.9
May
63 76
24.4
71
21.7
Jul
79 45
7.2
42
5.6
Jan
78 27.42
1324
Kota
0
F
0
C
27
15.00
113
45.0
75
23.9
May
17 99
37.2
80
26.7
Jul
44 45
7.2
41
5.0
Jan
70 25.11
257
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 17 OF 20
TCE FORM NO. 120R1
ISSUE
R3
Kurnool
0
F
0
C
23
12.78
108
42.2
80
26.7
May
30 93
33.9
81
27.2
Sep
60 60
15.6
53
11.7
Dec
62 15.50
281
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 18 OF 20
TCE FORM NO. 120R1
ISSUE
R3
APPENDIX 2 (CONTD.)
LAT(
0
N
)
CITY
DAILY
RANGE
DB WB RH% DB WB RH
%
DB WB RH%
ALT
FROM
MSL (M)
Lucknow
0
F
0
C
30
16.67
109
42.8
79
26.1
May
26 94
34.4
83
28.3
Aug
64 48
8.9
43
6.1
Jan
67 26.52
111
Madurai
0
F
0
C
20
11.11
101
38.3
78
25.6
May
36 94
34.4
78
25.6
Oct
49 68
20.0
62
16.7
Jan
72 9.55
133
Mangalore
0
F
0
C
11
6.11
96
35.6
82
27.8
May
55 85
29.4
82
27.8
Jul
88 70
21.1
64
17.8
Jan
72 12.52
22
Meerut
0
F
0
C
110
43.3
75
23.9
May
20 95
35.0
83
28.3
Aug
60 45
7.2
41
5.0
Jan
70 28.35
Mumbai
0
F
0
C
12
6.67
95
35.0
83
28.3
Apr
60 85
29.4
82
27.8
Jul
88 65
18.3
58
14.4
Jan
65 18.54
11
Mysore
0
F
0
C
21
11.67
100
37.8
78
25.6
Apr
38 85
29.4
77
25.0
Oct
69 66
18.9
60
15.6
Dec
70 12.18
767
Nagpur
0
F
0
C
26
14.44
112
44.4
76
24.4
May
18 85
29.4
81
27.2
Jul
82 60
15.6
52
11.1
Dec
58 21.09
310
Nellore
0
F
0
C
22
12.22
108
42.2
83
28.3
May
35 94
34.4
82
27.8
Nov
60 65
18.3
57
13.9
Jan
61 14.27
20
New Delhi
0
F
0
C
25
13.89
110
43.3
75
23.9
May
20 95
35.0
83
28.3
Aug
60 45
7.2
41
5.0
Jan
70 28.35
216
Ootacamund
0
F
0
C
22
12.22
73
22.8
60
15.6
May
48 66
18.9
58
14.4
Jul-
Oct
62 38
3.3
33
0.6
Dec
60 11.24
2249
Patna
0
F
0
C
26
14.44
108
42.2
78
25.6
May
26 90
32.2
84
28.9
Aug
78 50
10.0
44
6.7
Jan
62 25.37
53
Pune
0
F
0
C
31
17.22
104
40.0
76
24.4
Apr
28 83
28.3
79
26.1
Jul
82 50
10.0
42
5.6
Dec
50 18.32
559
Raichur
0
F
0
C
107
41.7
79
26.1
May
29 93
33.9
82
27.8
Sep
62 60
15.6
54
12.2
Dec
69 16.12
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 19 OF 20
TCE FORM NO. 120R1
ISSUE
R3
Raipur
0
F
0
C
25
13.89
110
43.3
77
25.0
May
22 92
33.3
83
28.3
Jul
68 50
10.0
45
7.2
Dec
70 21.14
298
TCE.M1-ME-811-302
VENTILATION SYSTEM
SHEET 20 OF 20
TCE FORM NO. 120R1
ISSUE
R3
APPENDIX 2 (CONTD.)
LAT(
0
N
)
CITY
DAILY
RANGE
DB WB RH% DB WB RH
%
DB WB RH%
ALT
FROM
MSL (M)
Ranchi
0
F
0
C
27
15.00
100
37.8
82
27.8
May
46 84
28.9
78
25.6
Jul
76 48
8.9
42
5.6
Jan
60 23.23
655
Rentachintala
0
F
0
C
110
43.3
83
28.3
May
32 94
34.4
82
27.8
Oct
60 55
12.8
49
9.4
Dec
65 16.33
Rourkela
0
F
0
C
28
15.56
110
43.3
78
25.6
May
25 87
30.6
82
27.8
Jul
81 54
12.2
44
6.7
Dec
41 21.28
148
Salem
0
F
0
C
18
10.00
103
39.4
80
26.7
May
38 93
33.9
77
25.0
Oct
49 65
18.3
59
15.0
Jan
70 11.39
278
Sambalpur
0
F
0
C
28
15.56
110
43.3
78
25.6
May
25 87
30.6
82
27.8
Jul
81 54
12.2
44
6.7
Dec
41 21.28
148
Shillong
0
F
0
C
14
7.78
85
29.4
71
21.7
Apr
50 74
23.3
70
21.1
Jun
82 38
3.3
32
0.0
Jan
50 25.34
1500
Sholapur
0
F
0
C
27
15.00
108
42.2
77
25.0
May
25 92
33.3
82
27.8
Sep
65 55
12.8
47
8.3
Jan
55 17.40
479
Thane
0
F
0
C
15
8.33
100
37.8
82
27.8
Apr
47 86
30.0
83
28.3
Jul
86 65
18.3
58
14.4
Jan
65 18.54
10
Thiruchirapalli
0
F
0
C
20
11.11
104
40.0
81
27.2
May
38 95
35.0
81
27.2
Oct
55 70
21.1
64
17.8
Jan
72 10.49
88
Thiruvanan-
thapuram
0
F
0
C
15
8.33
92
33.3
80
26.7
Mar
59 85
29.4
80
26.7
Jun
80 72
22.2
65
18.3
Jan
69 8.29
64
Vadodara
0
F
0
C
26
14.44
110
43.3
78
25.6
May
24 88
31.1
79
26.1
Jul
68 50
10.0
43
6.1
Jan
55 22.18
34
Varanasi
0
F
0
C
29
16.11
109
42.8
76
24.4
May
25 94
34.4
83
28.3
Aug
64 50
10.0
47
8.3
Jan
80 25.18
76
Vijaywada
0
F
0
C
24
13.33
110
43.3
83
28.3
May
32 94
34.4
82
27.8
Oct
60 55
12.8
49
9.4
Dec
65 16.33
106
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Visakhapatnam
0
F
0
C
11
6.11
92
33.3
82
27.8
May
65 87
30.6
82
27.8
Oct
81 65
18.3
57
13.9
Jan
60 17.42
3
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APPENDIX 3
DEFAULT VALUES FOR SOME DESIGN PARAMETERS
1.0 INSIDE DESIGN CONDITIONS
1.1 Dry ventilation systems : 2 to 3
0
C above the ambient DBT
1.2 Wet ventilation systems : 6

to 7
0
C above the ambient WBT
2.0 AIR FLOW RATES
2.1 DRY EXHAUST VENTILATION
2.1.1 Kitchen and pantries 50 air changes per hour or 152 M
3
/Hr
per M
2
whichever is higher
2.1.2 Boiler house, DG rooms, weld shops, foundry
or furnace rooms, heat treatment shop,
laundries, refinery hot oil pump houses and
public toilets
3
/Hr
per M
2
or as dictated by the heat
dissipation loads whichever is highest
2.1.3 Pump houses, compressor houses, welding
and smithy, canteen and transformer rooms
3
/Hr
per M
2
whichever is higher
2.1.4 Locker rooms, stores, warehouses, private
toilets, machinery assembly shops, water
treatment plant, HVAC plant rooms and
battery rooms
3
/Hr
per M
2
whichever is higher
2.2 DRY PRESSURISED VENTILATION
MCC rooms and manufacturing areas 25 air changes per hour or 76 M
3
/Hr
per M
2
or as dictated by the heat
dissipation loads whichever is highest
3.0 OVER-PRESSURE
3.1 MANUFACTURING AREAS
3.1.1 Areas requiring dust-free environment and not
having hazardous fumes or vapours
(+) 1 mmWG
3.1.2 Areas where hazardous fumes are generated (-) 1 mmWG
3.1.3 Areas where recoverable dust is generated (-) 1 mmWG
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APPENDIX-3 (CONTD.)
3.1.4 Areas where active air is handled e.g. nuclear
power plants
(-) 1 mmWG
3.2 MCC AND PCC ROOMS (+) 1 mmWG
3.3 BATTERY ROOMS AND TOILETS (-) 1 mmWG
3.0 FILTRATION
4.1 For MCC rooms, control rooms, manufacturing areas in hazardous areas having
flammable vapour e.g. hydrocarbons as in refinery areas, glycol vapours as in
synthetic fibre plants, chemical filters may have to be provided in case intake of
ventilation air is not possible from a safe area. These filters are required to filter
hydrocarbons or vapour like chlorine, ammonia, oxides of nitrogen, sulphur or its
oxides, compounds etc. Some of this vapour is detrimental to the contacts of
electronic components used in control systems and it is essential to remove them to
ensure the full working life of the components.
4.2 For MCC rooms and manufacturing areas in active areas of nuclear power plant,
carbon filters may have to be provided to remove the radioactive elements in the
ventilation air.
4.3 For MCC rooms and manufacturing areas in safe areas, pre-filters with filtering
efficiency of 80% down to a particle size of 20 microns as per IS 7613 test dust G2
shall be provided.
4.4 For manufacturing areas in pharmaceutical plants handling powder, fine filters having
filtering efficiency of 90 % down to a particle size of 5 microns as per IS 7613 test
dust G2 and HEPA filters having filtering efficiency of 99.99 % down to a particle
size of 0.3 microns as per ISO 14644-1 and ISO 14644-2 shall be provided.
5.0 LIGHTING LOADS
DESCRIPTION OF THE AREA Watts/M
2
Pharmaceutical areas 30
Machine, Assembly, Press shops 20
Commercial areas, Show rooms 50
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APPENDIX 3 (CONTD.)
6.0 OCCUPANCY
DESCRIPTION OF THE AREA M
2
/ PERSON
Office areas 5
Auditorium 2
Conference rooms 2.5
Manufacturing areas 10
SECTION: TITLE
TCE.M6-ME-127-214
DESIGN GUIDE FOR
INDUCED DRAFT COOLING TOWERS
SHEET i OF iii
REV.NO. R0 R1 R2 R3 ISSUE
PPD.BY DP Sd/- KVS/TSR Sd/-/Sd/- SDP Sd/- SDP
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APD.BY CFC Sd/- KG Sd/- RL Sd/- RL
DATE 86.09.26 94.03.31 99.06.30 01.10.11
TCE FORM NO. 020R2
DESIGN GUIDE FOR
FLOPPY NO. : TCE.00000-ME-FP-136
FILE NAMES : M6ME214R3.DOC AND
SECTION: TITLE
TCE.M6-ME-127-214
DESIGN GUIDE FOR
SHEET i OF iii
REV.NO. R0 R1 R2 R3 ISSUE
PPD.BY DP Sd/- KVS/TSR Sd/-/Sd/- SDP Sd/- SDP
CHD.BY AR Sd/- TSR Sd/- TSR Sd/- TSR R3
APD.BY CFC Sd/- KG Sd/- RL Sd/- RL
DATE 86.09.26 94.03.31 99.06.30 01.10.11
TCE FORM NO. 020R2
M6ME214R3.DWG
SECTION: CONTENTS
TCE.M6-ME-127-214
DESIGN GUIDE FOR
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TCE FORM NO. 120 R1
CONTENTS
SL.NO. TITLE SH. NO.
1.0 SCOPE 1
2.0 CLASSIFICATION 1
3.0 DATA TO BE COLLECTED 1
4.0 DESIGN PARAMETERS 2
5.0 DESIGN PROCEDURE 3
6.0 COOLING TOWER COMPONENTS, ACCESSORIES AND 9
BASIN
7.0 EVALUATION AND PENALTY FACTORS 15
8.0 REFERENCES 16
APPENDICES
1. RE-CIRCULATION ALLOWANCE 17
2. ORIENTATION AND SPACING OF INDUCED 18
DRAFT COOLING TOWERS
3. TYPES OF INDUCED DRAFT COOLING TOWERS 19
4. BASIC CONSTRUCTION OF INDUCED DRAFT 20
COOLING TOWERS
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REVISION STATUS
R0 86.09.26 --
R1 94.03.31 Addendum added.
R3 01.10.11 Paras 6.4 and 6.12
revised.
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1.0 SCOPE
This design guide outlines the data to be collected, analysis of the data and
guidelines to decide the design parameters, design aspects and layout of induced
draft cooling towers. This guide shall form the basis for further detailed engineering
and preparation of enquiry specification.
2.0 CLASSIFICATION
Induced draft cooling towers covered in this design guide are classified under three
(3) categories as follows :
(a) Large size : Total tower capacity above 5,000 M
3
/Hr
(b) Medium size : Total tower capacity above 750 M
3
/Hr and upto
5,000 M
3
/Hr
(c) Small size : Total tower capacity upto 750 M
3
/Hr
3.0 DATA TO BE COLLECTED
3.1 Following data shall be collected from sources such as client, meteorological
department, process collaborator, bidders, vendors and past in-house data :
(a) Location
(b) Site meteorological data preferably covering the daily and hourly wet bulb
temperature and wind velocity and direction data. If daily and hourly data is
not available, at least monthly maximum, minimum and mean values shall be
obtained.
(c) Soil conditions
(d) Total cooling water requirements for process plant, power plant, air-
conditioning, chilling plant, diesel generator set, and various other equipment
such as pumps, compressors, turbines, diesel engines etc.
(e) Heat load for each of the equipment mentioned in (d) above.
(f) Maximum hot water outlet temperature and cold water inlet temperature for
each of the equipment mentioned in (d) above.
(g) Make-up water source, quality and availability of water on continuous basis
(h) Disposal point for blowdown
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(i) Space provided for cooling tower in plot plan
(j) Distance of nearby tall buildings from cooling tower
(k) Availability of power supply on continuous basis
(l) Statutory requirements and project specific requirements regarding disposal
of blowdown, restriction on use of certain materials like asbestos, timber
etc.
(m) Plan for any future expansion
(n) Details of existing cooling tower, if any
3.2 Following parameter is not applicable for induced draft cooling towers :
Relative humidity - Since the tower performance is independent of relative humidity
due to presence of fans.
4.0 DESIGN PARAMETERS
Based on the data collected, following design parameters are required to be
established :
(a) Design ambient wet bulb temperature
(b) Re-circulation allowance and design entering wet bulb temperature
(c) Cooling water requirement, design hot water inlet temperature and design
cold water outlet temperature
(d) Drift loss
(e) Make-up water quantity and cycles of concentration
(f) Siting, orientation and spacing
(g) Types of cooling towers
(h) Number of cells
(i) Materials of construction
Following paras briefly describe the procedure for establishing each of these design
parameters.
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5.0 DESIGN PROCEDURE
5.1 DESIGN AMBIENT WET BULB TEMPERATURE
Data for ambient Wet Bulb Temperature(WBT) throughout the year shall be
reviewed and WBT duration curve prepared. Generally, design ambient WBT is the
temperature where 95% of the ambient WBTs are below that particular
temperature.
5.2 RE-CIRCULATION ALLOWANCE AND DESIGN ENTERING WET BULB
TEMPERATURE
Due to the low height of the tower and the suction head created by the fan there is a
possibility of some of the hot air, discharging from the fan, being sucked in along
with the inlet air thereby causing slight rise in the inlet air WBT. The re-circulation
allowance is the difference between the WBT of air at tower inlet i.e. design entering
WBT and the design ambient WBT. This has to be considered in the design of the
tower, as it reduces the available approach between cold water outlet temperature
and design entering WBT. The re-circulation allowance can be determined from the
curve indicated in appendix 1. The design entering WBT shall be specified after
adding the re-circulation allowance. It may also be added that no further re-
circulation allowance needs to be considered by the bidders.
5.3 COOLING WATER REQUIREMENT, DESIGN HOT WATER INLET
TEMPERATURE AND DESIGN COLD WATER OUTLET TEMPERATURE
The size and cost of cooling tower is proportional to the heat load and approach. It
is of primary importance that a reasonably accurate heat load determination be
made. Hence, it is advisable to determine the heat load of each user equipment as
realistically as possible. From the cooling water inlet and outlet temperatures, flow
rates and heat loads for each user equipment, determine hot water return
temperature assuming mixing of all the return streams. This temperature is nothing
but the Design Hot Water Inlet Temperature for the cooling water. The heat load
imposed on the cooling tower is determined by the amount of water circulated
through the process and by the number of degrees centigrade that the process
elevates the circulating water temperature.
Q = m x Cp x T

Where Q = Heat load in Kcal/Hr
m = Mass flow rate in Kg/Hr
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Cp = Specific heat of water (1 Kcal/Kg/
0
C)
T = Design hot water inlet temperature design cold water
outlet temperature in
0
C
It may appear from the above that any combination of flow rate and cooling range
can be selected to give the required heat load. However, in reality, it is not so, since
design cold water outlet temperature is fixed by Approach.
Approach = Design cold water outlet temperature Design Entering WBT
Generally, the approach shall be more than 3
0
C as it is not customary in cooling
tower industry to guarantee any approach less than 2.8
0
C
As the size of cooling tower is inversely proportional to the approach, it is advisable
to decide on a design cold water outlet temperature which neither results in large
cooling tower nor a very high water circulation rate. Though it is possible to carry
out a theoretical economic analysis resulting in most optimum solution, experience
has shown that an approach of 4
0
C to 5
0
C results in a near optimal solution.
Hence, decide on a design cold water outlet temperature, design hot water inlet
temperature and circulation water flow rate. Check whether these parameters satisfy
all the user equipment also.
Add 5% to 10% margin on the cooling water requirement based on reliability of
input data indicated at 3.1.d, 3.1.e and 3.1.f.
5.4 DRIFT LOSS
This is loss of water due to water particles carried away by the outgoing air. Due to
the suction created by the fan, the drift loss is high. However, this is minimised by
providing drift eliminators. Depending on the design and effectiveness of drift
eliminators the drift loss varies between 0.005% to 0.1 % of the cooling water flow.
Drift loss shall be specified as 0.1 % maximum for small and medium size cooling
towers.
Drift loss shall be specified as 0.05 to 0.1% maximum for large size cooling towers.
When the electrical substation is nearby, cooling media is sea water and cooling
tower size is large, the drift loss shall be specified as 0.005% maximum.
5.5 MAKE-UP WATER QUANTITY AND CYCLES OF CONCENTRATION
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Refer "Basic Study Guide for Cooling Tower Make-up System" TCE.M1-ME-
127-201.
5.6 SITING, ORIENTATION AND SPACING
5.6.1 Siting
The major disadvantage of induced draft cooling towers is the drift nuisance i.e.
falling of water particles carried away by the discharge air on to the surrounding
structures particularly on electrical equipment such as transformer and switch yard
etc. Normally drift dispersion study is not carried out and towers are located as per
para 5.6.3 below. If required in a particular project due to space constraint, this
study may be carried out for large cooling towers either in-house or from outside
agency . However, this study involves extra cost to the project and shall be carried
out in consultation with the client.
5.6.2 Orientation ( Refer appendix 2)
(a) Towers with air inlets on only one side shall be oriented so that the air inlets
face the prevailing wind.
(b) Towers with air inlets on opposite sides shall be oriented so that the air inlet
sides are either parallel to or at an angle to prevailing wind direction.
5.6.3 Spacing
Towers shall be located so that the clear distance between the tower and any
surrounding structure is at least equal to the height of the tower and distance
between the two parallel cooling towers is at least equal to the length of the longest
tower and the spacing between the towers shall be as shown in appendix 2. It is
also advisable to consult cooling tower vendors in case of space limitations.
5.7 TYPES OF COOLING TOWERS
It is advisable to provide separate cooling towers for process and utility plants, if
there is a possibility of contamination of cooling water in the process plant.
There are two types of induced draft cooling towers
(a) Cross-flow tower
(b) Counter-flow tower
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The arrangements of the above two types are indicated in appendix 3.
In cross-flow tower the air flow is horizontal across the downward fall of water
whereas in counter-flow tower the air and the water flow are opposite in vertical
directions.
The advantages and disadvantages of each of the above types of induced draft
cooling towers are :
5.7.1 Cross-Flow Towers
Advantage
The water distribution system can be attended to without taking tower shut down.
Disadvantages
(a) Prevention of icing during extreme whether conditions demand more care
from the operator. (Applicable only for sub-zero climates.)
(b) The exposure of water distribution basin to sunlight promotes growth of
algae.
5.7.2 Counter-Flow Towers
Advantages
(a) The plan area at basin level and the total power for fans is less than that for
cross-flow towers.
(b) Economical choice for difficult duties (large cooling range combined with
close approach).
(c) Less prone to icing than cross-flow towers. (Applicable only for sub-zero
climates.)
(d) The enclosed nature of counter-flow tower restricts exposure of water to
direct sunlight , thus retarding the growth of algae.
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Disadvantage
The water distribution system (generally piping or troughs with spray nozzles) can
not be easily inspected and cleaned unless the tower is shut down.
5.7.3 Choice of Type of Induced Draft Cooling Tower
As explained above since either of the type do not have any overwhelming
advantage over the other type and since different vendors normally specialise in
either one of the two(2) types, the choice of the type of tower is left open to the
bidder. The towers may be single air entry type or double air entry type. If nearby
structures located within a distance of one(1) tower height from the cooling tower
obstruct the free flow of air then single air entry from the unobstructed side may be
considered. Otherwise, it is preferable to adopt double air entry type.
5.8 NUMBER OF CELLS
Large and medium size towers are of multi-cell, each cell having its own fan, water
distribution system, fill, drift eliminators and louvers. This facilitates flexibility of
operation by distribution of water load and control of cooling water temperature
by operation of required number of cells. The maximum fan tip speed shall
be limited to 65 metres per second. On this basis the maximum capacity of each
cell shall be about 3,000 M
3
/Hr. Depending on the total capacity of tower, number
of cells may be selected. e.g. 30,000 M
3
/hr capacity tower may have 10 cells.
Normally, standby cells are not provided. Instead standby equipment such as fan,
gearbox, motor and nozzles/orifices shall be provided. However, standby cells may
be provided based on project specific requirement.
5.9 MATERIALS OF CONSTRUCTION
The basic construction features of an induced draft cooling tower are shown in
appendix 4. The major components and their materials of construction are described
in following paras.
5.9.1 Timber
Because of its availability, workability, relative low cost and its durability under the
very severe operating conditions encountered in cooling towers, timber is the
predominant structural material utilized. Normally, timber is not recommended for
hot water inlet temperature above 65
0
C. Above 65
0
C, lower permissible stress
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value of timber with safety margin shall be considered or RCC cooling tower shall
be considered.
Timber shall be as per IS 2372.
The following pressure preservative treatments are used for the treatment of timber
used in industrial water cooling towers :
(a) Chromated Copper Arsenate (CCA)
(b) Acid Copper Chromate (ACC)
CTI Bulletin WMS-112, " Pressure Preservatives Treatment of Lumber for
Industrial Water" governs the treating procedure, the minimum retentions and
penetrations to be obtained, and the physical condition of the timber when pressure
treating industrial water cooling tower timber. Treatment to timber shall conform to
IS 401.
5.9.2 Asbestos Cement Board (ACB)
ACB has excellent resistance to normal industrial atmosphere. It is a non-
combustible material and is not subject to micro-biological decay. The
disadvantages of ACB are as follows :
(a) ACB can hamper manual fire fighters as it explodes in fragments in case of
fire.
(b) It is degraded if exposed to cooling water with relatively high chlorides (>
1000 mg/l).
(c) It is not suitable for water having pH 5.5 or lower.
(d) It is not suitable for food and pharmaceutical industries.
Corrugated asbestos, if used for casing, shall be as per IS 459 and of minimum 6
mm thickness.
5.9.3 Plastics
Plastics used as materials of construction in cooling towers may be grouped into two
classes :
(a) Glass Reinforced Polyesters(GRP) and Fiber Reinforced plastics(FRP)
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GRP or FRP are not suitable when the hot water inlet temperature is above
60
0
C.
(b) Thermoplastics
The non-reinforced thermoplastic resins include polyvinyl chloride(PVC)
and polypropylene. PVC is not suitable for temperature above 55
0
C.
5.9.4 Hardware
The choice of materials for cooling tower hardware and fasteners involves the
factors of cost, strength, and corrosion resistance.
Hardware above and below fan deck level shall be normally provided with hot dip
galvanised steel or stainless steel or phosphor bronze or naval brass for fresh water
application.
Hardware above and below fan deck level shall be of silicon bronze or Super
Molybdenum stainless steel for sea water application.
5.9.5 RCC
RCC is most commonly used as basin construction material. Large cooling towers
shall be constructed of RCC to minimise the risk of fire and for larger structure,
higher load carrying capacity.
6. 0 COOLING TOWER COMPONENTS, ACCESSORIES AND BASIN
6.1 CASING
Cooling tower casing acts to contain water within tower, provide an air plenum for
the fan, and transmit wind loads to the tower frame work. It shall be watertight and
shall have corrosion resistant and have fire retardant qualities. It is the enclosure
housing the fill (packing) and drift eliminators. It is normally of RCC or treated
timber with FRP corrugated panel for large towers, timber with FRP corrugated
panel or corrugated asbestos (ACB) for medium size towers and treated timber or
FRP for small towers.
6.2 LOUVERS
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These are provided on the sides of the tower to equalise the air flow into the fill and
to prevent the water drops from falling out. The most utilised louver materials are
FRP or corrugated asbestos sheet or treated timber for all types of towers and pre-
cast, pre-stressed concrete for RCC towers.
6.3 FILL (PACKING)
This is the main component of cooling tower responsible for heat transfer and is of
two types i.e. splash type and film type.
Advantages of splash fill
(a) It reduces air pressure losses.
(b) It is not conducive to clogging.
Disadvantages of splash fill
(a) It is very sensitive to inadequate support.
(b) If proper level is not maintained, there are chances of sagging and
channelling of water and air.
Advantage of film fill
It requires less space for same amount of cooling than the splash type fill.
Disadvantage of film fill
The use of film fill shall be avoided in situations where the circulating water
can become contaminated with debris.
Based on type of application, the type of fill shall be decided.
For splash type - PVC or FRP or treated timber for all towers and sometimes of
RCC for large RCC cooling towers
For film type - PVC
6.4 FILL AND TOWER SUPPORTING STRUCTURE
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The fill, casing and fan deck are all supported from the basin and the supporting
structure shall be of RCC or GRP or CS or SS for large towers, treated timber or
GRP or CS or SS for medium and GRP or CS or SS for small towers.
6.5 FAN DECK
This is the deck (floor) at the top ( above the fill ) to provide access to the fan and
water distribution system. The deck shall be of RCC or treated timber or marine
ply timber for large towers and treated timber or marine ply timber for medium and
small towers.
6.6 FANS
Fans create the required air flow through the tower and are driven by electric
motors through gear drives for all towers. The motors shall be suitable for outdoor
location. The fan drive shaft shall be of hollow HDGS or stainless steel. The fan
blades shall be either of cast aluminium alloy or FRP or GRP. In case of corrosive
water, FRP or GRP fan blades shall be used. The gears shall be of enclosed type.
The fan blades shall have manually adjustable pitch.
6.7 FAN CYLINDERS AND RECOVERY STACK
Recovery stack is provided above fan cylinder to recover kinetic energy of air
thereby reducing the power consumption. Suitable air tight access door shall be
provided in the cylinder for approach to the fans and for maintenance of gear box
and fans etc. Suitable removable rail with tripod and handrail shall be provided for
large cooling towers. It is not essential for small towers. Fan cylinder and recovery
stack shall be of RCC or FRP or GRP for large towers and treated timber or FRP
or GRP for small and medium towers.
6.8 DRIFT ELIMINATORS
These are provided at the air outlet from fill, to trap the water particles carried by
the air stream and thereby reduce the drift loss. Most widely used drift eliminators
material is treated timber or PVC.
6.9 WATER DISTRIBUTION SYSTEM
In case of cross-flow tower the hot water is fed to hot water basins or troughs
located on the top of tower by means of hot water inlet pipes. From this basin,
water flows over the fill by gravity through orifices located in hot water basin.
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Counter-flow system normally necessitates the use of a pressure-type system of
closed pipe and spray nozzles.
The hot water basin is of RCC or marine plywood for large towers and FRP or
RCC or timber for medium and small towers. The feed pipes are of hot dip
galvanised steel or cast iron. Presently fibre reinforced pipes are used because of
low pressure application, light weight, good resistant to both corrosion and erosion.
Pre-cast and pre-stressed concrete pipes are also used in RCC tower. The nozzles
are of polypropylene or bronze or SS.
6.10 STAIRCASE
This is required for providing approach from ground to the fan deck. For large
towers, one or two staircases one on either side shall be provided and for medium
size tower one staircase is adequate. The staircase is of RCC or treated timber or
HDGS for large tower and of treated timber for medium and small towers.
For small towers only access ladder of HDG steel or treated timber shall be
provided instead of staircase.
6.11 OTHER COMPONENTS AND ACCESSORIES
(a) Fan Deck Illumination
This is required for large towers to provide illumination of deck at night.
(b) Lightning Protection
This is also required only for large cooling towers.
(c) Vibration Limit Switch
This is provided to trip the fan motor in case of excessive vibration of fan.
(d) Vibration Isolators
These are provided if considered necessary, to minimise transfer of vibration
of rotating parts to fan deck and tower structure.
(e) Dual Speed Motors
SECTION: WRITE-UP
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DESIGN GUIDE FOR
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These are provided only in case where the towers are intended for very
widely varying duty conditions which is achieved by varying the fan speed
(f) Fan Guards
These are provided on top of fan cylinder or recovery stack of medium and
small size towers to prevent birds falling into the stack of standby cell. These
are not essential for large towers in view of large size of fan as the fan noise
keeps the birds away. The guards are normally HDG steel or SS wire mesh.
(g) De-icing System
This is required to be provided only in place having extreme cold climate
which requires passing part of hot water and spraying on to the louvers to
prevent the ice formation.
(h) Hot Water Basin Cover
The hot water distribution basin shall be provided with a suitable cover in
cross-flow cooling towers to avoid direct sun rays falling on the distribution
trough or basin, to minimise algae growth and to prevent choking of
distribution nozzles from external falling objects. In case of dusty
atmosphere, hot water basin cover shall be provided.
(i) Low Oil Level Switch
This is generally provided to trip the fan in case low oil level in gear box.
(j) Mechanical Equipment Removal Devices
These shall be provided in case of large cooling towers. These shall be
provided at fan deck level to remove the mechanical equipment, to lift oil
drums and maintenance tools and tackles. This consists of swivel hoist, track
and dolley arrangement. The removed component can be dollied to the end
of the fan deck, and lowered by means of a properly designed hoisting
structure. This structure shall consist of an endwall derrick or an endwall
davit depending upon magnitude of load.
(k) Screens
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Screens shall be provided at the outlet of each basin cell to prevent
suspended particles entering to cooling water pumps. Generally, screens of
12 mm mesh opening shall be provided. The material of construction for
screen shall be carbon steel with epoxy painting or HDGS in case of fresh
water and of SS 316L in case of sea water. Normally, width of screen shall
be 1.2 metres.
(l) Stoplogs
Insertion plate for water-tight stoplogs shall be provided at the outlet of each
basin. Two(2) stoplogs shall be provided to isolate individual basin
compartments during maintenance. Material of construction of stoplogs shall
be FRP with SS316L frame for sea water and carbon steel with epoxy
painting or timber or HDGS for fresh water application. Insertion plate shall
be of SS316L for sea water and carbon steel with epoxy painting for fresh
water.
(m) Monorail with hoist shall be provided for lifting screens and stoplogs.
6.12 COLD WATER BASIN
This holds the re-cooled water falling through the fill and provides an outlet for the
cooled water. The basin is of RCC for large and medium size towers and of steel
with epoxy painting or FRP or steel for smaller towers.
Basin depth may be decided based on following considerations:
(a) Flooded suction and NPSH required for cooling water pumps, if horizontal
pumps are used and submergence and pump dimensions if vertical pumps are
used.
(b) Cooling tower should be able to supply cooling water within acceptable
temperature limits under variable cooling loads during normal operation.
(c) Cooling tower should be able to supply cooling water within acceptable
temperature limits during start-up, shut-down and emergency conditions, if so
specified.
(d) Basin should be able to hold back-flow during pump shut-down and cooling
water shall not overflow into drains. This is particularly important if treated
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DESIGN GUIDE FOR
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water is used as cooling water make-up or water is scarce and wastage is to
be minimized.
(e) Basin should have enough reserve capacity during interruption of make-up
water supply.
(f) If basin is to be used as a reservoir for fire water supply, take inputs from
Basic Study for Fire Protection System.
(g) For underground basins, soil conditions and ground water table etc. may be
checked with civil department while deciding the depth of the basin.
The large and medium towers shall be supported on RCC foundation whereas small
cooling tower shall be supported on either concrete pedestals or steel sections.
The basin for large towers may be completely underground whereas the basins for
medium size and small towers may be above ground level, if required, to provide
flooded suction for the pumps.
The cold water outlet from basin shall be through channel for large cooling towers
and through pipes for medium and small towers.
Normally, the cold water basin may be partitioned cell wise to facilitate cleaning
during individual cell maintenance. Outlet of each partition shall be connected to
common sump.
In case of large cooling towers with more than 5 cells, the cold water basin may be
partitioned into two compartments along the length of tower and cleaning of one
compartment of cold water basin may be carried out by shutting down half part of
individual cells of entire cooling tower.
7.0 EVALUATION AND PENALTY FACTORS
7.1 FOR PUMPING HEAD
Increase in cooling tower height i.e. height from basin curb to centre line of riser at
fan deck increases the cooling water pump head
For cooling water circulation pumps
S x Q x H
BKW =
367.2 x
where S = specific gravity of water
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Q = Capacity in M
3
/Hr
H = Differential Head in M
= Efficiency of pumps
For every metre excess head, there is rise in pump power consumption. For every
rise in excess BKW, the penalty factor (P) shall be calculated as follows:
P = Energy charge in Rs/KwHr x number of operating hours per
year x N x differential power
where N = Capitalisation Factor
( 1 + r/100)n - 1
=
r/100 x (1 + r/100)n
r = Rate of interest in %
n = number of years
P = Penalty in Rs.
7.2 FOR FAN POWER CONSUMPTION
For every KW differential of excess fan power consumption, penalty factor P shall
be calculated as shown in para 7.1
8.0 REFERENCES
References for design and construction features, thermodynamic aspects and testing
requirements of cooling towers are given below :
(a) The Industrial Cooling Tower by Mckelvey and Brooke
(b) BS 4485 Specification for Water Cooling Towers
Part 1 - Glossary of Terms
Part 2 - Methods of Performance Testing
Part 3 - Thermal and Functional Design
Part 4 - Structural Design of Cooling Towers
(c) Cooling tower performance curves published by Cooling Tower Institute
(CTI)
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(d) CTI acceptance test procedure as per CTI code ATC 105 for Water
Cooling Towers
(e) Cooling Tower Manual
(f) CTI Bulletin WMS-112, " Pressure Preservatives Treatment of Lumber for
Industrial water"
TCE.M6-ME-613-215
DESIGN GUIDE FOR
HORIZONTAL CIRCULATING WATER PUMPSETS
SHEET i OF iii
ISSUE
PPD. BY DGR Sd/- SCP Sd/- SHN Sd/- VB
CHD. BY RKJ Sd/- MPB Sd/- RKJ Sd/- PDG
APD. BY KG Sd/- SCM/RL Sd/-/Sd/- SCM/RL Sd/-/Sd/- RL
DATE 02.05.1994 06.08.1999 17.08.2002 28.10.2003
R4
TCE FORM NO. 020R2
DESIGN GUIDE FOR
FILE NAMES: M6ME215R4.DOC AND
M6ME215R4.DWG
TCE.M6-ME-613-215
DESIGN GUIDE FOR
SHEET ii OF iii
TCE FORM NO. 120R1
ISSUE
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CONTENTS
1.0 SCOPE 1
2.0 INPUT DATA REQUIRED 1
3.0 APPLICATION 1
4.0 SELECTION OF PARAMETERS 1
5.0 TYPE OF PUMP 3
6.0 CONSTRUCTION FEATURES 3
7.0 MATERIALS OF CONSTRUCTION 4
8.0 PERFORMANCE CHARACTERISTICS 5
9.0 LAYOUT CONSIDERATIONS 5
10.0 MOTORS 5
11.0 PERFORMANCE TEST 5
12.0 NOISE AND VIBRATION 5
13.0 CROSS REFERENCES 6
APPENDICES
1. COOLING WATER REQUIREMENTS 7
2. MATERIALS OF CONSTRUCTION 8
3. PRESSURE ACTING ON A DOUBLE SUCTION
IMPELLER
9
4. DOUBLE FLAT RING TYPE WEARING RING 10
5. CONVENTIONAL STUFFING BOX 11
6. LAYOUT OF SUCTION PIPING 12
SECTION: REV.
STATUS
TCE.M6-ME-613-
215
DESIGN GUIDE FOR
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REVISION STATUS
R0 24.07.1986 - -
R1 02.05.1994 Contents Sheet, Write-up Sheets 3, 4, 9, 11, 12 and Table II
revised.
R2 06.08.1999 Overall Revision
R3 17.08.2002 Clauses 3.0, 4.1, 4.2.1 and 10.0 revised. Clause 4.3.2
added.
R4 28.10.2003 Appendix 2 revised.
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1.0 SCOPE
This design guide deals with selection of parameters, types, construction features,
materials of construction, performance characteristics, tests etc. for horizontal
circulating water pumpsets of cooling system for power plants.
2.0 INPUT DATA REQUIRED
The following data shall be obtained for the selection of the proper pumpset for the
intended service:
(a) Cooling water requirement of the plant, with complete break-up
(b) Normal, maximum and minimum water level in the sump
(c) Minimum and maximum water temperature
(d) Analysis of water
(e) Information regarding screening of water ahead of the pumps by means of
trash racks/screens.
(f) Chlorine dosage and maximum residual chlorine
3.0 APPLICATION
Normally, it is the practice to keep the plant grade level above the highest flood level
to avoid flooding of the power station. Keeping in mind the above, usually it will not
be possible to go in for horizontal pumps for once through cooling system due to the
high suction lift because of variation in water level at the source. Hence, possibility of
using horizontal pumps for once through system is very remote.
In cooling tower installations sometimes it becomes necessary to locate the cooling
tower basin and cold water channels above the grade level due to the soil conditions at
site. It is preferable to go in for horizontal pumps for such installations. It is
recommended to finalise the choice in this case, after cost comparison with the option
of below ground basin with vertical turbine pumps.
4.0 SELECTION OF PARAMETERS
The three important parameters that are to be decided for the pumps are:
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(a) Capacity
(b) Total head
(c) Speed
4.1 CAPACITY
4.1.1 The capacity of the pump depends on the total quantity of water required for the
circulating water system and the number of pumps to be provided for the system. The
number of pumps provided could be any of the following alternatives:
(a) Two numbers each of 50% capacity
(b) Three numbers each of 33.3% capacity
(c) Four numbers each of 25% capacity
4.1.2 The approximate cooling water requirements for different sizes of generating units are
given Appendix-1.
4.1.3 The quantity of standby pumps shall be finalised after discussion with client. Typical
guidelines could be:
(a) Nil or minimum standby pumps for fresh water application.
(b) One number standby for (a) and (b) above for sea water application.
(c) For configuration (c) above for seawater application, quantity could be
decided after doing economic analysis of providing standby pump vis--vis
loss of generation.
4.2 TOTAL HEAD
Total head comprises static head and friction losses.
4.2.1 Static Head
The static head shall be either the difference in elevation between the water level in the
circulating water sump and the maximum water level or discharge pipe elevation
whichever is higher. For efficient operation of the circulating water pumpsets the
normal water level in the sump shall be considered for computation of the static head.
Minimum water level in sump could be considered in case a prolonged duration of
water level being at minimum level is anticipated.
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4.2.2 Friction Head
Friction head is the head necessary to overcome the friction losses in the heat
exchanger, piping, valves and fittings for the system in which the pump operates. The
friction head depends on several factors like velocity of water, type of fittings, inside
surface roughness of the pipeline, length of the pipeline involved in the system etc. The
method of calculation of friction head for a given system is explained in the Design
Guide No. TCE.M6-ME-613-212 Guide for Calculation of Hydraulic Losses for
Water in Pipes, Fittings and Valves.
4.3 SPEED
4.3.1 Selection of speed is governed by following considerations:
(a) Type of driver contemplated for the unit
(b) Higher specific speed results in a smaller pump and cheaper drivers.
4.3.2 The pump parameters shall be achievable at a speed corresponding to normally
available frequency.
5.0 TYPE OF PUMP
The pumps could be classified according to the orientation of the suction and discharge
nozzles or could be classified according to the design of the casing. Side suction and
side discharge (horizontal split casing pumps) are generally used. In horizontal split
casing pumps the casing is divided by a horizontal plane through the shaft centre line or
axis. Since both suction and discharge nozzles are in the lower half of the casing the
upper half of the casing could be removed for inspection of the interior without
disturbing the bearings or the piping. The benefit of this type is that the mechanical
design of casing is structurally stable, since the impeller is supported by bearings on
either side of the impeller.
6.0 CONSTRUCTION FEATURES
6.1 ENCLOSED IMPELLER
Only enclosed impellers of double suction type are used for these pumps. The impeller
incorporates shroud that totally encloses the impeller waterways from the suction eye
to the periphery. This design prevents the leakage of water between the impeller and
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its side plates. However, a running joint must be provided between the impeller and
the casing to separate the discharge and suction chambers of the pumps. The thrust
developed for a closed impeller is minimum.
6.2 DOUBLE SUCTION IMPELLER
In a double suction impeller theoretically a hydraulic axial balance exists with the
pressure on one side of the impeller equal to and counter balancing the pressure on the
other side of the impeller. However, in practice it may not be possible to achieve this
hydraulic balance. The forces acting on a double suction impeller is shown in
Appendix-3.
6.3 WEARING RINGS
Wearing rings provide an easily and economically renewable leakage joint between
impeller and casing. The material of the wearing ring shall be softer than the impeller
material so that impeller does not get worn out. Some times pumps are provided with
two wearing rings, one on the casing and the other on the impeller. A double flat-ring
construction type of wearing ring is shown in Appendix-4.
6.4 SHAFT COUPLING
The pump shaft is to be connected to the motor shaft by means of flexible/spacer
coupling.
6.5 SHAFT SLEEVE
The shaft sleeve to be provided to protect shaft from direct wear.
6.6 STUFFING BOX
If the pump works with suction lift and the pressure at the interior of stuffing box end is
below atmospheric, stuffing box prevents air leakage into the pump. If the pressure
inside the pump is above atmospheric the stuffing box prevents the liquid being
pumped from leaking out. A conventional stuffing box used in a horizontal pump is
shown in Appendix-5. Mechanical seal instead of gland packing also can be provided
to prevent leakage.
6.7 LUBRICATION AND COOLING OF PUMPS
The stuffing box gland/mechanical seal shall be supplied water for
lubrication/cooling/sealing of the stuffing box packing/mechanical seal. The water for
lubrication/cooling/sealing shall be taken from the pump discharge itself. When pump
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is handling seawater, filtered seawater should be used.
7.0 MATERIALS OF CONSTRUCTION
The materials of construction of the various components of the pump shall be selected
based on the type of water being handled. The materials shall be so selected that
corrosion of the parts is prevented which in turn reduces the maintenance of the pump.
The materials to be adopted for various components of the pump are indicated in the
Appendix-2.
8.0 PEFORMANCE CHARACTERISTICS
The pump at constant speed delivers any capacity from zero to maximum value
depending on the size, design and suction condition of the pump. The pump shall have
stable rising (H Vs Q) characteristic curve from run out flow to no flow condition. The
maximum head developed by the pump shall be at shut off condition. The pumps shall
operate at the best efficiency point. At least 1 MLC difference shall be maintained
between (NPSHa NPSHr) throughout NPSH curve.
9.0 LAYOUT CONSIDERATIONS
The sump shall be so designed that the velocity of water in the sump is sufficiently low
not to cause any turbulence near the pump. The sump dimensions shall be based on
the recommendations of Hydraulic Institutes Standard. Layout of suction piping with
tentative dimensions is given in Appendix-6 (also refer design guide TCE.M6-ME-
613-213 Design Guide for Pump Sump).
10.0 MOTORS
Normally, circulating water pumps require 6.6 kV or 3.3 kV, 3 phase, 50 Hz, motors.
The selection of the proper motor rating is a very important factor in satisfactory
operation of the pump sets. The motor rating shall be at least 116% of the power
required by the pump at duty point. The enclosure for the motors shall be Totally
Enclosed Fan Cooled (TEFC), Circulating Air Closed Air (CACA) or Circulating Air
Closed Water (CACW). CACA motors though costlier than CACW motors, are
normally preferred as it eliminates the water circulation arrangement for motor.
11.0 PERFORMANCE TEST
Performance test of prototype pump shall be conducted at manufacturers works as
per BS: 5316, Part 2/ISO 3555 to find out whether the pumps meet the guaranteed
values of capacity, head, efficiency and power input.
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12.0 NOISE AND VIBRATION
After installation of pumpsets the following parameters are to be checked:
(a) The noise level of the pumpset shall not exceed 85 dBA measured at a
distance of 1.86 m from the outline of the equipment.
(b) The velocity of vibration shall not exceed 4.5 mm/sec (Refer ISO-10816-
1/BS: 7854 Part-I).
13.0 CROSS REFERENCES
This document makes reference to the following standard documents:
DOCUMENT NO. DOCUMENT TITLE
TCE.M6-ME-613-212 Guide for Calculation of Hydraulic losses for Water in
Pipes, Fittings and Valves
TCE.M6-ME-613-213 Design Guide for Pump Sump
TCE.M6-ME-613-215
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APPENDIX - 1
COOLING WATER REQUIREMENTS
MW/UNIT TOTAL COOLING WATER REQUIRED (M
3
/Hr)
50 10,000
110 17,000 to 18,000
200 32,000
500 66,000
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TCE FORM NO.120R1
APPENDIX-2
MATERIALS OF CONSTRUCTION
MATERIAL OF CONSTRUCTION
SEA WATER SERVICE
SL.
NO.
COMPONENT
ALTERNATIVE-1 ALTERNATIVE-2
FRESH WATER
SERVICE
1. Casing Ni-resist as per BS
3468 GR S2W
Ni-resist as per ASTM
A436 Type 2 OR
Stainless steel as per
ASTM A351 GR
CF3M OR CF8M
Cast iron as per IS 210
GR FG 220 OR ASTM
A48 CL 35
2. Impeller Stainless steel as per
ASTM A351 GR
CF3M OR CF8M
ASTM A351 GR
CF3M OR CF8M
Bronze as per IS 318
GR LTB2 OR Cr-Ni
alloy as per ASTM
A743 GR CF-8
3. Shaft Cr-Ni alloy as per
ASTM A743 GR CK-
20
Cr-Ni alloy as per
ASTM A743 GR CK-
20 OR Cr-Ni-Mo alloy
as per ASTM A743 GR
CF-8M
Carbon steel as per IS
1570 40C8 OR ASTM
A107 GR 1040
4. Shaft Sleeves Cr-Ni alloy as per
ASTM A743 GR CK-
20
Cr-Ni alloy as per
ASTM A743 GR CK-
20 OR Cr-Ni-Mo alloy
as per ASTM A743 GR
CF-8M
GR LTB2
5. Wearing rings/
Casing rings
Ni-resist as per BS
3468 GR S2W
A436 Type 2
Leaded bronze
6. Gland Ni-resist as per BS
3468 GR S2W
A436 Type 2
GR LTB2
7. Lantern ring Ni-resist as per BS
3468 GR S2W
A436 Type 2
GR LTB2
8. Packing PTFE PTFE Graphited asbestos
9. Base plate Carbon steel epoxy
painted
Carbon steel epoxy
painted
Fabricated steel as per
IS 2062
10. Hardware in
contact with water
ASTM A276 Type
316L
ASTM A276 Type
316L
ASTM A276 Type 410
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TCE FORM NO.120R1
APPENDIX-2
MATERIALS OF CONSTRUCTION
MATERIAL OF CONSTRUCTION
SEA WATER SERVICE
SL.
NO.
COMPONENT
ALTERNATIVE-1 ALTERNATIVE-2
FRESH WATER
SERVICE
11. Hardware not in
contact with water
1367-Class 6.6
1367-Class 6.6
1367-Class 6.6
TCE.M6-ME-610-217
DESIGN GUIDE FOR
TOTAL HEAD AND NPSH CALCULATIONS FOR
CENTRIFUGAL PUMPS
SHEET i OF iii
ISSUE
PPD. BY DVL Sd/- MMK Sd/- MMK Sd/- SDP
CHD. BY OKM Sd/- TSR Sd/- TSR Sd/- TSR
APD. BY KG Sd/- RL Sd/- RL Sd/- RL
DATE 29.11.984 17.01.1998 02.01.2001 02.02.2004
R4
TCE FORM NO. 020 R2
DESIGN GUIDE FOR
CENTRIFUGAL PUMPS
TCE.M6-ME-610-217
DESIGN GUIDE FOR
CENTRIFUGAL PUMPS
SHEET ii OF iii
ISSUE
R4
TCE FORM NO. 120 R1
CONTENTS
1.0 SCOPE 1
2.0 TYPICAL PUMP SKETCH 1
3.0 TOTAL HEAD CALCULATIONS 1
4.0 NPSH CALCULATIONS 2
TCE.M6-ME-610-217
DESIGN GUIDE FOR
CENTRIFUGAL PUMPS
SHEET iii OF iii
ISSUE
R4
TCE FORM NO. 120 R1
REVISION STATUS
R0 10.09.1981 - -
R1 29.11.1984 - -
R2 17.01.1998 Reformatted in MS Word.
R4 02.02.2004 Reformatted.
TCE.M6-ME-610-217
DESIGN GUIDE FOR
CENTRIFUGAL PUMPS
SHEET 1 OF 2
ISSUE
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TCE FORM NO. 120 R1
1.0 SCOPE
This document gives guidelines for calculating total head and Net Positive Suction
Head (NPSH) for centrifugal pumps.
2.0 TYPICAL PUMP SKETCH
EL.Ed Pd
EL.En
EL.Es Ps
PSSSSS
DISCHARGE VESSEL
SUCTION VESSEL
C EL.Ep
PUMP
3.0 TOTAL HEAD CALCULATIONS
SL. NO. ITEM SYMBOL UNIT FORMULA VALUE
3.1 Elevation of water level in
suction vessel
Es M
3.2 Elevation of water level in
discharge vessel
Ed M
3.3 Elevation of centre-line of
nozzle on discharge vessel
En M
3.4 Elevation of centre-line of pump Ep M
3.5 Static suction head hs MLC Es - Ep
3.6 Friction losses in suction piping
and entry losses
hfs MLC
3.7 Gauge pressure in suction vessel Ps Kgf/
cm
2
g
3.8 Specific gravity of the liquid
handled
S
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SL. NO. ITEM SYMBOL UNIT FORMULA VALUE
3.9 Suction head Hs MLC hs - hfs +
(Ps 10 )/S
3.10 Static discharge head hd MLC (Greater of
Ed or En) -
Ep
3.11 Friction losses in discharge
piping, equipment and the exit
losses
hfd MLC
3.12 Gauge pressure in discharge
vessel
Pd Kgf/
cm
2
g
3.13 Delivery head Hd MLC hd + hfd +
(Pd 10)/S
3.14 Total head H MLC Hd - Hs
4.0 NPSH CALCULATIONS
SL.NO. ITEM SYMBOL UNIT FORMULA VALUE
4.1 Absolute vapour pressure at the
temperature at which liquid is
handled
Pv Kgf/
cm
2
4.2 Absolute atmospheric pressure Pa Kgf/
cm
2
4.3 Net Positive Suction Head
Available (NPSH A)
NPSH MLC (Pa 10)/S +
Hs -
(Pv 10 )/S
NOTES
1. All elevations shall be considered from common datum.
2. Elevations mentioned correspond to normal conditions. However, these shall be cross-
checked with the extreme conditions.
3. Ps and Pd are positive if the pressure is above atmospheric pressure and negative if the
pressure is below atmospheric pressure.
4. Hs and hs may either be positive or negative.
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TCE FORM NO. 120 R1
SECTION: TITLE
TCE.M6-ME-811-301
DESIGN GUIDE FOR
AIR-CONDITIONING LOAD CALCULATIONS
SHEET
i OF iii
REV. NO. R0 R1 R2 ISSUE
PPD. BY PRJ Sd/- HRK Sd/- HRK
CHD. BY DJ Sd/- PRJ Sd/- PRJ R2
APD. BY JSK Sd/- RL Sd/- RL
DATE 22.12.1988 27.12.1999 01.12.2002
TCE FORM NO. 020R2
DESIGN GUIDE FOR
SECTION: TITLE
TCE.M6-ME-811-301
DESIGN GUIDE FOR
SHEET
ii OF iii
REV. NO. R0 R1 R2 ISSUE
PPD. BY PRJ Sd/- HRK Sd/- HRK
CHD. BY DJ Sd/- PRJ Sd/- PRJ R2
APD. BY JSK Sd/- RL Sd/- RL
DATE 22.12.1988 27.12.1999 01.12.2002
TCE FORM NO. 020R2
SECTION: CONTENTS
TCE.M6-ME-811-301
DESIGN GUIDE FOR
SHEET ii OF iii
TCE FORM NO.
120R1
ISSUE
R2
CONTENTS
SL. NO. TITLE SH.NO.
1.0 SCOPE 1
2.0 INPUT DATA 1
3.0 COMPONENTS AIR-CONDITIONING LOAD 2
4.0 ESTIMATION OF AIR-CONDITIONING LOAD 5
5.0 APPARATUS DEW POINT 27
6.0 DEHUMIDIFIED AIR FLOW RATE 28
7.0 REFERENCES 28
APPENDICES
1. TYPICAL AIR-CONDITIONING PSYCHROMETRIC
PROCESS
29
2. SAMPLE AIR-CONDITIONING LOAD CALCULATIONS 30
3. ASHRAE PSYCHROMETRIC CHART NO. 1 FOR
NORMAL TEMPERATURES AT SEA LEVEL
41
SECTION: REV.STATUS
TCE.M6-ME-811-301
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REVISION STATUS
R0 88.12.22 ----------------
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TCE.M6-ME-811-301
DESIGN GUIDE FOR
SHEET 1
OF 41
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ISSUE
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1.0 SCOPE
This document outlines the procedure for performing air-conditioning cooling load,
heating load and dehumidified air flow rate calculations.
2.0 INPUT DATA
collaborator, other groups in the mechanical department, other departments, bidders
and vendors.
2.1 Location of the site and the plot plan
2.3 Names of areas to be air-conditioned
2.4 Equipment layout drawings of the areas to be air-conditioned
2.5 Architectural drawings and civil Reinforced Cement Concrete (RCC) or
structural steel drawings of the areas to be air-conditioned
2.6 Outside design conditions like Dry Bulb Temperature (DBT), Wet Bulb
Temperature (WBT) and Relative Humidity (RH) for summer, monsoon and
winter and daily temperature range
2.7 Inside design conditions and internal loads for each of the areas to be air-
conditioned
(a) DBT range
(b) RH range
(c) Lighting loads
(d) Sensible and latent equipment heat loads of heat sources within and
adjacent to the air-conditioned areas with specific periodic loading
patterns, if any
(e) Occupancy
(f) Fresh air and exhaust air requirements, if any
(g) Filtration and cleanliness requirements, if any
(h) Pressurisation requirements, if any
(i) Air flow pattern requirements, if any
(j) Hazardous area classification
2.8 Duration of air-conditioning for each of the areas to be air-conditioned
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2.9 Availability of cooling water, make-up water, quality of water, inlet and outlet
Some of the input data indicated above may not be readily available at the time of
performing these calculations. Appendices 1 to 4 of TCE.M1-ME-811-301 give
guidelines for assuming such data.
3.0 COMPONENTS OF AIR-CONDITIONING LOAD
3.1 STRUCTURAL HEAT GAIN
3.1.1 Sensible Heat Gain
(a) External Walls
This component of heat gain is by virtue of the Equivalent Temperature
Difference (ETD) across walls, ceiling, exposed roof or floor RCC slabs
and door or window glass. The ETD is the DBT difference across the wall
and the outdoor. Additional corrections in the temperature differential are
due to conduction across the surface, convection and incident radiation on
the surface, month of the year, time of the day, storage effect due to the heat
capacity of the structure, the latitude and the orientation of the building or
structure with respect to the true north. The estimation of this component of
heat gain requires the estimation or establishing of the following parameters
for each of the surfaces of the structure which are exposed to the outside:
(i) Heat transfer area
(ii) Heat transfer coefficient
(iii) ETD
(b) Internal Walls (Partition Walls)
This component of heat gain is by virtue of the temperature difference across
the internal walls of the building, i.e. the areas of the building adjacent to the
area to be air-conditioned. The estimation of this component of heat gain
requires the estimation or establishing of the following parameters for each
of the surfaces of the structure which are not exposed to the outside:
(i) Heat transfer area
(ii) Heat transfer coefficient
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DESIGN GUIDE FOR
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(iii) Temperature difference (T)
3.1.2 Latent Heat Gain
The structural heat gain also includes the latent heat load due to the moisture
transmission across the walls, roof or ceiling and floor slabs of the structure or by
ingress with the air that enters the room through door openings, fixed wall openings
for conveyers or open windows. This load component is especially significant for
areas having inside design RH values of 45% and lower. The moisture transmission
load is a function of the differential vapour across the structure.
3.2 FENESTRATION HEAT GAIN
This component of heat gain considers the radiation entering the air-conditioned area
through exposed glass surfaces. The conduction and convection components of
fenestration heat gain have been described in para 3.1.1. This component is not
normally applicable to internal walls. The estimation of this component requires the
estimation or establishing of the following parameters:
(a) Glass area
(b) Glass transmittance factor
(c) Glass Solar Heat Gain Factor (SHGF)
3.3 INFILTRATION HEAT GAIN
This component is due to ambient air leaking into the air-conditioned area through
gaps between door or window frames and their shutters, cracks in the walls etc. The
estimation of this component requires the estimation or establishing of the following
parameters:
(a) Area of gaps between door and window frames, cracks in walls etc.
(b) Air pressure difference across the gap or crack
3.4 INTERNAL HEAT GAIN
This component is due to heat dissipation by the equipment, people and lighting. The
estimation of this component requires the estimation or establishing of the following
parameters:
(a) Sensible and latent heat dissipation loads from equipment, the locations and
quantities of the equipment
(b) Number of people occupying each of the areas and the activities performed
by these people
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(c) Number, type (fluorescent or incandescent) of lighting fixtures in each of the
areas and their rating in watts. In some cases special fixtures are provided
which also serve as return air inlets. Such fixtures (Troufers) do not reduce
the total heat dissipation from the lighting fixture but reduce the lighting heat
dissipation into the room. The reduction in the lighting heat dissipation into
the room is instead transferred to the return air, reducing the room sensible
heat gain and consequently the room dehumidified air flow rate. This heat
dissipation load, within the room and in the return air, shall be furnished by
the electrical department from approved vendor drawings or catalogues.
The diversity factor for the heat dissipation from each of the above shall be
considered.
3.5 FAN AND DUCT HEAT GAIN
This component is due to the supply air fan power consumption and the heat gain to
the supply and return air duct. In addition to the above, a notional heat gain is
considered for the leakage from the supply air and the return air. Heat gain from
return air fan, if provided, shall be added to the return air.
3.6 FRESH AIR HEAT GAIN
This component is due to the fresh air introduced into the air-conditioned area to
maintain indoor air quality or pressurisation. The estimation of this component
requires the estimation or establishing of the following parameters:
(a) Quantity of fresh air
(b) Cooling coil bypass factor
3.7 RETURN AIR HEAT GAIN
The heat gain to the return air, after collection from the area to be air-conditioned
may form a significant proportion of the total cooling load. This cooling load does
not form part of the room cooling load and therefore has no contribution to the
dehumidified air flow rate calculation. The return air heat gain shall be estimated for
the heat gain through the return air duct, which may be sheet metal or masonry.
The heat gain to return air, when collected above the false ceiling, from exposed
roof or ceiling is theoretically not part of the room load and therefore should not be
considered as the room heat gain which is considered for the estimation of the
dehumidified air flow rate. However, to simplify the procedure for the air-
conditioning load calculation, this load is considered as part of the room load. This
will give about 2 to 3% higher dehumidified air flow rate which is more conservative
and acceptable. This return air heat gain above the false ceiling can, if so desired by
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DESIGN GUIDE FOR
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the designer, be estimated by an iterative procedure and considered for the
dehumidified air flow rate estimation.
The parameters which are to be established are :
(a) Overall heat transfer coefficient across the return air duct
(b) Area of the return air duct
(c) ETD for the return air duct
ETD shall be estimated for return air routed through masonry or exposed insulated
sheet metal ducts, which are exposed to the ambient. In case the ducts are located
indoors, the DBT difference shall be the temperature difference across the return air
duct wall.
4.0 ESTIMATION OF AIR-CONDITIONING LOAD
4.1 STRUCTURAL HEAT GAIN
4.1.1 Sensible Heat Gain
(a) Heat Transfer Area
The areas of the heat transfer surfaces of each the air-conditioned areas
shall be estimated from the architectural drawings. The heat transfer areas
include the following:
(i) Wall face areas. These include walls exposed to the ambient
(exposed walls) and walls which are internal to the building.
(ii) Floor, ceiling or exposed roof RCC slab
(iii) Glass areas. These are for doors or windows. These, like walls,
could also be exposed or internal.
The orientation of the respective exposed walls and glass surfaces, above
and below the false ceiling, shall be noted with respect to the true north.
The wall and slab area shall be estimated considering the grouping of the
various areas, for the purpose of combining the areas under one unit or
under multiple units, each being operated separately. For example, in case
two adjacent areas are being air-conditioned simultaneously and the inside
design temperatures are similar, there will be no heat transfer between these
areas. The common glass, wall or RCC slab between these areas shall not
be considered for heat transfer area calculations. In case the areas have
different hours of operation of the air-conditioning systems, the common
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glass, walls and RCC slabs shall be considered for heat transfer for the
duration of time that either of the areas is not air-conditioned.
Normally, it is recommended that for adjacent areas, which are separately
air-conditioned, the common glass, walls and RCC slabs be considered for
heat transfer, for each of the areas. This would give a higher cooling load
estimate than that considering the adjacent rooms being air-conditioned.
However, the designer has to take an overall system design approach while
considering this element of heat gain.
(b) Heat Transfer Coefficient
The overall heat transfer coefficient (U-factor) shall be estimated for each of
the walls, ceiling and floor slabs and glass areas. The U-factor is the
reciprocal of the sum of the total thermal resistance across the slab, wall or
glass. The total thermal resistance shall be estimated for each component of
the thermal resistance as listed below:
(i) Walls
Outer air film
Outer cement plaster
Wall (Ordinary brick, hollow concrete block, concrete,
plywood etc.)
Inner cement plaster
Inner air film
(ii) Floor Slabs, Roof or Ceiling
Outer air film
Floor finish- tiled finish for floors or water-proofing finish for
exposed roof slabs
RCC slab
Thermal insulation
Inner cement plaster
Inner air film
Thermal resistances for above shall be referred to in ASHRAE
Handbook, Fundamentals 1993 Edition, Chapter 22, Tables 1, 2, 3
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and 4. The construction materials for the walls, RCC slabs, window
or door glass etc. shall be taken from the architectural drawings. If
necessary, the civil engineer may be consulted. The above
components are listed as guidelines and are generally adequate for
most applications. The components for specific applications or
projects may be established from the respective architectural
drawings.
The insulation thickness required to be provided, shall be calculated
for prevention of condensation on the external surfaces or the
optimised insulation thickness considering the operating and
installation costs for the insulation, whichever is more stringent. For
exposed roofs, thermal insulation is generally provided out of 50
mm thick expanded polystyrene or equivalent insulation material.
In cases where the room temperatures are low enough to cause
condensation on the external surface of the room wall, it may be
necessary to provide thermal insulation. This requirement of thermal
insulation may be verified by the following equation:
T
od
< T
r
+ (T
od
T
r
) x (U/U
1
)
Where,
T
od
= Dew point temperature of the area adjacent to the
air-conditioned room
T
r
= DBT of air-conditioned room
U = Overall heat transfer coefficient of the common wall
U
1
= The reciprocal of the common wall thermal
resistance considered without the wall outer air film
resistance
The outdoor air dew point temperature shall be taken from the
psychrometric chart for the most stringent conditions. Generally, this
will be for the monsoon season. In cases where the adjacent area is
to be maintained at a high RH, the same shall be considered.
Thermal insulation may also be provided for conservation of heat in
case of heating applications. This insulation may serve a dual
purpose. It may serve as a heat conservator to minimise the heating
load during winter and to minimise the heat gain during summer. This
will be applicable to sites located in regions having extreme climates.
In case of dual duty, the thermal insulation thickness for the more
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stringent requirement shall be provided and considered for the air-
conditioning load estimation.
(iii) The heat transfer coefficients in Watts /M
2 O
C for conduction
through glass shall be taken from the table 1:
TABLE 1
HEAT TRANSFER COEFFICIENTS FOR CONDUCTION THROUGH GLASS
VERTICAL GLASS HORIZONTAL GLASS
SINGLE DOUBLE SINGLE DOUBLE TRIPLE
SUMMER WINTER SUMMER WINTER
AIR SPACE THICKNESS
mm
- - 6 12.5 20
TO
100
6 12.5 20
TO
100
- - - -
6 6
WITHOUT STORM
WINDOWS
6.4 3.5 3.1 3.0 2.3 2.0 1.9 4.9 7.9 2.8 4.0
WITH STORM WINDOWS
3.1 3.5 3.1 3.0 2.3 2.0 1.9 2.4 3.6 2.8 4.0
SOURCE: ISHRAE 1997, PART I, TABLE 6, PAGE 1.7
(c) ETD
Table 2 gives the uncorrected ETD (tes for wall in shade and tem for
wall exposed to the design conditions) values for varying weights of wall.
Table 3 gives the uncorrected ETD (tes for roof in shade and tem for
roof exposed to the design conditions) values for varying weights of the roof
structure.
Table 4 gives the corrections (tc) to be made to the uncorrected ETD
(tes and tem) from tables 2 and 3 for a variation in the outdoor to indoor
DBT difference and daily range.
The corrected ETD shall be calculated as per the following equation:
ETD = tesc + {(temc - tesc) x c x Rs/Rm}
where,
ETD = Corrected ETD across the wall or roof (
O
C)
tesc = Corrected ETD of the roof or the wall under consideration
in shade (
O
C).
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= tes + tc
temc = Corrected ETD of the roof or the wall under consideration
subjected to the design condition. i.e. load on the exposed
roof or on walls facing the respective directions (
0
C).
= tem + tc
c = Correction factor for colour shade of wall
= 1 for dark coloured roof or wall
= 0.778 for medium coloured roof or wall
= 0.556 for light coloured roof or wall
Rs = Maximum Solar Heat Gain Factor (SHGF) incident on glass
or wall or horizontal roof for the month and latitude desired.
Rs values shall be taken from ASHRAE Handbook,
Fundamentals, 1993 Edition, Chapter 27, Tables 12 to 18.
(Watts /M
2
)
Rm = Maximum SHGF incident on glass or wall or horizontal roof
for the month of July and latitude of 40
0
North. Rm values
shall be taken from ASHRAE Handbook, Fundamentals,
1993 Edition, Chapter 27, Table 15. (Watts /M
2
)
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4
SECTION: WRITE-UP
TCE.M6-ME-811-301
DESIGN GUIDE FOR
SHEET
11 OF 41
TCE FORM NO.
120R1
ISSUE
R2
9
8
-
1
.
1
-
2
.
2
-
2
.
2
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1
0
.
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2
6789
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0
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2
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1
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1
2
12345
T
A
B
L
E

2

(
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.
)
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9
,

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1
.
1
4
SECTION: WRITE-UP
TCE.M6-ME-811-301
DESIGN GUIDE FOR
SHEET
12 OF 41
TCE FORM NO.
120R1
ISSUE
R2
4
9
-
2
.
2
-
3
.
3
-
3
.
9
-
2
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TCE.M6-ME-811-301
DESIGN GUIDE FOR
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TABLE 4
CORRECTIONS TO ETD tc C
DAILY RANGE C
OUTDOOR
TO INDOOR
DBT
DIFFERENCE
C
4.4 5.6 6.7 7.8 8.9 10.0 11.1 12.2 13.3 14.4 15.6 16.7 17.8 18.9 20.0 21.1 22.2
-16.7 -21.7 -22.2 -22.8 -23.3 -23.9 -24.4 -25.0 -25.6 -26.1 -26.7 -27.2 -27.8 -28.3 -28.9 -29.4 -30.0 -30.6
-11.1 -16.1 -16.7 -17.2 -17.8 -18.3 -18.9 -19.4 -20.0 -20.6 -21.1 -21.7 -22.2 -22.8 -23.3 -23.9 -24.4 -25.0
-5.6 -10.6 -11.1 -11.7 -12.2 -12.8 -13.3 -13.9 -14.4 -15.0 -15.6 -16.1 -16.7 -17.2 -17.8 -18.3 -18.9 -19.4
0.0 -5.0 -5.6 -6.1 -6.7 -7.2 -7.8 -8.3 -8.9 -9.4 -10.0 -10.6 -11.1 -11.7 -12.2 -12.8 -13.3 -13.9
2.8 -2.2 -2.8 -3.3 -3.9 -4.4 -5.0 -5.6 -6.1 -6.7 -7.2 -7.8 -8.3 -8.9 -9.4 -10.0 -10.6 -11.1
5.6 0.6 0.0 -0.6 -1.1 -1.7 -2.2 -2.8 -3.3 -3.9 -4.4 -5.0 -5.6 -6.1 -6.7 -7.2 -7.8 -8.3
8.3 3.3 2.8 2.2 1.7 1.1 0.6 0.0 -0.6 -1.1 -1.7 -2.2 -2.8 -3.3 -3.9 -4.4 -5.0 -5.6
11.1 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0.0 -0.6 -1.1 -1.7 -2.2 -2.8
13.9 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8 2.2 1.7 1.1 0.6 0.0
16.7 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6 5.0 4.4 3.9 3.3 2.8
19.4 14.4 13.9 13.3 12.8 12.2 11.7 11.1 10.6 10.0 9.4 8.9 8.3 7.8 7.2 6.7 6.1 5.6
22.2 17.2 16.7 16.1 15.6 15.0 14.4 13.9 13.3 12.8 12.2 11.7 11.1 10.6 10.0 9.4 8.9 8.3
The temperature difference for internal surfaces like walls, ceiling, roof or
floor slab or glass, shall be the temperature difference between the area to
be air-conditioned and the respective adjoining areas. In case the
temperature in the adjoining area is not available from the input data, the
room shall be assumed to be non-air-conditioned. The temperature
difference (T) for such cases shall be taken as:
T = DBT(ambient) - DBT(air-conditioned area) - 2.8
O
C
For external glass, the temperature difference shall be taken as:
T = DBT(ambient) - DBT(air-conditioned area)
For heating coil calculations, the ambient DBT will be lower than the DBT
for the air-conditioned area. The temperature difference for all glass area,
exposed and internal walls, for heating load calculations shall be the
difference between room and ambient DBT.
T = DBT(air-conditioned area) - DBT(ambient)
4.1.2 Latent Heat Gain
This component of heat gain is to be calculated for room design RH values of 45%
or lower as the contribution for higher indoor RH values is not significant. The latent
heat gain due to moisture ingress shall be estimated by the following equations:
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(a) Moisture Load Through the Fabric of the Structure
H
LS
= 2.225 x H x V x G x F1 x F2 x F3 x F4
Where,
H
LS
= Latent load due to vapour permeance through structure
(watts)
H = Enthalpy differential between humidity ratios Gi for room
and Go for the adjacent area, at the room DBT from
psychrometric chart at altitude of the site (KJ/Kg).
V = Room volume (M
3
)
G = Differential humidity ratio across the room i.e. difference
between outside humidity ratio Go and room humidity ratio
Gi (gms of moisture per Kg of dry air)
F1 = Factor for differential humidity ratio (Refer table 5)
F2 = Factor for space permeance (Refer table 6)
F3 = Factor for wall or slab construction (Refer table 7)
F4 = Factor for vapour treatment (vapour barrier) of walls (Refer
table 8)
(b) Moisture Load Due to Door Openings
H
LD
= 1.357 x H x N x A x G x F1
Where,
H
LD
= Latent load due to vapour permeance through door
openings (watts)
psychrometric chart at altitude of the site KJ/Kg.
N = Number of door openings per hour
A = Area of door opening (M
2
)
G = Differential humidity ratio across the door (gms of moisture
per Kg of dry air)
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(c) Moisture Load Through Fixed Openings (Conveyors, Open Windows etc.)
H
LO
= 62.039 x H x (A x G x F1) / D
Where,
H
LO
= Latent load due to vapour permeance through fixed
openings (Watts)
psychrometric chart at altitude of the site KJ/Kg
A = Area of fixed opening (M
2
)
G = Differential humidity ratio across the fixed opening (gms of
moisture per Kg of dry air)
D = Depth of the opening (M)
(d) Total Latent Heat Gain
H
L
= H
LS
+ H
LD
+ H
LO
TABLE 5
FACTOR F1 FOR DIFFERENTIAL HUMIDITY RATIO
DIFFERENTIAL HUMIDITY
RATIO (gms per Kg of dry air) 5.00 5.71 7.14 8.57 10.00
FACTOR F1 1.00 1.11 1.35 1.58 1.82
DIFFERENTIAL HUMIDITY
RATIO (gms per Kg of dry air) 11.43 12.86 14.29 15.71 17.14
FACTOR F1 2.05 2.29 2.59 2.76 2.99
SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS, TABLE II, PAGE 8.
TABLE 6
FACTOR F2 FOR SPACE PERMEATION
VOLUME OF ROOM
(IN 1000 M
3
)
0.28 0.57 0.85 1.13 1.42 1.70 1.98 2.27 2.55 2.83
FACTOR F2 0.64 0.57 0.53 0.50 0.47 0.44 0.42 0.40 0.38 0.37
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TABLE 6 (CONTD.)
VOLUME OF ROOM
(IN 1000 M
3
)
3.40 3.96 4.53 5.10 5.66 6.23 6.80 7.36 7.93 8.50
FACTOR F2 0.36 0.34 0.33 0.32 0.29 0.28 0.27 0.27 0.26 0.25
SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS,TABLE III, PAGE 8.
TABLE 7
FACTOR F3 FOR WALL OR SLAB CONSTRUCTION
DETAILS OF CONSTRUCTION FACTOR F3
Masonry or frame construction 1.0
Sheet metal, steel welded 0.2
Module panel, caulked and sealed 0.5
SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS, TABLE IV, PAGE
8.
TABLE 8
FACTOR F4 FOR VAPOUR BARRIER
DETAILS OF VAPOUR BARRIER FACTOR F4
Laminated mylar metallic or polyethylene film 0.50
Two layers edge sealed moisture paper 0.67
Two coats vapour proof paint 0.75
SOURCE: ENGINEERING DATA MANUAL, BRY-AIR, DEHUMIDIFIERS, TABLE IV, PAGE 8.
NOTES:
1. If product of F3 and F4 is less than 0.5, use 0.5.
2. If room is completely vapour proofed with continuous vapour barrier under
the floor (or of all-metal welded construction) the factor (F3 x F4) may be
reduced to 0.2
4.2 FENESTRATION HEAT GAIN
(a) Glass Transmittance Factor (G)
This factor considers the type of glass whether single, double etc., the type
of shading for the glass whether provided with shading, tints, curtains or
blinds etc. This factor shall be referred to in tables 9, 10 and 11.
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(b) Glass Solar Heat Gain Factor (SHGF)
SHGF shall be selected from ASHRAE Handbook, Fundamentals 1993
edition, Chapter 27, Tables 12 to 18. This component takes into
consideration the orientation of the glass with respect to the true north,
latitude, time of the day and month of the year.
The fenestration heat gain shall be calculated as follows:
Q
f
= G x SHGF x A
Where,
Q
f
= Fenestration heat gain for the glass (Watts)
G = Glass transmittance factor (dimensionless)
SHGF = Solar Heat Gain Factor (watts / M
2
)
A = Area of the glass (M
2
)
The glass transmittance factor shall be referred from tables 9, 10 and 11.
TABLE 9
GLASS TRANSMITTANCE FACTOR (G) FOR SOLAR HEAT
GAIN THROUGH GLASS WITH AND WITHOUT SHADING
INSIDE VENETIAN BLIND
45
o
HORIZ. OR VERTICAL OR
ROLLER SHADE
OUTSIDE
VENETIAN BLIND
45
o
HORIZ. SLATS
OUTSIDE SHADING
SCREEN
17
o
HORIZ. SLATS
OUTSIDE AWNING
VENT. SIDES &
TOP
TYPE OF
GLASS
GLASS
FACTOR
NO
SHADE
LIGHT
COLOUR
MEDIU
M
COLOUR
DARK
COLOUR
LIGHT
COLOUR
LIGHT ON
OUTSIDE
DARK ON
INSIDE
MEDIU
M
COLOUR
DARK
COLOUR
LIGHT
COLOUR
MEDIU
M OR
DARK
ORDINARY
GLASS
1.00 0.56 0.65 0.75 0.15 0.13 0.22 0.15 0.20 0.25
REGULAR
PLATE
6 mm
0.94 0.56 0.65 0.74 0.14 0.12 0.21 0.14 0.19 0.24
HEAT ABSORBING GLASS
40 TO 48%
0.80 0.56 0.62 0.72 0.12 0.11 0.18 0.12 0.16 0.20
48 TO 56%
0.73 0.53 0.59 0.62 0.11 0.10 0.16 0.11 0.15 0.18
56 TO 70%
0.62 0.51 0.54 0.56 0.10 0.10 0.14 0.10 0.12 0.16
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TABLE 9 (CONTD.)
DOUBLE PANE
ORDINARY
GLASS
0.90 0.54 0.61 0.67 0.14 0.12 0.20 0.14 0.18 0.22
REGULAR
PLATE
0.80 0.52 0.59 0.65 0.12 0.11 0.18 0.12 0.16 0.20
48 TO 56%
ABSORBING
OUTSIDE,
ORDINARY
GLASS INSIDE
0.52 0.36 0.39 0.43 0.10 0.10 0.11 0.10 0.10 0.13
48 TO 56%
ABSORBING
OUTSIDE,
REGULAR
PLATE INSIDE
0.50 0.36 0.39 0.43 0.10 0.10 0.11 0.10 0.10 0.12
TRIPLE PANE
ORDINARY
GLASS
0.83 0.48 0.56 0.64 0.12 0.11 0.18 0.12 0.16 0.20
REGULAR
PLATE
0.69 0.47 0.52 0.57 0.10 0.10 0.15 0.10 0.14 0.17
TABLE 10
OVERALL FACTOR (G) FOR SOLAR
HEAT GAIN THROUGH PAINTED
GLASS
PAINTED GLASS LIGHT COLOUR MEDIUM COLOUR DARK COLOUR
GLASS FACTOR NO SHADE
0.28 0.39 0.50
TABLE 11
OVERALL FACTOR (G) FOR SOLAR HEAT GAIN THROUGH STAINED GLASS
STAINED GLASS AMBER
COLOUR
DARK
RED
DARK
BLUE
DARK
GREEN
GREYED
GREEN
LIGHT
OPALESCEN
T
DARK
OPALESCEN
T
GLASS FACTOR NO SHADE
0.70 0.56 0.60 0.32 0.46 0.43 0.37
4.3 INFILTRATION HEAT GAIN
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The infiltration air flow rate is approximately proportional to the square root of the
pressure differential across the gaps. The air conditions vary as the air moves
through the various areas or stages of the air-conditioning system. To enable the
estimation of the cooling or heating load the air properties are taken at standard air
conditions, i.e. at sea level with air pressure of 101.323 KPa and temperature of
21.11
0
C. The RH of air is taken as 50%. The major parameters of the air used for
the calculation with the values at the standard air conditions are as follows:
Specific heat of air = 1000 J/Kg
0
C
Density of air = 1.187 Kg/M
3
Latent heat of moisture = 2502.5 KJ/Kg
The cooling load may be calculated from the following formula:
F = Cd x A x ( 2p/ )
Where,
F = Air flow rate (M
3
/sec)
A = Area of the gap between door or window and its frame or the crack
in the structure (M
2
)
p = Pressure drop across the gap (N / M
2
)
= Density of air (Kg/M
3
)
Cd = Discharge coefficient (normally taken as 1.0)
The infiltration air adds latent and sensible load to the total cooling load. Generally,
the room pressures are higher than the adjacent areas and will indicate a leakage of
conditioned air from the room to the outside. Only the air ingress is to be considered
for the cooling load estimation.
4.3.1 The sensible heat gain from the infiltration air ingress into the room shall be
calculated from the following formula:
QFs = F x Cp x x (To Ti)
Where,
QFs = Sensible heat gain due to the infiltrated air ingress (Watts)
F = Infiltrated air flow rate (M
3
/ sec)
Cp = Specific heat of air (Joules/Kg
0
C)
= Air density (Kg / M
3
)
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To = Outside air DBT (
o
C)
Ti = Inside air DBT (
o
C)
4.3.2 The latent heat gain from infiltration air ingress into the room shall be calculated from
the formula:
QFl = F x x H x 1000
Where,
QFl = Latent heat gain due to the infiltrated air ingress (Watts)
3
/ sec)
3
)
H = Enthalpy differential between humidity ratios Gi for room and Go for
the adjacent area, at the room DBT from psychrometric chart for
the altitude of the site (KJ/Kg).
4.4 INTERNAL HEAT GAIN
The internal heat gain includes the following components:
(a) Heat dissipation loads from equipment located within the room. This load
includes the sensible and latent loads that may be dissipated by the
equipment located within the room. The actual heat dissipated into the room
shall be considered for the cooling load estimation. Considering that motor
ratings are selected with a margin of about 15 to 20% above the equipment
BKW, this load will generally be lower than the connected electrical rating
or rated capacity of a driver of a rotating equipment like pump, compressor,
spindle or shaft of a machine etc.
(b) Heat dissipation from the occupancy in the room. This heat dissipation has
latent and sensible component. The total heat dissipation is a function of the
activity. The proportion of the sensible and the latent components of this
total heat dissipation is a function of the temperature in the room. These
loads shall be taken from TCE.M1-ME-811-301 - Basic Study Guide For
Air-conditioning Systems.
(c) Lighting loads from the lighting system for the room. In some cases special
fixtures are provided which also serve as return air inlets. Such fixtures
(Troufers) do not reduce the total heat dissipation from the lighting fixture
but reduce the lighting heat dissipation into the room. The reduction in the
lighting heat dissipation to the room is instead transferred to the return air,
reducing the room sensible heat gain and consequently the room
dehumidified air flow rate.
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(d) For heating load calculations the internal heat dissipation loads such as the
equipment heat dissipation, lighting loads and occupancy shall not be
considered. This will give a higher heating load requirement.
4.5 FAN AND DUCT HEAT GAIN
The heat gain to the supply air due to supply air fan, duct heat gain shall be
estimated as follows:
(a) Fan Heat Gain
Q
fan
= F
bkw
+ B + M
where,
Q
fan
= Fan heat gain (watts)
F
bkw
= Fan shaft power consumption (watts)
B = Fan belt drive losses (normally considered as 3% of
fan shaft power consumption) (Watts)
= 0.03 x F
bkw
M = Heat gain due to motor efficiency () (Watts)
= {(1 - ) x F
bkw
}/
The above calculation cannot be made for the first estimation of the cooling
load. This component therefore shall be taken as a percentage of the
estimated total room heat gains (Sum of heat gains as per paras 4.1, 4.2,
4.3 and 4.4) as follows:
(i) Upto fan static pressure of 50 mmWG= 7.5%
(ii) Add 3% for every 25 mmWG increase in fan
static pressure
(b) Duct Heat Gain
Q
duct
= U
duct
x A
duct
x T
where,
Q
duct
= Duct heat gain due to the temperature difference
across the duct wall (Watts)
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U
duct
= Overall heat transfer coefficient across the duct wall
estimated as indicated in para 4.1.1 (b) (watts / M
2
0
C)
A
duct
= Surface area of the duct (M
2
)
T = Temperature difference across the duct wall (
0
C)
The total duct area will not be available for the first estimate of the cooling
load calculation. The duct heat gain shall therefore be taken as a percentage
of the estimated total room heat gains (Sum of heat gains as per paras 4.1,
4.2, 4.3 and 4.4) as follows:
(i) Duct heat gain = 2.5%
(ii) Air leakage from supply or return air duct = 2.5%
(iii) Safety and contingencies = 2.5%
Hence total fan and duct heat gain
(Fan static pressure upto 50 mmWG)
= 15.0%
4.6 FRESH AIR HEAT GAIN
The fresh air taken into the air-conditioning system adds to the room heat gain due
to the bypass of the air over the cooling coil of the air handling unit. This bypass
of the air over the cooling coil is characterised by the Bypass Factor (BF). It is a
measure of the efficiency of the heat exchange over the cooling coil. The higher the
BF the lower is the efficiency of the cooling coil.
This factor is dictated by the cooling coil size i.e. the number of rows of the cooling
coil and the air velocity across the coil face. The higher the velocity of air across the
cooling coil the higher is the BF. On the other hand the higher the number of rows of
tubes of the cooling coil across the air flow or the lower the fin spacing, the lower is
the BF.
The component of the fresh air load to be considered as part of the room load is
given by equations listed in paras 4.6.1 and 4.6.2.
The balance fresh air load does not constitute a part of the room load. However,
this load shall be taken in the total cooling load estimate as indicated in paras 4.6.3
and 4.6.4.
4.6.1 The fresh air sensible heat gain due to the bypass of the fresh air over the cooling
coil in the room is given by the following equation:
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FASH = F x Cp x x (To - Ti) x BF
Where,
FASH = Fresh Air Sensible Heat (watts)
F = Fresh air flow rate (M
3
/ sec)
0
C)
3
)
To = Outdoor air DBT (
0
C)
Ti = Room air DBT (
0
C)
4.6.2 The fresh air latent heat gain due to the bypass of the fresh air over the cooling coil
in the room is given by the following equation:
FALH = F x x H x BF x 1000
Where,
FALH = Fresh Air Latent Heat (watts)
3
/ sec)
3
)
H = Enthalpy differential between humidity ratios Gi for room and Go for
the adjacent area, at the room DBT from psychrometric chart at
altitude of the site (KJ/Kg).
4.6.3 The balance fresh air sensible heat gain on the cooling coil is given by the following
equation:
BFASH = F x Cp x x (To - Ti) x (1 - BF)
Where,
BFASH = Fresh Air Sensible Heat (watts)
3
/ sec)
0
C)
3
)
To = Outdoor air DBT (
0
C)
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Ti = Room air DBT (
0
C)
4.6.4 The balance fresh air latent heat gain on the cooling coil is given by the following
equation:
BFALH = F x x H x (1- BF) x 1000
Where,
BFALH = Fresh Air Latent Heat (watts)
3
/ sec)
3
)
psychrometric chart at altitude of the site (KJ/Kg).
The values of the BF to be considered for the purpose of cooling load estimation for
various applications are as given in table 12.
The BF ranges given in table 12 are indicative. For the purpose of the estimation of
the cooling load for preparation of specification a conservative value i.e. the highest
value given in the range for the particular application may be taken. The correct
value of the BF will be available on selection of the cooling coil by the vendor.
The fresh air load into the room is a part of the total cooling load due to fresh air,
proportional to the BF. The balance of the fresh air cooling load does not constitute
a part of the room load. However, this load shall be part of the cooling load
imposed on the cooling coil. In case a preliminary cooling coil selection has been
done, the values of the BF for finned cooling coil may be taken from table 13.
TABLE 12
COOLING COIL BYPASS FACTORS FOR VARIOUS APPLICATIONS
COOLING COIL BY-
PASS FACTOR (BF)
TYPE OF APPLICATION EXAMPLE
0.30 to 0.50 A small total load or a load that has a low sensible load
factor (i.e. high latent load)
Residence
0.20 to 0.30 Typical comfort application with a relatively small total
load or a low sensible heat factor with a somewhat
larger load
Residence, Small retail
shop, Factory
0.10 to 0.20 Typical comfort application Department store, Bank,
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Factory
0.05 to 0.10 Applications with high internal sensible loads or requiring a
large amount of outdoor air for ventilation
Department store,
Restaurant, Factory
0.00 to 0.10 100% outdoor air applications Hospital operation
theatres, Clean room, etc.
TABLE 13
COOLING COIL BYPASS FACTORS WITH AND WITHOUT SPRAYS,
VARIOUS AIR VELOCITIES AND FIN SPACING
WITHOUT SPRAYS WITH SPRAYS (NOTE 1)
3.1 FINS PER cm 5.5 FINS PER cm 3.1 FINS PER cm 5.5 FINS PER cm
AIR VELOCITY M / sec
1.5 to 3.5 1.5 to 3.5 1.5 to 3.5 1.5 to 3.5
DEPTH OF
COOLING COIL
NUMBER OF ROWS
BYPASS FACTOR (BF)
2 0.42 to 0.55 0.22 to 0.38 - -
3 0.27 to 0.40 0.10 to 0.23 - -
4 0.19 to 0.30 0.05 to 0.14 0.12 to 0.22 0.03 to 0.10
5 0.12 to 0.23 0.02 to 0.09 0.08 to 0.14 0.01 to 0.08
6 0.08 to 0.18 0.01 to 0.06 0.06 to 0.11 0.01 to 0.05
8 0.03 to 0.08 - 0.02 to 0.05 -
NOTES:
1. Sprayed coils have a lower BF because the spray provides more heat
transfer surface for contacting air.
2. The BFs are to be taken in proportion with the air velocity across the
cooling coil.
3. The number of rows for residences and comfort applications may be taken
as 4 rows, whereas those for high latent load applications i.e. for room
sensible heat factor values lower than 0.75 may be taken as 6 rows.
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4. The fin spacing for cooling coils may be taken as 36 fins per cm of cooling
coil finned tube length.
5. The air velocity may be taken as 2.5 M/sec across the cooling coil.
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4.7 RETURN AIR DUCT HEAT GAIN
The return air heat gain shall be estimated using the following equation:
RAHG = U x A x T
where,
RAHG = Return Air Heat Gain (Watts)
U = Overall heat transfer coefficient across the duct wall. U is to
be estimated as per para 4.1.1(b) (Watts / M
2 0
C)
A = Area of the duct wall (M
2
)
T = Temperature difference across the duct wall (
0
C)
4.8 SUMMARY
Various heat gains calculated as per paras 4.1 to 4.7 are summarised in the table
14.
TABLE 14
SUMMARY OF HEAT GAIN CALCULATION
SL.NO. ITEM SENSIBLE
HEAT GAIN
(Calculated as
per para)
LATENT
HEAT GAIN
(Calculated as
per para)
TOTAL
1. Structural heat gain 4.1.1 4.1.2
2. Fenestration heat gain 4.2 -
3. Infiltration heat gain 4.3.1 4.3.2
4. Internal heat gain 4.4 a, b, c 4.4 a, b
5. Total room heat Sl.Nos.
1+2+3+4 =
(RSH)
Sl.Nos.
1+2+3+4 =
(RLH)
6. Room Sensible Heat Factor
(RSHF)
RSH
RSH+RLH
7. Fan and duct heat gain 4.5 a, b -
8. Fresh air bypass heat gain 4.6.1 4.6.2
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TABLE 14 (CONTD.)
9. Effective room heat Sl.Nos.
5+7+8 =
ERSH
Sl.Nos.
5+7+8 =
ERLH
10. Effective Room Sensible Heat
Factor (ESHF)
ERSH
ERSH+ERLH
11. Balance fresh air heat gain 4.6.3 4.6.4
12. Return air heat gain 4.7 -
13. Grand Total Heat (GTH)
= GSH + GLH
Sl.Nos.
9+11+12 =GSH
Sl.Nos. 9+11+12
=GLH
14. Grand Sensible Heat Factor
(GSHF)
GSH
GSH+GLH
In cases where the air-conditioning cooling load is to be met by a chilled water or
brine system the total refrigeration capacity (Q
ch
) of the chilled water or brine units
shall be calculated as follows:
Q
ch
= GTH x 1.1
The additional 10% load is to account for the pumping and piping heat gain.
5.0 APPARATUS DEW POINT
The ESHF is utilised to calculate the Apparatus Dew Point (ADP). This is the
temperature that the air would achieve at the outlet of an ideal cooling coil. This
temperature is represented by the intersection of the ESHF line and the saturation
curve on the psychrometric chart.
The ADP is not a temperature that can be physically measured, but is a parameter
which is used to estimate the dehumidified air flow rate. The ADP is also used to
select the evaporating temperature in case of Direct Expansion (DX) cooling coils or
the chilled water supply temperature in case of chilled water cooling coils.
The evaporating temperature for DX systems shall be at least 4 to 5
0
C lower than
the ADP. Whereas, the chilled water cooling coil entering temperature should be at
least 3.5 to 4.5
0
C lower than the air leaving temperature.
Appendix 1 indicates a typical plot of the various sensible heat factors listed in table
14. The ESHF, GSHF, RSHF and ADP are indicated on this representation. In the
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process of calculating the cooling loads the air-conditioning process shall be
represented on a psychrometric chart for the altitude of the area being air-
conditioned.
6.0 DEHUMIDIFIED AIR FLOW RATE
The dehumidified air flow rate is given by the equation:
DHF = ERSH .
(1-BF) x (Room DBT ADP) x Cp x
Where,
DHF = Dehumidified air flow rate (M
3
/sec)
0
C)
3
)
7.0 REFERENCES
7.1 ASHRAE Handbook, Fundamentals, 1993 Edition
7.2 Indian Society of Heating Refrigerating and Air-Conditioning Engineers HVAC
Handbook, 1997 Edition, Part I Air-Conditioning
7.3 Engineering Data Manual BRY-AIR, Dehumidifiers
7.4 Basic Study Guide for Air-conditioning System TCE.M1-ME-811-301
7.5 Handbook of Air-conditioning System Design Carrier Air-Conditioning Company,
1965 edition
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APPENDIX 1
TYPICAL AIR-CONDITIONING PSYCHROMETRIC PROCESS
O
U
T
D
O
O
R

D
E
S
I
G
N
C
O
N
D
I
T
I
O
N
M
I
X
T
U
R
E

A
I
R
C
O
N
D
I
T
I
O
N
R
O
O
M
R
O
O
M

E
N
T
E
R
I
N
G

A
I
R
C
O
N
D
I
T
I
O
N
A
P
P
A
R
A
T
U
S
D
E
W

P
O
I
N
T
(
A
D
P
)
S
A
T
U
R
A
T
I
O
N
C
U
R
V
E
E
S
H
F

L
I
N
E
G
S
H
F
R
S
H
F

L
I
N
E
SPECIFIC HUMIDITY GMS PER KG OF DRY AIR
D
R
Y

B
U
L
B

T
E
M
P
E
R
A
T
U
R
E
0
C
R
O
O
M

A
I
R
C
O
N
D
I
T
I
O
N
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APPENDIX 2
SAMPLE AIR-CONDITIONING LOAD CALCULATIONS
1.0 INPUT DATA
SL.
NO.
ITEM PARAMETER
1. Location of site New Delhi
2. Latitude 28.35
0
N
3. Altitude 216 M above MSL
4. Name of area Office premises
5. General arrangement / Arch. drawing Refer sketch below
6. Outside design conditions DBT
0
C
WBT
0
C
Specific Humidity
gms/Kg of dry air
6.1 Summer 43.3 23.9 10.70
6.2 Monsoon 35.0 28.3 21.74
6.3 Winter 7.2 5.0 4.60
6.4 Daily range 13.89
7. Inside design conditions
7.1 Temperature 24 1
0
C DB
7.2 RH 55 + 5 % - No lower limit on RH
7.3 Specific humidity 10.25 gms / Kg of dry air
8. Lighting loads 15 Watts/M
2
of floor area
9. Equipment loads Sensible load 1.5 KW, Latent load 0 KW
10. Occupancy 15 persons - Office activity
11. Fresh air requirements 1 air change per hour
12. Exhaust air requirements Nil
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APPENDIX 2 (CONTD.)
13. Filtration Pre-filters to be provided
14. Pressurisation Nil
15. Air flow pattern No specific requirements
16. Hazardous area classification Safe area
17. Duration of air-conditioning system From 0800 Hrs to 1800 Hrs continously
18. Availability of cooling water / make-up water No water available
19. Future expansion plans No specific plans. Roof is exposed and floor
below is not air-conditioned.
OFFICE AREA
GENTS AND
LADIES TOILET
AIR-CONDITIONING PLANT
ROOM
DOOR (TYP)
WINDOW W1 (TYP)
(SIZE 4000 X 1200)
18,000
6,00
1
2
,
0
0
0
3
,
0
0
0
3
,
0
0
0
3,00
FALSE CEILING
EXPOSED
ROOF
3
,
0
0
0
SECTION AA
PLAN
4
,
5
0
0
PLAN AND SECTION OFFICE AREA
NORTH
A A
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APPENDIX 2 (CONTD.)
2.0 AREA CALCULATIONS
The area calculations are based on the layout sketch above
WALL HEIGHT M SURFACE FACE AREA M
2
WALL
LENGTH
M
TOTAL UPTO
FALSE
CEILING
IN ROOM ABOVE FALSE
CEILING
GLASS
AREA M
2
WALL AREA
M
2
SL.
NO.
SURFACE
a b c d = a-c
1. North wall 18.0 4.5 3.0 54.0 27.0 14.4 39.6
2. West wall 12.0 4.5 3.0 36.0 18.0 4.8 31.2
3. Part. wall 30.0 4.5 3.0 90.0 45.0 - 90.0
4. Plant room
4.1 East
wall
3.0 4.5 - 13.5 - - 13.5
4.2 Part.
wall
9.0 4.5 - 40.5 - - 40.5
5. Exposed roof
5.1 Office
area
- - - 216.0 - - -
5.2 Plant
room
- - - 9.0 - - -
6. Floor area
6.1 Office
area
- - - 216.0 - - -
6.2 Plant
room
- - - 9.0 - - -
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APPENDIX 2 (CONTD.)
3.0 OVERALL HEAT TRANSFER COEFFICIENT
3.1 External Wall
(a) Outer air film 0.030 Table 1*
(b) Outer cement plaster 20 mm thick 0.028 Table 4*
(c) Wall 230 mm thick brick 0.299 Table 4*
(Density 1760 Kg/M
3
as per IS 875 Part 1)
(d) Inner cement plaster 15 mm thick 0.021 Table 4*
(e) Inner air film 0.120 Table 1*
Total thermal resistance (R) of external wall 0.498
Overall heat transfer coefficient (U= 1/R) 2.008 W/M
2
C
3.2 Internal Wall
(a) Outer air film 0.120 Table 1*
(b) Outer cement plaster 15 mm thick 0.021 Table 4*
(c) Wall 115 mm thick brick
(Density 1760 Kg/M
3
as per IS 875 Part 1) 0.150 Table 4*
(d) Inner cement plaster 15 mm thick 0.021 Table 4*
(e) Inner air film 0.120 Table 1*
(f) Total thermal resistance (R) of internal wall 0.432
(g) Overall heat transfer coefficient (U = 1/R) 2.315 W/M
2
C
3.3 Exposed Roof
(a) Outer air film 0.030 Table1*
(b) Water proofing 0.026 Table 4*
(c) RCC slab 100 mm thick = 0.1 x 0.69 0.069 Table 4*
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APPENDIX 2 (CONTD.)
(d) Thermal insulation (t/k) = 0.05/0.034 1.471
(Para 6.4 of TCE.M1-ME-811-301 R2)
(e) Inner cement plaster 15 mm thick 0.021 Table 4*
(f) Inner air film 0.160 Table 1*
(g) Total thermal resistance (R) of roof 1.777
(h) Overall heat transfer coefficient (U = 1/R) 0.563 W/M
2
C
3.4 Floor
(a) Inner air film 0.110 Table 1*
(b) Floor tile plaster 25 mm thick 0.035 Table 4*
(c) RCC slab 100 mm thick = 0.1 x 0.69 0.069 Table 4*
(d) Cement plaster 15 mm thick 0.021 Table 4*
(e) Tile terrazo 25 mm thick 0.014 Table 4*
(f) Outer air film 0.110 Table 1*
(g) Total thermal resistance (R) of floor 0.359
(h) Overall heat transfer coefficient (U = 1/R) 2.786 W/M
2
C
3.5 Glass
(a) Conduction (single glass without storm windows) 6.4 W/M
2
C
(Table 1 of this guide)
(b) Glass transmittance factor (G) 0.56
(Table 9 of this guide Ordinary glass with light coloured inside venetian
blinds)
* Table numbers referred are as per ASHRAE Handbook, Fundamentals 1993
Edition, Chapter 22. The outer air film resistance is assumed for wind velocity of
24 KM/Hr and inner film resistance for still air.
3.6 Equivalent Temperature Difference (ETD)
3.6.1 Outdoor and indoor temperature difference (T)
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APPENDIX 2 (CONTD.)
T = 43.3 24 = 19.3C
For daily range of 13.89C, the correction to T is interpolated from table 4 of this
design guide as follows:
DAILY RANGE C T C
13.3 13.89 14.4
16.7 7.2 6.93 6.7
19.3 9.58
19.4 10.0 9.68 9.4
Correction to T = 9.58 Say 9.6C.
3.6.2 Factor c for colour shade assumed to be for dark walls = 1
3.6.3 Exposed Walls
(a) North Wall
ETD = tesc

+ {(temc - tesc ) x c x Rs/Rm}
tes = 2.2 C (From table 2 for wall weight of 488 Kg/M
2
)
tem = 2.2C (From table 2 for wall weight of 488 Kg/M
2
)
tesc

= 2.2 + 9.6C = 11.8C
temc

= 2.2 + 9.6C = 11.8C
Rs = 98 W/M
2
From Table 14 of ASHRAE Fundamentals, 1993
Edition, Chapter 27.
Rm = 90 W/M
2
Substituting in equation for ETD above:
ETD = 11.8C
(b) West Wall
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ETD = tesc

APPENDIX 2 (CONTD.)
tes = 2.2C (From table 2 for wall weight of 488 Kg/M
2
)
tem = 6.7C (From table 2 for wall weight of 488 Kg/M
2
)
tesc

= 2.2 + 9.6C = 11.8 C
temc

= 6.7 + 9.6C = 16.3C
Rs = 679 W/M
2
Rm = 680 W/M
2
ETD

= 16.29C say 16.3C
(c) East Wall
ETD = tesc

2
)
tem = 10.0C(From table 2 for wall weight of 488 Kg/M
2
)
tesc

= 2.2 + 9.6C = 11.8 C
temc

= 10.0 + 9.6C = 19.6C
Rs = 82 W/M
2
Rm = 83 W/M
2
ETD

= 19.51C say 19.5C
(d) Roof
ETD = tesc

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2
)
tem = 19.4C(From table 3 for wall weight of 293 Kg/M
2
)
APPENDIX 2 (CONTD.)
tesc

= 4.4 + 9.6C = 14.0 C
temc

= 19.4 + 9.6C = 29.0C
Rs = 457 W/M
2
Rm = 459 W/M
2
Substituting in equation for ETD above,
ETD

= 28.93C say 28.9C
(e) Partition Walls
T = (43.3-24) - 2.8C
= 16.5 C
(f) Floor
T = (43.3-24) - 2.8C
= 16.5 C
3.6.4 Solar Heat Gain
(a) Glass transmission factor G = 0.56 (table 9 of this guide)
(b) SHGF North glass = 98 W/M
2
*
(c) SHGF West Glass = 679 W/M
2
*
(d) SHGF East Glass = 82 W/M
2
*
(*From Table 14 of ASHRAE Fundamentals, 1993 Edition, Chapter 27.)
3.6.4 Infiltration Heat Gain
NIL - as room is to be kept under slight positive pressure.
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3.6.6 Internal Heat Gain
(a) For office worker at 24C room DBT for office activity the sensible and
latent heat dissipation loads from appendix 2 of TCE.M1-ME-811-301
APPENDIX 2 (CONTD.)
(i) Sensible heat load = 75 Watts/person
(ii) Latent heat load = 60 Watts/person
(b) Equipment heat dissipation load = 1.5 KW
3.6.7 Fresh Air Heat Gain
Fresh air flow rate = 1 air change per hour
= 12M width x 18M length x 3M height
= 648 M
3
/Hr
= 0.18 M
3
/sec
For a coil bypass factor of 0.165, from table 13 of this design guide, considering a 3
row deep cooling coil, 5.5 fins per cm and an air face velocity on the cooling coil of
2.5 M/sec, the fresh air bypass sensible and latent loads as per paras 4.6.1 and
4.6.2 of this guide will be as follows:
FASH = 0.18 x 1000 x 1.187 x (43.3 - 24) x 0.165
= 680.4 Watts
FALH = 0.18 x 1.187 x (10.7 - 10.25) x 1000 x 0.165
= 15.9 Watts
The fresh air balance load on the cooling coil given as per paras 4.6.3 and 4.6.4 of
this guide will be as follows:
BFASH = 0.18 x 1000 x 1.187 x (43.3 - 24) x (1 - 0.165)
= 3443.2 Watts
BFALH = 0.18 x 1.187 x (10.7 - 10.25) x 1000 x (1 - 0.165)
= 80.3 Watts
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APPENDIX 2 (CONTD.)
TATA CONSULTING ENGINEERS
AIR-CONDITIONING LOAD ESTIMATION
BY : CLIENT : TCE PROJECT:
DATE : JOB NO. : 971 DOC. NO. : TCE.971-ME-811-01
CHD. : OFFICE : DW
SUBJECT :
HVAC CALCULATION
DATE: DEPT. : ME SH : 1 OF 1 REV. NO. : 0
DESIGNCONDITIONS SUMMER / MONSOON / WINTER LOCATION : NEW
DELHI
LATITUDE:28.35
N
ALTITUDE: 216M
DBT
(
0
C)
WBT
(
0
C)
RH
(%)
SP.HUM.
(gm/kg)
ENTHALPY
(J/KG)
NAME OF THE AREA : OFFICE
OUTSIDE 43.3 23.9 10.70 72 FLOOR : FIRST
INSIDE 24.0 55 10.25 50 ROOF : EXPOSED UNEXPOSED
DIFF. 19.3 0.45 ROOF INSULATION : 50 mm THK EPS or PUF
DAILY RANGE (
0
C)
13.89
DESIGN TIME (AM /
PM)
4 PM
ROOM AREA (M
2
) 216 ROOM VOLUME (M
3
) 648
ASSUMED BYPASS FACTOR (BF) 0.165 SELECTED FRESH AIR (M
3
/sec) 0.18
GLASS FENESTRATION GAIN TRANSMISSION GAIN - GLASS
AREA (M
2
) SOL HEAT G. FACT WATTS AREA (M
2
) TEMP. U. FACT WATTS
N GLASS 14.4 98 0.56 790.3 N GLASS 14.4 19.3 6.4 1778.7
S GLASS S GLASS
E GLASS E GLASS
W GLASS 4.8 679 0.56 1825.2 W GLASS 4.8 19.3 6.4 592.9
NW GLASS NW GLASS
NE GLASS NE GLASS
SW GLASS SW GLASS
SE GLASS SE GLASS
SKYLIGHT SKYLIGHT
SOLAR & TRANS. GAIN - WALLS AND
ROOF
TRANSMISSION GAIN
N WALL 39.6 11.8 2.008 938.3 PART. 1 90 16.5 2.315 3437.8
S WALL PART. 2
E WALL PART. 3
W WALL 31.2 16.3 2.008 1021.2 PRT.GLASS
NW WALL CEILING
NE WALL FLOOR 216 16.5 2.786 9929.3
SW WALL FLOOR
SE WALL ROOF 216 28.9 0.563 3514.5
INTERNAL HEAT GAIN INFILTRATION HEAT GAIN
OCCUP. -- 15 75 1125.0
LIGHTING -- 15 X 216 3240.0
EQUIPT. -- 1.5 1000 1500.0
SUBTOTAL1 10440.0 SUBTOTAL2 19253.2
SUBTOTAL 1 + SUBTOTAL 2 29693.2
SAFETY FACTOR % - - APPARATUS DEW POINT TEMPERATURE (
0
C)
ROOM SENSIBLE HEAT ( RSH ) ESHF = ERSH/ERTH 34827.6 / 35833.5 0.97
SUPPLY DUCT HEAT GAIN IN % INDICATED ADP (
0
C) SELECTED ADP
0
C
14.5
SUPPLY DUCT LEAK LOSS 15 % OF ST1 & 2 4454.0 ENTHALPY AT ADP (KJ/Kg) 41.0
SECTION: APPENDIX
TCE.M6-ME-811-301
DESIGN GUIDE FOR
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FAN HEAT GAIN IN % COIL ENTERING AIR TEMPERATURE
/ENTHALPY
24.9 / 51.1
FRESH AIR SENSIBLE LOAD 680.4 COIL LEAVING AIR TEMPERATURE
/ENTHALPY
16.2 / 42.7
EFFECTIVE ROOM SENSIBLE HEAT (ERSH) 34827.6 DEHUMIDIFIED AIR
QUANTITY M
3
/sec
3.7
APPENDIX 2 (CONTD.)
LATENT HEAT
RETURN DUCT HEAT GAIN IN % PLANT ROOM 2635.7
OCCUPANCY 15 x 60 900 RETURN DUCT LEAK LOSS IN 2% OF
SUBTOTAL 3
787.1
EQUIPMENT ------ GRAND TOTAL HEAT ( GTH ) 42779.8
SAFETY FACTOR (%) 10 90 AC LOAD IN TR = GTH /3520 12.2
ROOM LATENT HEAT ( RLH ) 990 CHECK FIGURES:
SUPPLY DUCT LEAK LOSS IN % ------ COOLING LOAD / UNIT FLOOR AREA
(WATTS/M
2
)
198.05
FRESH AIR LATENT LOAD 15.9 DEHUMIDIFIED AIR QUANTITY / UNIT FLOOR
AREA (M
3
/sec.M
2
)
0.0171
EFFECTIVE ROOM LATENT HEAT (ERLH) 1005.9 NOTES :
EFFECTIVE ROOM TOTAL HEAT (ERTH) 35833.5 PLANT ROOM GAIN:
FRESH AIR HEAT E
WALL
= 13.5 x 19.5 x 2.008 = 528.6
SENSIBLE 3443.2 PART. = 40.5 x 16.5 x 2.315 = 1547.0
LATENT 80.3 ROOF = 9 x 28.9 x 0.563 = 146.4
FRESH AIR HEAT SUBTOTAL 3523.5 3523.5 FLOOR = 9 x 16.5 x 2.786 = 413.7
SUBTOTAL 3 39357.0 Total load 2635.7 WATTS
SUMMARY
The summer load for the room is 12.2 TR with a dehumidified air flow requirement of 3.7
M
3
/sec and an ADP of 14.5
0
C
SECTION: APPENDIX
TCE.M6-ME-811-301
DESIGN GUIDE FOR
SHEET 41 OF 41
APPENDIX 3
ASHRAE PSYCHROMETRIC CHART NO. 1 FOR NORMAL TEMPERATURES AT SEA LEVEL
TCE FORM NO.
120R1
ISSUE
R2
TCE.M6-ME-811-304
GUIDE FOR SELECTION OF
COOLING AND HEATING COILS
SHEET i OF iv
REV. NO. R0 R1 R2
ISSUE
PPD. BY RRC Sd/- TPR Sd/- TPR
CHD. BY SCM Sd/- PRJ Sd/- HRK
APD. BY SJB Sd/- RL Sd/- RL
DATE 27.12.1989 27.03.2000 20.03.2003
R2
TCE FORM NO. 020 R2
020R2
M6ME304R2.DWG
TCE.M6-ME-811-304
SHEET ii OF iv
ISSUE
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CONTENTS
SL.NO. TITLE SH.NO.
1.0 SCOPE 1
2.0 USES OF COILS 1
3.0 DESIGN AND CONSTRUCTION FEATURES 2
4.0 APPLICATION RANGE 8
5.0 INPUT AND OUTPUT DATA FOR COIL SELECTION OR
SIZING
8
6.0 PROCEDURE FOR SELECTION OR SIZING 9
7.0 REFERENCES 10
APPENDICES
1. EXAMPLES OF COOLING COIL SELECTION PROCEDURE 11
2. EXAMPLES OF HEATING COIL SELECTION PROCEDURE 20
FIGURES
1. TYPES OF FIN-COIL ARRANGEMENTS 28
2. WATER CIRCUIT ARRANGEMENTS 29
FOR COOLING COILS
3. CHILLED WATER FLOW ARRANGEMENTS 30
4. TYPICAL REFRIGERANT DISTRIBUTORS 31
5. COIL CONTROL ARRANGEMENTS FOR MULTIPLE 32
THERMOSTATIC EXPANSION VALVE FED COILS
6. WATER CIRCUIT ARRANGEMENTS FOR 33
HEATING COILS
7. TYPICAL BYPASS FACTORS FOR COILS 34
8. CHILLED WATER COIL PERFORMANCE CURVES 35
9. TYPICAL PERFORMANCE CURVES FOR 36
DIRECT EXPANSION COIL
10. WATE PRESSURE DROP 37
11. WATER VELOCITY FACTOR F2 37
12. FACTOR F3 38
13. AIR PRESSURE DROP 38
TABLES
1. RANGES OF STANDARD RATING CONDITIONS 39
2. PHYSICAL DATA AIR HANDLING UNITS 40
3. AIR SIDE RESISTANCE OF COOLING AND HEATING COILS 41
4. PHYSICAL PARAMETERS OF COIL 42
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CONTENTS (CONTD.)
TABLES
(CONTD.) TITLE SH.NO.
5. K FACTORS FOR CHILLED WATER COILS 43
6.
MULTIPLIERS W
S
FOR WETTED CHILLED WATER COOLING
44
COIL SURFACES
7. COIL FACE AREAS (FA) 45
8. WATER VELOCITY CONSTANT R 46
9. HOT WATER BTU CONSTANTS 47
10. 2 ROW HOT WATER COIL CAPACITIES 48
11. STEAM HEATING COIL CAPACITIES 49
TCE CONSULTING ENGINEERS LIMITED SECTION: REV.STATUS
TCE.M6-ME-811-304
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REVISION STATUS
REV.NO. DATE DESCRIPTION
R0 27.12.1989 ---
R1 27.03.2000 Generally revised. Heating
coils added.
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1.0 SCOPE
Cooling coils for air-conditioning applications are generally used in Air Handling
Units (AHUs), fan coil units, packaged air-conditioners, split air-conditioners and
window air-conditioners. Steam or hot water heating coils are generally used in
AHUs to heat, pre-heat or re-heat air whereas for smaller capacity heating
applications such as in window air-conditioners, electric resistance heating coils are
used.
This document describes various types, design and construction features of cooling
and heating coils for air-conditioning applications and provides guidelines for
selection and sizing of these coils.
2.0 USES OF COILS
2.1 COOLING COILS
2.1.1 Cooling coils are generally used for air cooling with or without accompanying
dehumidification. Examples of cooling applications without dehumidification are
pre-cooling coils, sensible cooling coils or coils that use ordinary or cooling tower
water at relatively high temperatures to reduce refrigeration capacity. However, a
sizeable portion of coil applications involves simultaneous air sensible cooling and
dehumidification.
2.1.2 The usual cooling media used in extended surface coils are chilled water or volatile
refrigerants. Brines are seldom used for air-conditioning applications but could be
used for some process air cooling or low humidity and low temperature applications
or sometimes when brine from industrial system already installed is the only source
of refrigeration.
2.1.3 Generally, for air-conditioning applications the temperature of cooling medium
such as chilled water or brine or volatile refrigerants like R22, R134a, R123,
ammonia etc. are sufficiently above 0
0
C and no frosting is expected in normal
operation. For coils operating with cooling medium temperature below 0
0
C, a
defrosting mechanism has to be provided. The method of defrosting may be hot gas,
electric heaters, water sprays or air.
2.2 HEATING COILS
2.2.1 Heating coils are generally used for temperature and humidity control. Normally,
the heating media used in coils is steam or hot water.
2.2.2 Heating coils may be used in AHUs as pre-heating or re-heating coils in
conjunction with cooling and dehumidifying coils. These may also be installed in
supply air ducts to air-conditioned areas for re-heating. Sometimes these coils are
used in fresh air supply system as pre-heating coils.
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2.2.3 Direct electric resistance air heating coils, also known as blast coils or duct heaters
may be used for the same applications as steam or hot water coils. These may be
used in smaller sizes and where flow connections or maintenance of pitch in piping
would be troublesome. Electric coils are sometimes installed in branch ducts of
central fan system and hot water systems to provide the final temperature and
relative humidities required for comfort or process air-conditioning. Electric coils
installed for use primarily in the heating cycle can also be utilised for re-heat in the
cooling cycle if located downstream of the cooling coil. When using electric coils
safety aspects like fire hazards should be considered.
3.0 DESIGN AND CONSTRUCTION FEATURES
Coils are basically of two types, those consisting of bare tubes and those having
extended or finned surfaces. The former is seldom times used where conditions can
cause frost accumulation or for cooling within sprayed coil dehumidifiers. The
design and arrangement of a coil, constructed with extended surface on the air side,
involves consideration of various parameters such as :
(a) Air face velocity
(b) Material of fins and tubes
(c) Types and spacing of fins
(d) Tube diameters and nesting centre dimensions
(e) Surface ratio
(f) Provisions to increase air turbulence
(g) Chilled water flow or refrigerant distribution for cooling coils and hot water
flow or steam distribution for heating coils.
3.1 AIR FACE VELOCITY
Air flow rate, M
3
/Hr
Air face velocity, M/sec =
Coil face area, M
2
x 3,600
3.1.1 Cooling Coil
The extended surface coils may be designed with air face velocity of 1.5 to 4 M/sec.
Higher air face velocities give better heat transfer characteristics with higher
pressure drop and higher coil bypass. Higher velocities used with dehumidifying
coils may also lead to condensed moisture carry-over in ducting system downstream
of the coil. As a good compromise between various factors dehumidifying coils are
normally designed for an air face velocity of around 2.5 M/sec. However, sensible
cooling coils may be designed for air face velocity as high as 4 M/sec.
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3.1.2 Heating Coil
The extended surface coils may be designed with air face velocity of 1 to 4 M/sec.
Higher air face velocities give better heat transfer characteristics with higher
pressure drop. When heating coils are used in conjunction with cooling and
dehumidifying coils in AHUs, the air face velocity is kept same as for cooling and
dehumidifying coil. For duct mounted or independent heating coils higher air face
velocities may be used.
3.2 MATERIAL OF FINS AND TUBES
3.2.1 Cooling Coil
Cooling coils for water or volatile refrigerants usually have aluminium fins and
copper tubes. Copper tubes and copper fins are also used quite frequently in
corrosive atmosphere like marine applications. Copper tubes and fins also minimise
galvanic corrosion and loss of fins bonding to the tube, extending the life of the
coil. Aluminium tubes with aluminium fins are also finding usage. Although copper
tubes with copper fins are expected to give best heat transfer characteristics most
commonly available indigenous designs are with copper tubes and flat or
configurated plate aluminium fins.
For ammonia refrigeration system normally carbon steel tubes are used since
ammonia reacts with copper.
3.2.2 Heating Coil
Copper and aluminium are the materials most commonly used in the fabrication of
extended surface heating coils. Tubing made of steel or various copper alloys is
used in applications where corrosive forces might attack the coils from either inside
or outside. The most common combination for low-pressure applications is
aluminium fins on copper tubes. Low-pressure steam coils are usually designed to
operate upto 10 to 13 Kg/cm
2
(g). Above this pressure, tube materials such as red
brass, admiralty brass or cupronickel is selected. It is preferable to operate steam
heating coil below 3.5 Kg/cm
2
(g), as otherwise IBR approval is required.
3.3 TYPES AND SPACING OF FINS
3.3.1 Numerous types of fin arrangements are used such as smooth spiral, flat plate and
configurated plate fins as shown in Figure 1. The spiral fins surround each tube
individually in all cases, while the plate type may be either continuous including
several rows of tubes or individual fin for each tube in round or square shape. Most
common designs available in India are flat plate or configurated plate continuous
fins.
3.3.2 A major factor in performance of extended surface coils is the bond between the fin
and the tube. An intimate contact must be permanently maintained to assure
unimpeded heat transfer.
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3.3.3 In individually finned tubes, fins are generally wound on the tube under pressure, to
upset the metal slightly at the fin root and are then given a coating of solder while
still revolving to assure a uniform coat. In some designs the spiral fins are knurled
into a shallow groove on the tube exterior. In very common flat or configurated
continuous plate fin designs, the tubes are usually mechanically expanded after the
fins are assembled or tube hole collars of a fin are made to override those in the
preceding fin thus compressing the fins on the tubes. Most designs available
indigenously are of the two types described last.
3.3.4 Various coil designs are made with fins spaced from 3 to 14 per 25 mm. However,
most coils used in air-conditioning applications are with 8 to 14 fins per 25 mm.
Although the coils with densely packed fins are expected to give better heat
transfer, fin spacing should be selected according to job to be performed with
special attention given to practical considerations such as condensate drainage,
possibility of lint and dust product accumulation and especially at lower
temperatures, frost accumulation. Based on above, for normal comfort air-
conditioning, one may select the coils with 14 fins per 25 mm, while applications
such as textile processing industry, pharmaceutical formulation plants (granulating
and tabling sections) may require wide spaced fins say 8 fins per 25 mm.
Applications involving possibility of frost formation such as cold diffusers may call
for still wider fin spacing, say 3 to 5 fins per 25 mm.
3.4 TUBE DIAMETERS AND NESTING CENTRE DIMENSIONS
3.4.1 The cooling and heating coils are built with tubes of commonly 6.4 mm(1/4), 9.5
mm(3/8), 12.7 mm(1/2), 15.9 mm(5/8), 19.1 mm(3/4) and 25.4 mm(1) outside
diameter. However, most commonly available designs are with 12.7 and 15.9 mm
outside diameter tubes. The tube nesting centres generally vary from 15.9 to 63.5
mm for cooling coils and 25 mm to 75 mm for heating coils. Spacing for 15.9 mm
outside diameter tubes is usually 38 to 50 mm vertical and 27 to 38 mm horizontal.
Coils with closely spaced tubes are expected to result in better-finned surface
effectiveness.
3.4.2 Due to high temperature difference between the heating medium (i.e. hot water or
steam) and air, one or two tube rows are normally sufficient for heating
applications.
For Direct Expansion (DX) coils, a three or four row deep coil is the most common
coil used for comfort air-conditioning applications. A five row DX coil may be
required for applications having a large percentage of latent load.
For chilled water coils, three, four or five rows are used for normal air-conditioning
applications. Six row coils are generally used for very large percentage latent load
applications.
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3.5 SURFACE RATIO
The surface ratio is defined as ratio of total external heat transfer surface of coil to
that of internal surface of tubes. Most common designs of extended surface coils
usually have surface ratios ranging from 18 to 34.
3.6 PROVISIONS TO INCREASE AIR TURBULENCE
Air turbulence and hence outer surface heat transfer could be improved in extended
coils by using configurated fins rather than flat fins and staggered tube arrangement
as against in-line tube arrangements. However, these features also add to air side
friction resistance, though slightly.
3.7 CHILLED AND HOT WATER FLOW & REFRIGERANT AND STEAM
DISTRIBUTION
3.7.1 Chilled Water Flow Distribution
To ensure sufficient water velocities inside tube for adequate heat transfer and at the
same time to avoid excessive pumping head, water coils can be provided with
various water circuit arrangements. For instance a typical 12 tubes high and six
tubes deep coils can be arranged in 3 circuits (quarter-circuited), 6 circuits (half-
circuited), 12 circuits (full-circuited) or 24 circuits (double- circuited) parallel water
circuits as shown in Figure 2. The circuits could be arranged to get water velocities
usually ranging between 0.3 and 2.4 M/sec and pressure drop across coils varying
between 1.5 and 15 MWC. Common designs are usually with 1 to 2 M/sec and
pressure drop of around 7 MWC. The normal air-conditioning system designs
usually employ full circuited coils while half or quarter circuited coils may find
application for sensible cooling coils operating with large Log Mean Temperature
Difference (LMTD). Double-circuited coils may have application in all fresh air
cooling coils handling relatively smaller volumes of air with large tonnages.
The chilled water flow through coil can be in parallel or counter flow arrangement
as shown in Figure 3. Counter flow is most preferred arrangement for normal coils
to secure advantage of highest possible mean temperature difference between air
and chilled water. However, parallel flow arrangement may find usage while sizing
coil with large terminal temperature difference between leaving air and leaving
chilled water.
3.7.2 Refrigerant Distribution (DX Coils)
Coils using volatile refrigerants present more complex cooling fluid distribution
problems than water or brine coil. DX coils are used on two types
of refrigeration systems i.e. flooded and dry expansion.
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The flooded system is used mainly for low temperature applications where a small
temperature difference between the air and refrigerant is required. However, this
system needs large volume of refrigerant.
For dry expansion coils two of the most commonly used refrigerant liquid metering
devices are the capillary tube and the thermostatic expansion valve. Capillary tube
is frequently used with factory built self-contained air-conditioning units upto
maximum capacity of 35.2 KW (10 TR) while it is extensively used in India for
small capacity models such as window air-conditioners and split units.
The thermostatic expansion valve is commonly used for all larger factory assembled
units as well as all field assembled central AHUs.
Internally equalised thermostatic expansion valves are used for capacity upto about
5 TR. Beyond this capacity, it is recommended that externally equalised
thermostatic expansion valves be used. Thermostatic expansion valve maintains a
constant superheat for the leaving refrigerant gas. For details of thermostatic
expansion valves, refer ASHRAE Handbook, Refrigeration.
To ensure reasonably uniform refrigerant distribution in multi-circuit coils,
distributing means are provided between expansion valve and the coil to divide
refrigerant equally among all coil circuits. Such a refrigerant distributor must be
effective in distributing both liquid and vapour, because the entering refrigerant is a
mixture of the two. Figure 4 shows five typical types of refrigerant distributors.
(a) In refrigerant distributor 'A', the liquid vapour mixture from the thermostatic
expansion valve is led tangentially into a chamber. The coil circuit
connections extend outward radially at the top of this chamber.
(b) In distributor 'B', the refrigerant is discharged at a high velocity through an
orifice against the end plate, forming a uniform mixture of vapour and liquid
within the refrigerant distributor, from which individual connections are led.
(c) In distributor 'C' the refrigerant enters at high velocity from the thermostatic
expansion valve and is discharged against sidewall to operate a liquid
vapour mixture, which is led to the end plug in which the individual circuit
connections are closely arranged.
(d) 'D' and 'E' are typical pressure type distributors. The venturi throat in 'D'
minimises pressure loss. The liquid vapour mixture flows into the orifice,
which is selected to match the load so that adequate mixing of the two
phases is maintained to feed equal portions of the mixture to individual
circuits. Beyond the orifice, a conical part deflects the refrigerant stream
towards the individual circuits. The distributors can be used in either vertical
or horizontal position. However, operation in vertical position leads to best
distribution.
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Large coils fed with multiple thermostatic expansion valves can be provided with
two arrangements for partial load control i.e. face control and depth control as
shown in Figure 5. Face control is used in most cases and provides substantially
equal loading on various refrigerant circuits. However, this has the disadvantage of
permitting re-evaporation of condensate on the coil and bypassing air into
conditioned space during partial load operation. Depth control, seldom available as
standard equipment, is usually supplied on special orders. Depth control usually
produces unequal loading on the thermostatic expansion valve. Hence, care shall be
taken to properly design and size the thermostatic expansion valves to overcome
this unbalance. Normally, depth control would be required for deep row coils
having six or more rows used for high latent load applications. Depth control
eliminates air bypassing during partial load operation and minimises condensate re-
evaporation.
3.7.3 Hot Water Flow Distribution
To obtain proper water velocity in tubes for most efficient heat transfer capacity,
without excessive pressure drop through the coil, various circuit arrangements are
used as shown in Figure 6.
The most common circuiting arrangement is full circuiting, which is considered as
standard circuiting. In this arrangement, all tubes in each coil row are supplied with
an equal amount of water through a manifold commonly called coil header. A
single tube serpentine circuit arrangement can be used on small size booster heater
requiring small water quantities upto a maximum of approximately 0.25 to 0.32
lit/sec. With this arrangement a single tube handles the entire water quantity.
3.7.4 Steam Distribution
For proper performance of steam heating coils, condensate must be rapidly
eliminated and steam must be uniformly distributed to the individual tubes.
Condensates are removed by providing proper steam traps and condensate drain
lines. Uniform steam distribution is accomplished by different methods such as :
(a) Individual orifices in the tubes
(b) Distributing plates in the steam headers and
(c) Special perforated small diameter inner steam distributing tubes extending
into the larger diameter tubes of the primary surface.
Coils of the perforated inner tube type are constructed with different arrangements
such as :
(a) Supply and return on one end, with the incoming steam used to heat the
leaving condensate ( non-freeze type)
(b) Supply and return on opposite ends and
(c) Supply and return on one end and a supply on the opposite end( non-freeze
type).
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Properly designed and selected steam distribution tube coils distribute the steam
throughout the entire length of all primary tubes, even when the leaving air
temperature is controlled by modulating the steam supply through a steam metering
valve.
As steam is condensing, the steam temperature is constant. The LMTD is not
dependent on direction of steam flow. Steam and air in steam heating coils are in
cross flow only.
4.0 APPLICATION RANGE
As per ARI 410-2001, cooling coil and heating coil standard rating shall be shown
within the range of operating conditions in Table-1. For special applications the
range in above design variables could be exceeded.
5.0 INPUT AND OUTPUT DATA FOR COIL SELECTION OR SIZING
5.1 INPUT DATA
Following input data is required for selection and sizing of coils :
5.1.1 Cooling Coil
(a) Air flow rate
(b) Entering air DBT and WBT
(c) Leaving air DBT and WBT
(d) Total cooling load
(e) Sensible cooling load
(f) Entering chilled water temperature
(g) Maximum leaving chilled water temperature
(h) Maximum allowable water side and air side pressure drop
(i) Assumed bypass factor in arriving at the air flow rate
5.1.2 Heating Coil
(a) Air flow rate
(b) Entering air DBT
(c) Leaving air DBT
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(d) Total heating load
(e) Entering hot water pressure, temperature and available water flow rate or
desired temperature drop (for hot water coils)
(f) Steam pressure and temperature (for steam coils)
(g) Maximum allowable water side and air side pressure drop
5.2 OUTPUT DATA
The following are the output data from a cooling or heating coil selection :
(a) Coil face area and overall dimensions
(b) Coil cooling or heating medium flow rate
(c) Coil cooling or heating medium temperature rise or drop
(d) Coil cooling or heating medium pressure drop
(e) Coil air side pressure drop
(f) Coil air outlet DBT and WBT
(g) Coil spin spacing, tube size, number of rows.
6.0 PROCEDURE FOR SELECTION OR SIZING
6.1 COOLING COILS
6.1.1 Unit Rating Method
Coils can be sized or selected from manufacturers data furnished for specific unit
size of given face area and rows depth. Typical examples of sizing coils by this
method are illustrated for chilled water coil and DX coil in examples 1 and 3
respectively of Appendix-1.
6.1.2 Basic Data Method
Certain manufacturers furnish derived heat transfer parameters in the form of tables
or charts from which by taking certain physical dimensions of coil face area the coil
rows depth is determined. In this procedure it is frequently necessary to re-check
and re-select the various parameters to more closely match the required air and
cooling fluid conditions with integral rows depth. Typical example of sizing coil by
this method is illustrated in example 2 of Appendix-1.
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6.2 HEATING COILS
The selection of heating coils is relatively simple, because it involves DBT and
sensible heat only. Heating coils are usually selected from manufacturers
performance charts or tables giving final air temperature at various air face
velocities, entering air temperatures and steam or water temperatures. Most coil
manufacturers have their own methods of producing performance rating charts or
tables from a suitable number of coil performance tests. Typical example of
selecting coil from manufacturers charts, table or curves is given in Appendix-2.
6.3 COIL SIZING FROM FUNDAMENTAL PRINCIPLES
By this method coil can be sized by estimating fundamental heat transfer resistances.
This method helps in sizing coils without much relying on manufacturers data or
establishing the performance of already installed coil with varying parameters. This
method also needs few iterations to finalise the exact parameters. This method is
normally not used in jobs executed by TCE.
6.4 COMPUTER SELECTION
Some manufacturers use computer programmes to select the cooling and heating
coils. Input requirements are the same as given in para 5.1. Computer output gives
the various parameters of the selected coils.
7.0 REFERENCES
7.1 ASHRAE Handbook, Equipment, 1979 Edition
7.2 ASHRAE Handbook, Refrigeration, 2002 Edition
7.3 ARI 410-2001 Standard for Forced-Circulation Air-Cooling and Air-Heating Coils
7.4 Engineering Bulletin - Hot water heating coils - Blue Star Limited
7.5 Engineering Bulletin - Air Handling Units - Frick India Limited
7.6 Air-Conditioning & Refrigeration Engineers Handbook - Voltas Limited,
1977 Edition
SECTION: APPENDIX
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APPENDIX-1
EXAMPLES OF COOLING COIL SELECTION PROCEDURE
The following abbreviations and suffixes are used in Appendix-1 and Appendix-2.
Units are indicated at appropriate places.
ABBREVIATIONS
Q = Flow rate
h
= Difference in enthalpy
V = Velocity t = Difference in temperature
t = Temperature BF = Bypass Factor
h = Enthalpy FA = Face Area
p
= Pressure drop GTH = Grand Total Heat
SUFFIXES
1 = entering af = air face
2 = leaving adb = air dry bulb
o = outside awb = air wet bulb
i = inside cw = cold water
a = air hw = hot water
EXAMPLE-1: CHILLED WATER COIL - BASED ON RATING CHARTS
FURNISHED BY VOLTAS LIMITED
1.0 INPUT DATA
(a) Air flow rate, Q
a
= 14,000 CFM
(b) Entering air DBT, t
adb1
= 79
0
F
(c) Entering air WBT, t
awb1
= 68
0
F
(d) Leaving air DBT, t
adb2
= 59
0
F
(e) Leaving air WBT, t
awb2
= 58
0
F
(f) Entering chilled water temperature , t
cw1
= 46
0
F
(g)
Allowable chilled water pressure drop, p
cw
= 7 MWC
(h) BF (Assumed during estimation of air flow
rate)
= 0.10
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 12 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
2.0 SELECT COIL FACE AREA
Minimum coil face area to keep the air face velocity around 500 FPM (2.5
M/sec)
Coil face area, FA = Q
a
/ 500 = 14,000 / 500
= 28 FT
2
From Table-2 select AH-11 having nearest face area to meet the requirement
i.e. 34 FT
2
(3.16 M
2
)
Air face velocity, V
af
= 14,000 / 34
= 411.76 FPM
Say = 410 FPM (Acceptable)
3.0 CHECK BYPASS FACTOR
From Figure-7, select 4 rows depth coil as it has bypass factor of about 0.08 at
410 FPM, which is reasonably close to assumed bypass factor of 0.1.
4.0 ESTIMATE CHILLED WATER FLOW RATE
Enthalpy of entering air, h
a1
= 32.50 BTU/lb (*)
Enthalpy of leaving air, h
a2
= 25.25 BTU/lb (*)
---------------
h
a1
-h
a2
= h = 7.25 BTU/lb
(*) From psychrometric chart
Grand Total Heat (GTH) = 4.5 x Q
a
x h
= 4.5 x 14,000 x 7.25
= 4,56,750 BTU/Hr
Say = 4,57,000 BTU/Hr
(t
adb1
- t
adb2
)
Apparatus Dew Point (ADP) = t
adb1
-
(1 - BF)
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 13 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
(79 - 59)
= 79 -
(1 - 0.08)
= 57.26
0
F
Say = 57
0
F
GTH
Coil loading rate (q) =
(ADP t
cw1
)
4,57,000
=
(57-46)
= 41,545 BTU/Hr
0
F
As indicated in Figure-8, Chart q = Actual q / Factor. Factor for Unit AH-11 is 3.
41,545
Chart q = = 13,848 BTU/Hr
0
F
3
Say = 13,900 BTU/Hr
0
F
From Figure-8, read chilled water flow rate at
q = 13,900 BTU/Hr
0
F and air face velocity = 410 FPM
Chart chilled water flow rate = 23 USGPM
Actual GPM = Chart GPM x 3. Factor for Unit AH-11 is 3
Actual flow rate, Q
cw
= 23 x 3 = 69 USGPM
= 15.68 M
3
/Hr
Say = 16 M
3
/Hr
5.0 ESTIMATE WATER SIDE PRESSURE DROP
From Figure-8 top curve read water side pressure drop for unit flow of 23
USGPM as 2 psi
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 14 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
Actual psi = Chart psi x Factor. Factor for Unit AH-11 is 0.92
Pressure drop referred to actual coil size
= 2 x 0.92
= 1.84 psi
= 1.84 x 0.7 MWC
Chilled water pressure drop, p
cw
= 1.29 MWC Say 1.3 MWC
6.0 ESTIMATE AIR SIDE PRESSURE DROP
From Table-3 read air side pressure drop for 4 row wet coil corresponding to
410 FPM air face velocity and wet surface coil (interpolated value) as
Pressure drop = p
a
= 0.384 inches of WC
= 9.75 mmWC
7.0 ESTIMATE CHILLED WATER TEMPERATURE RISE
GTH
Chilled water temperature rise , t
cw
=
Q
cw
(GPM) x 500
= 4,57,000 / (69 x 500)
= 13.25
0
F = 7.36
0
C
This temperature is higher than the maximum temperature rise of about 6
0
C
generally specified. If the temperature rise is higher than that specified, another
coil has to be selected meeting other requirements and temperature rise brought
within the specified limit.
8.0 SUMMARY OF PARAMETERS
Coil face area ,FA = 3.16 M
2
(34 FT
2
)
Total cooling capacity = 38 TR (4,57,000 BTU/Hr)
Chilled water flow rate, Q
cw
= 16 M
3
/Hr
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 15 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
Number of rows deep = 4
Fin spacing = 5 fins/cm (13 fins/inch)
Water side pressure drop, p
cw
= 1.3 MWC
Air side pressure drop, p
a
= 9.75 mmWC
Based on the layout constraints and meeting the coil face area requirements,
manufacturer shall furnish coil dimensions.
EXAMPLE-2: CHILLED WATER COIL - BASED ON BASIC DATA
FURNISHED BY FRICK INDIA LIMITED
1.0 INPUT DATA
Same as for example 1.
Minimum coil face area to keep air face velocity around 500 FPM (2.5 M/sec)
Coil face area, FA = Q
a
/ 500 = 14,000 / 500
= 28 FT
2
From Table-4 select model FAH-145 having face area of 29 FT
2
and 28 tubes
in face.
Actual air face velocity, V
a
= 14,000/29
= 482.76 FPM
Say = 480 FPM
3.0 ESTIMATE CHILLED WATER FLOW RATE
Assume temperature rise through coil (t
cw
) = 10
0
F

GTH
cw
=
500 x t
cw
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 16 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
4,57,000
=
500 x 10
= 91.4 USGPM
Say = 90 USGPM
91.4 x 10
Actual temperature rise, t
cw
=
90
= 10.16
0
F
Leaving chilled water temperature,
t
cw2
= t
cw1
+ t
cw
= 46 + 10.16 = 56.16
0
F
4.0 ESTIMATE WATER VELOCITY THROUGH TUBES
Assuming full circuited coil
Q
cw
(USGPM) x 1.235
Water velocity V
cw
=
Number of tubes in face
where 1.235 is the factor for 5/8diameter coil
90 x 1.235
=
28
= 3.97 FPS(Acceptable as within applicable range)
Say = 4 FPS
5.0 ESTIMATE SENSIBLE HEAT TRANSFER FACTOR (K) AND
MULTIPLYING FACTOR FOR WETTED SURFACE COIL (Ws)
From Table-5 read value of K for water velocity of 4 FPS and air face velocity
of 480 FPM (interpolated) as
K = 173.20 BTU/(Hr row FT
2
of coil face area
0
F LMTD)
Coil Sensible Load = 1.08 x Q
a
(t
adb1
- t
adb2
)
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 17 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
= 1.08 x 14,000 x (79-59)
= 3,02,400 BTU/Hr
Coil Sensible Load 3,02,400
Sensible Heat Factor (SHF) = =
GTH 4,57,000

= 0.6617
Say = 0.66
From Table-6 read value of Ws for SHF = 0.66 and water velocity = 4 FPS
Ws = 0.891
(t
adb1
- t
cw2
) - (t
adb2
- t
cw1
)
LMTD =
(t
adb1
- t
cw2
)
ln
(t
adb2
- t
cw1
)
(79 - 56.16) - (59 - 46)
=
(79 - 56.16)
ln
(59 - 46)
= 17.46
0
F
Say = 17.5
0
F
6.0 ESTIMATE NUMBER OF ROWS
GTH x SHF
Number of rows =
K x LMTD x Ws x FA
4,57,000 x 0.66
=
173.20 x 17.5 x 0.891 x 29
= 3.85 rows
Say = 4 rows
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 18 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
7.0 Water side pressure drop and air side pressure drop can be estimated from the
water pressure drop and air pressure drop tables or charts.
Coil face area, FA = 2.7 M
2
(29 FT
2
)
Total cooling capacity = 38 TR (4,57,000 BTU/Hr)
cw
= 20.5 M
3
/Hr
Fin spacing = 3.15 fins/cm (8 fins/inch)
EXAMPLE-3: DIRECT EXPANSION VOLATILE REFRIGERANT COILS
1.0 INPUT DATA
Same as for example 1.
From Table-2 select AH-9 with 22.6 FT
2
(2.10 M
2
) coil face area .
Air face velocity = 14000 / 22.6
= 619.47 FPM
Say = 625 FPM
This air face velocity is on a higher side of the recommended velocity of
around 2.5 M/sec. However, the refrigerant evaporating temperature selection
method is explained below.
Grand Total Heat (GTH) = 4,57,000 BTU/Hr
3.0 ESTIMATE REFRIGERANT EVAPORATING TEMPERATURE
In Figure-9, enter at upper right hand side with GTH = 4,57,000 BTU/Hr and
move upto intersection with 625 FPM curve. From this point project down to
intersect with air entering wet bulb temperature curve of 68
o
F, reading
refrigerant evaporating temperature of approximately 50
o
F.
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 19 OF 49
ISSUE
R2
APPENDIX-1 (CONTD.)
2
(22.6 FT
2
)
Total cooling load, GTH = 38 TR (4,57,000 BTU/Hr)
Refrigerant (R - 22)
Refrigerant evaporating temperature = 10
o
C (50
o
F)
Number of rows deep = 5 (from Figure-9)
Fin spacing = 5 fins/cm (13 fins/inch)(from Figure-9)
Air side pressure drop = 0.89 INCHES WC ( 23mmWC)
(from Table-3)
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 20 OF 49
ISSUE
R2
APPENDIX-2
EXAMPLES OF HEATING COIL SELECTION PROCEDURE
For abbreviations and suffixes, refer Appendix-1.
EXAMPLE-1: HOT WATER COIL - BASED ON RATING CHARTS AND
TABLES FURNISHED BY BLUE STAR LIMITED
1.0 INPUT DATA
(a) Heating load = 1,02,000 BTU/Hr
(b) Air flow rate, Q
a
= 2,500 CFM
(c) Entering air DBT , t
adb1
= 60
0
F
(d) Air face velocity, V
af
= 600 FPM
(e) Water pressure drop, p
hw
= 10 feet of water
(f) Entering water temperature , t
hw1
= 150
0
F
(g) Leaving water temperature, t
hw2
= 138
0
F
2.0 DETERMINE COIL FACE AREA
Qa 2,500
Coil face area = = = 4.17 FT
2
V
af
600
3.0 TUBES HIGH (TH) AND FINNED LENGTH (FL)
From Table-7 select TH =10 and FL =48 INCHES
Coil face area ,FA = 4.2 FT
2
Several combinations of TH and FL are possible to obtain same area. Select
TH and FL based on layout consideration.
4.0 KBH / FT
2
, where KBH = 1,000 BTU/Hr
102
= 24.5 KBH/ FT
2
4.17
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 21 OF 49
ISSUE
R2
APPENDIX-2 (CONTD.)
5.0 CALCULATE QB
QB = (Average water temp t
adb1
) x 0.308 (constant)
= (144-60) x 0.308 = 25.9 KBH/ FT
2
6.0 For heating, F1 (water temperature rise factor) = 1.0
7.0 ESTIMATE HOT WATER FLOW RATE
KBH x 2 102 x 2
Hot water flow rate, Q
hw
= = = 17 USGPM
t
hw
12
= 17/4.4 = 3.9 M
3
/Hr
8.0 ESTIMATE HOT WATER PRESSURE DROP
In Figure-10 choose a water circuit, taking into consideration any limitation on
Water Pressure Drop (WPD)
Accordingly choose circuit B, WPD = 6 FT
Q
hw
(USGPM)x R
Calculate water velocity, V
hw
=
TH x RD
Where R= water velocity constant to be obtained from Table-8 = 6.84
TH= Tubes High =10 (from para 3.0)
RD= Rows Deep = 2 (assumed)
17 x 6.84
V
hw
= = 5.81 FPS
10 x 2
V
hw
of 5.81 FPS is within acceptable limit.
Now correct the 6 FT WPD for V
hw
of 5.81
From Figure-10 multiplication factor = 1.95
6 FT x 1.95 = 11.7 FT
Now correct for t
hw1
of 150
0
F
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 22 OF 49
ISSUE
R2
APPENDIX-2 (CONTD.)
From formula given in Figure-10
Heating WPD = WPD[0.75 +0.0012 (180-t
hw1
)]
= 11.7 x [ 0.75 + 0.0012 (180-150)] = 9.2 FT
WPD of 9.2 FT is within specified limit.
9.0 OBTAIN WATER VELOCITY FACTOR , F2
From Figure-11 read F2 = 1.0
10.0 CALCULATE F3
KBH / FT
2
required = QB x F1 x F2 x F3
Where, KBH / FT
2
= 24.5 (from para 4.0) ; F1 = 1.0 (from para 6.0)
F2 = 1.0 (from para 9.0)
24.5 = 25.9 x 1 x 1 x F3
which gives F3 = 0.95
11.0 SELECT FINS PER INCH (FPI)
In Figure-12, for 2 rows deep, F3 = 0.95 and air face velocity = 600 FPM,
select a FPI that provides a value of F3 greater than required. Choose 10 FPI.
Then F3 = 1.0
12.0 ESTIMATE ACTUAL KBH
Actual KBH / FT
2
= QB x F1 x F2 xF3
= 25.9 x 1 x 1 x 1 = 25.9
Actual KBH = 25.9 x 4.17 = 108 KBH
or 1,08,000 BTU/Hr
13.0 CALCULATE LEAVING AIR DRY BULB TEMPERATURE (t
adb2
)
KBH x 1000 108.0 x 1,000
t
adb2
= t
adb1
+ = 60 + = 100
0
F
1.08 x Q
a
1.08 x 2,500
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 23 OF 49
ISSUE
R2
APPENDIX-2 (CONTD.)
14.0 CALCULATE AIR PRESSURE DROP (p
a
)
From Figure-13 , Y = 0.082
Air pressure drop, p
a
= Y x Rows deep = 0.082 x 2
= 0.164 INCHES WC = 4.17 mmWC
Coil face area, FA = 0.39M
2
(

4.17 FT
2
)
Total heating capacity = 25,760 Kcals/Hr (1,02,000 BTU/Hr)
hw
= 3.9 M
3
/Hr
Fins spacing = 4 fins /cm (10 fin/inch)
Water side pressure drop, p
w
= 2.8MWC
Air side pressure drop, p
a
= 4.17 mmWC
EXAMPLE-2: HOT WATER COIL - BASED ON RATING CHARTS AND
TABLES FURNISHED BY VOLTAS LIMITED
1.0 INPUT DATA
(a) Outside design temperature, t
o
= 0
0
F
(b) Inside design temperature, t
i
= 70
0
F
(c) Heating load = 2,00,000 BTU/Hr
(d) Total air flow rate, Q
a
= 4,000 CFM
(e) Outside air flow rate, Q
o
= 800 CFM
(f) Entering water temperature, t
hw1
= 180
0
F
(g) Unit size(Selected based on
total cooling load, dehumid- = AH-5
ified CFM and air face velocity)
(h) Air face velocity, V
a
= 500 FPM
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 24 OF 49
ISSUE
R2
APPENDIX-2 (CONTD.)
2.0 Calculate the temperature of the air mixture entering the coil
Q
o
x t
o
+ Q
i
x t
i
t
mixture
=
Q
a
(800 x 0 ) + (3,200 x 70)
= = 56
0
F
4,000
3.0 DETERMINE BTU CONSTANT
From Table-9
for water temperature drop = 20
0
F,
entering water temperature = 180
0
F and
entering air temperature = 56
0
F,
interpolating between 50
0
F and 60
0
F ,
the hot water BTU constant = 0.87
4.0 CALCULATE TABLE BTU/HR
Dividing the given heating load = 2,00,000 BTU/Hr by the BTU constant =
0.87,
Table BTU/Hr = 2,30,000 BTU/Hr
This value is to be used in Table-10 which is based on entering water
temperature = 200
0
F, entering air temperature =60
0
F and hot water
temperature drop =20
0
F.
5.0 DETERMINE HOT WATER FLOW RATE AND PRESSURE DROP
From Table-10 for 2 row coil, unit size = AH-5 and face velocity = 500 FPM
the BTU/Hr is 2,48,000,
Q
hw
= 25 USGPM = 25 x 0.227 M
3
/Hr = 5.7 M
3
/Hr
p
hw
= 0.98 psi =0.98 x 0.69 MWC = 0.68 MWC
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 25 OF 49
ISSUE
R2
APPENDIX-2 (CONTD.)
6.0 FIND THE LEAVING AIR TEMPERATURE
BTU / Hr required
T
adb2
= t
adb1
+
1.08 x CFM
2,00,000
= 56 + = 102.3
0
F
1.08 x 4,000
7.0 DETERMINE ACTUAL TEMPERATURE DROP
BTU/Hr required
Water temperature drop, t
hw
=
500 x Water Flow Rate (USGPM)

2,00,000
= = 16
0
F
500 x 25
2
(from Table-2)
Total heating capacity = 50,500 Kcal/Hr (2,00,000 BTU/Hr)
hw
= 5.7 M
3
/Hr.
Water side pressure drop,p
hw
= 0.68 MWC
Air side pressure drop , p
a
= 3 mmWC (0.12 INCHES WC) (from Table-3)
EXAMPLE-3: STEAM HEATING COIL : BASED ON RATING CHARTS
AND TABLES FURNISHED BY VOLTAS LIMITED
1.0 INPUT DATA
(a) Outside design condition, t
o
= 0
0
F
(b) Inside design condition, t
i
= 70
0
F
(c) Heating Load = 2,80,000 BTU/Hr
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 26 OF 49
ISSUE
R2
APPENDIX-2 (CONTD.)
(d) Total air flow rate, Q
a
= 4,000 CFM
(e) Outside air flow rate,Q
o
= 800 CFM
(f) Unit size ( selected based on total cooling load,
dehumidified CFM and air face velocity) = AH-5
(g) Air face velocity ,V
a
= 500 FPM
(h) Steam pressure available = 10 psig
2.0 Calculate the temperature of the mixed air entering the coil using the formula
Q
o
x t
o
+ Q
i
x t
i
t
mixture
=
Q
a
(800 x 0) + (3,200 x70)
= = 56
0
F
4,000
3.0 ESTIMATE EQUIVALENT HEATING COIL CAPACITY
As 10 psig steam is available, calculate the equivalent capacity of a heating
coil when operating at 2 psig steam and 70
0
F entering air
10 psig saturated steam temperature = 240
0
F
BTU/Hr required x 149
Equivalent capacity = (Voltas Handbook)
Steam temp. - entering air temp.
2,80,000x 149
= = 2,26,740 BTU/Hr
240 - 56
Say = 2,27,000 BTU/Hr
4.0 SELECT THE COIL
From Table-11 for AH-5 heating coil, for 2 psig steam and entering air
temperature = 70
0
F and coil air face velocity = 500 FPM, select a 1 row high
rise coil. Capacity = 2,33,000 BTU/Hr. This capacity will work satisfactorily.
SECTION: APPENDIX
TCE.M6-ME-811-304
SHEET 27 OF 49
ISSUE
R2
APPENDIX-2 (CONTD.)
The actual capacity of the coil = 2,33,000 x (240 - 56) / 149
= 2,88,000 BTU/Hr
5.0 DETERMINE LEAVING AIR TEMPERATURE
The leaving air temperature is found from the formula :
BTU/Hr required
t
adb2
= t
adb1
+
1.08 x Q
a

2,80,000
= 56 + = 120.8
0
F
1.08 x 4,000
Coil face area = 0.767 M
2
(from Table-2)
Total heating capacity = 70,700 Kcal/Hr (2,80,000 BTU/Hr)
Air side pressure drop , p
a
= 2 mmWC (0.08 INCHES WC) (from Table-3)
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 39 OF 49
ISSUE
R2
TABLE - 1 RANGES OF STANDARD RATING CONDITIONS
COOLING COILS HEATING COILS SL.
NO.
ITEM UNIT
VOLATILE
REFRIGE-
RANT
COLD
WATER
COLD
ETHYLENE
GLYCOL
SOLUTION
STEAM HOT
WATER
HOT
ETHYLENE
GLYCOL
SOLUTION
1. Standard air face
velocity
M/
sec
1 to 4 1 to 4 1 to 4 1 to 8 1 to 8 1 to 8
2. Entering air dry-
bulb temperature
0
C
18 to 38 18 to 38 18 to 38 (-) 29
to 38
(-) 18
to 38
(-) 29 to
38
3. Entering air wet-
bulb temperature
0
C
16 to 29 16 to 29 16 to 29 - - - - - -
4. Tube-side fluid
velocity
M/
Sec - -
0.3 to
2.4 (N1)
0.3 to 1.8
(N2) - -
0.1 to
2.4
(N1)
0.1 to 1.8
(N2)
5. Entering fluid
temperature
0
C
- - 1.7 to 18 (-) 18 to 32 - - 49 to
121
(-) 18 to
93
6. Saturated suction
refrigerant
temperature
at coil outlet
0
C (-) 1.1 to
13
- - - - - - - - - -
7. Minimum suction
vapour superheat at
coil outlet
0
C 3.3 - - - - - - - - - -
8. Steam pressure at
coil inlet
KPa
(g)
- - - - - - 14 to
1723
- - - -
9. Maximum superheat
in steam at coil inlet
0
C
- - - - - - 28 - - - -
10. Concentration by
mass %
- - - - 10 to 60 - - - - 10 to 60
11. Minimum fin
surface temperature
0
C
> 0.0 > 0.0 > 0.0 > 0.0 > 0.0 > 0.0
12. Minimum tube wall
surface temperature
0
C
> 0.0 > 0.0
> ethylene
glycol
solution
freeze
point
> 0.0 > 0.0
> ethylene
glycol
solution
freeze
point
NOTES
1. On lower limit, Reynolds Number shall exceed 3,100 at mean water temperature.
2. On lower limit, Reynolds Number shall exceed 700 at mean glycol temperature.
SOURCE: ARI 410-2001
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 40 OF 49
ISSUE
R2
A
H
-
1
2
5
3
7
9
0
4
6
1
0
0
3
8
4
2
0
3
0
7
3
5
2
3
0
5
0
4
.
2
0
1
4
0
2
2
2
.
1
2
3
3
3
.
6
4
4
4
4
.
2
4
5
5
5
.
7
6
6
6
7
.
2
9
3
4
5
7
0
.
9
7
6
9
0
0
2
4
3
6
.
4
7
2
.
8
A
H
-
1
1
4
0
4
6
0
3
4
6
8
0
2
8
9
0
0
2
3
1
2
0
1
7
3
5
0
3
.
1
6
0
3
0
1
6
6
.
8
2
2
5
0
.
0
0
3
3
3
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SECTION: TABLE
TCE.M6-ME-811-304
SHEET 41 OF 49
ISSUE
R2
TABLE-3 AIR SIDE RESISTANCE OF COOLING AND HEATING COILS
(INCHES OF WATER COLUMN)
COOLING COIL (NOTE 2) HEATING COIL
1 ROW
SL.
NO.
AIR
FACE
VELO-
CITY
FPM
(NOTE 1)
2
ROW
3
ROW
4
ROW
5
ROW
6
ROW LOW
RISE
HIGH
RISE
2
ROW
1. 300 0.12 0.18 0.24 0.30 0.36 0.01 0.03 0.05
2. 350 0.15 0.23 0.30 0.38 0.45 0.01 0.04 0.07
3. 400 0.18 0.28 0.37 0.47 0.55 0.02 0.06 0.08
4. 450 0.22 0.33 0.44 0.55 0.66 0.02 0.07 0.10
5. 500 0.26 0.39 0.52 0.65 0.78 0.03 0.08 0.12
6. 550 0.30 0.45 0.60 0.76 0.90 0.03 0.10 0.14
7. 600 0.34 0.51 0.68 0.85 1.00 0.04 0.11 0.17
8. 650 0.37 0.55 0.74 0.93 1.10 0.04 0.13 0.19
9. 700 0.40 0.66 0.81 1.01 1.21 0.05 0.15 0.22
NOTES
1. Air quantity for each unit size corresponding to the air face velocity is
shown in the physical data in Table-2.
2. Cooling coil resistance is based on wet surface.
SOURCE : VOLTAS HANDBOOK-1977
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 42 OF 49
ISSUE
R2
TABLE 4 PHYSICAL PARAMETERS OF COILS
( 8 FINS/INCH)
CONNECTION SIZES COILS
DX COILS WATER COILS
MODEL
NO.
PIPES
HIGH
NOM-
INAL
FACE
LEN-
GTH
FACE
AREA
INLET
OD
SUC-
TION
OD
INLET
OD
OUT-
LET
OD
INC-
HES FT
2
INC-
HES
INC-
HES
INC-
HES
INC-
HES
FAH-12 10 22 2.5 5/8 7/8 7/8 7/8
FAH-21 12 34 4.2 3/4 1-1/8 1-1/8 1-1/8
FAH-32 14 46 6.4 3/4 1-3/8 1-3/8 1-3/8
FAH-38 16 46 7.7 7/8 1-5/8 1-5/8 1-5/8
FAH-48 16 56 9.7 7/8 1-5/8 1-5/8 1-5/8
FAH-65 16 78 13.0 7/8 1-5/8 1-5/8 1-5/8
FAH-86 18 94 17.2 1-1/8 2-1/8 2-1/8 2-1/8
FAH-98 24 78 19.6 1-1/8 2-1/8 2-1/8 2-1/8
FAH-115 24 94 23.6 1-1/8 2-1/8 2-1/8 2-1/8
FAH-145 28 102 29.0 2 x 7/8 2 x
1-5/8
2 x 1-
5/8
2 x
1-5/8
FAH-170 28 118 34.4 2 x 1-
1/8
2 x
2-1/8
2 x 2-
1/8
2 x
2-1/8
FAH-230 38 118 46.7 2 x 1-
1/8
2 x
2-1/8
2x 2-
1/8
2x
2-1/8

SOURCE : FRICK INDIA LIMITED ENGINEERING BULLETIN
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 43 OF 49
ISSUE
R2
TABLE-5 K FACTORS FOR CHILLED WATER COILS
(8 FINS/INCH)
BTU PER HOUR PER ROW (SENSIBLE HEAT ) PER SQ.FT FACE AREA PER DEG. F LMTD
WATER VELOCITY IN COIL FEET PER SECOND SL.
NO.
AIR FACE
VELOCITY
FPM
1 1.5 2 2.5 3 3.5 4 5 6
1. 350 110 119 129 132 135 138 141 143 145
2. 375 115 124 134 138 141 144 147 150 153
3. 400 118 129 139 143 147 150 154 156 159
4. 425 122 144 144 148 153 156 160 163 166
5. 450 125 148 148 153 154 162 166 169 172
6. 475 128 152 152 157 164 168 172 175 179
7. 500 132 156 156 161 169 173 178 182 185
8. 525 135 160 160 166 173 178 183 187 190
9. 550 138 164 164 170 178 183 188 192 196
10. 575 140 168 168 174 183 187 194 197 204
11. 600 143 172 172 179 187 192 198 203 207
12. 625 146 176 176 184 192 196 203 208 212
13. 650 148 179 179 188 190 201 208 212 217
14. 675 150 182 182 191 200 205 212 217 222
15. 700 152 186 186 195 204 210 217 222 227
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 44 OF 49
ISSUE
R2
TABLE-6 MULTIPLIERS W
S
FOR WETTED
CHILLED WATER COOLING COIL SURFACES
(8 FINS PER INCH)
WATER VELOCITY (V
cw
) IN COIL ( FEET PER SECOND) SL.
NO.
SENSIBLE
HEAT
FACTOR
1 1.5 2 2.5 3 3.5 4 5 6
1. 0.40 0.605 0.638 0.688 0.690 0.707 0.722 0.736 0.750 0.765
2. 0.42 0.624 0.657 0.687 0.705 0.723 0.737 0.750 0.763 0.770
3. 0.44 0.643 0.676 0.706 0.720 0.739 0.750 0.764 0.777 0.787
4. 0.46 0.662 0.695 0.724 0.735 0.755 0.767 0.780 0.790 0.803
5. 0.48 0.680 0.714 0.739 0.752 0.772 0.784 0.795 0.803 0.818
6. 0.50 0.698 0.728 0.754 0.766 0.785 0.798 0.807 0.816 0.829
7. 0.52 0.713 0.740 0.769 0.782 0.800 0.811 0.820 0.829 0.841
8. 0.54 0.728 0.757 0.783 0.796 0.813 0.822 0.831 0.842 0.852
9. 0.56 0.743 0.770 0.796 0.810 0.824 0.833 0.841 0.853 0.860
10. 0.58 0.759 0.782 0.810 0.822 0.837 0.844 0.851 0.861 0.868
11. 0.60 0.772 0.796 0.823 0.835 0.849 0.855 0.862 0.872 0.880
12. 0.62 0.785 0.808 0.832 0.847 0.859 0.866 0.871 0.880 0.888
13. 0.64 0.800 0.822 0.846 0.857 0.868 0.876 0.881 0.889 0.896
14. 0.66 0.813 0.835 0.855 0.867 0.877 0.885 0.891 0.898 0.905
15. 0.68 0.826 0.848 0.867 0.876 0.887 0.893 0.900 0.907 0.913
16. 0.70 0.839 0.860 0.878 0.886 0.897 0.902 0.908 0.915 0.921
17. 0.72 0.850 0.871 0.888 0.896 0.906 0.911 0.916 0.923 0.928
18. 0.74 0.864 0.880 0.899 0.905 0.913 0.919 0.924 0.929 0.935
19. 0.76 0.875 0.890 0.907 0.914 0.922 0.926 0.931 0.936 0.941
20. 0.78 0.888 0.901 0.916 0.923 0.930 0.933 0.938 0.942 0.947
21. 0.80 0.899 0.911 0.925 0.932 0.938 0.940 0.944 0.948 0.952
22. 0.82 0.910 0.921 0.933 0.939 0.942 0.946 0.951 0.954 0.957
23. 0.84 0.921 0.931 0.942 0.945 0.950 0.952 0.957 0.960 0.962
24. 0.86 0.933 0.941 0.950 0.952 0.957 0.960 0.963 0.965 0.967
25. 0.88 0.944 0.951 0.956 0.959 0.963 0.964 0.970 0.971 0.972
26. 0.90 0.955 0.960 0.966 0.967 0.970 0.968 0.975 0.976 0.977
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 45 OF 49
ISSUE
R2
3
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5
.
0
5
.
8
6
.
7
7
.
5
8
.
3
9
.
2
1
0
.
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8
1
1
.
7
1
2
.
5
1
3
.
3
1
4
1
7
.
5
2
.
2
2
.
9
3
.
7
4
.
4
5
.
1
5
.
8
6
.
6
7
.
3
8
.
0
8
.
8
9
.
5
1
0
.
2
1
2
1
5
1
.
9
2
.
5
3
.
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3
.
8
4
.
4
5
.
0
5
.
6
6
.
3
6
.
9
7
.
5
1
0
1
2
.
5
1
.
0
1
.
6
2
.
1
2
.
6
3
.
1
3
.
7
4
.
2
4
.
7
5
.
2
81
0
.
0
0
.
8
1
.
3
1
.
7
2
.
1
2
.
5
2
.
9
3
.
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67
.
5
0
.
6
0
.
9
1
.
3
1
.
6
1
.
9
1
2
1
8
2
4
3
0
3
6
4
2
4
8
5
4
6
0
6
6
7
2
7
8
8
4
9
0
9
6
1
0
2
1
0
8
1
1
4
1
2
0
1
2
6
1
3
2
1
4
0
F
I
N
N
E
D

L
E
N
G
T
H

A
V
A
I
L
A
B
L
E

I
N

2

I
N
C
H

I
N
C
R
E
M
E
N
T
S

F
R
O
M

1
2

T
O

1
4
0

I
N
C
H
E
S
T
A
B
L
E
-
7

C
O
I
L

F
A
C
E

A
R
E
A
S

(
F
A
)
(
S
Q
U
A
R
E

F
E
E
T
)
T
U
B
E
S

H
I
G
H

(
T
H
)
F
I
N
N
E
D

H
E
I
G
H
T
(
F
H
)

-

I
N
C
H
E
S
FINNED LENGTH (FL) - INCHES

S
O
U
R
C
E
:

B
L
U
E

S
T
A
R

L
I
M
I
T
E
D

E
N
G
I
N
E
E
R
I
N
G

B
U
L
L
E
T
I
N
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 46 OF 49
ISSUE
R2
TABLE-8 WATER VELOCITY CONSTANT R
COIL CIRCUIT COOLING
ROWS DEEP
AVAILABLE
HEATING
ROWS DEEP
SAVAILABLE
TUBE WALL
THICKNESS
INCHES
CONSTANT
R
0.165(STD) 3.42
0.020 3.52 A 3,4 1,2,3,4
0.032 3.89
0.165(STD) 6.84
0.020 7.04 B 3,4,5,6,8 1,2,3,4
0.032 7.78
0.165(STD) 10.26
0.020 10.56 C 3,4,5,6,8 1,2,3,4
0.032 11.67
0.165(STD) 13.68
0.020 14.08 D 4,5,6,8 4
0.032 15.56
0.165(STD) 20.52
0.020 21.12 E 4,5,6,8 4
0.032 23.34
0.165(STD) 27.36
0.020 28.16 F 4,5,6,8 4
0.032 31.12
ALL COILS AVAILABLE WITH FIN SPACINGS OF 8,10 OR 12 FINS PER INCH
SOURCE: BLUE STAR LIMITED - ENGINEERING BULLETIN
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 47 OF 49
ISSUE
R2
TABLE-9 HOT WATER BTU CONSTANTS
(BASED ON 200
0
F ENTERING WATER, 20
0
F WATER TEMPERATURE DROP THROUGH
UNIT AND 60
0
F ENTERING AIR TEMPERATURE)
ENTERING WATER TEMPERATURE ,
0
F
WATER
TEMPE-
RATURE
DROP
THROUGH
UNIT
0
F
TEMPE-
RATURE
OF
ENTER-
ING AIR
0
F
140 160 180 200 220 240 260 280
40 0.69 0.86 1.02 1.19 1.35 1.50 1.65 1.78
50 0.59 0.77 0.93 1.10 1.26 1.41 1.56 1.70
60 0.48 0.66 0.83 1.00 1.16 1.32 1.47 1.62
70 0.40 0.58 0.75 0.91 1.07 1.22 1.37 1.52
20
80 0.33 0.50 0.67 0.83 0.99 1.13 1.29 1.42
40 0.63 0.78 0.92 1.07 1.22 1.36 1.53 1.70
50 0.56 0.70 0.85 0.99 1.13 1.28 1.44 1.62
60 0.47 0.62 0.77 0.91 1.06 1.21 1.35 1.52
70 0.38 0.53 0.68 0.82 0.97 1.12 1.27 1.43
30
80 0.30 0.45 0.59 0.72 0.88 1.03 1.17 1.34
40 0.57 0.71 0.86 1.00 1.15 1.30 1.48 1.63
50 0.49 0.63 0.77 0.92 1.07 1.22 1.38 1.54
60 0.40 0.55 0.69 0.83 0.99 1.14 1.29 1.47
70 0.32 0.47 0.61 0.75 0.90 1.04 1.19 1.33
40
80 0.22 0.37 0.52 0.67 0.82 0.96 1.10 1.25
40 0.48 0.63 0.78 0.92 1.07 1.22 1.36 1.53
50 0.41 0.56 0.70 0.85 0.99 1.13 1.28 1.44
60 0.32 0.47 0.62 0.77 0.91 1.06 1.21 1.35
70 0.23 0.38 0.53 0.68 0.82 0.97 1.12 1.27
50
80 0.15 0.30 0.45 0.59 0.72 0.88 1.03 1.17
SOURCE: VOLTAS HANDBOOK-1977
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 48 OF 49
ISSUE
R2
TABLE-10 2 ROW HOT WATER COIL CAPACITIES
(BASED ON 200
0
F ENTERING WATER, 20
0
F WATER TEMPERATURE DROP THROUGH
UNIT AND 60
0
F ENTERING AIR )
UNIT
SIZE
COIL
FACE
VELO-
CITY
FPM
1000
BTU/HR
GPM PRES-
SURE
DROP
PSI
UNIT
SIZE
COIL
FACE
VELO-
CITY
FPM
1000
BTU/HR
GPM PRES-
SURE
DROP
PSI
300 81 8.7 0.52 300 388 39.5 0.78
350 90 9.6 0.60 350 428 43.0 0.90
400 98 10.6 0.72 400 469 47.0 1.04
450 106 11.5 0.85 450 507 51.0 1.18
500 115 12.3 0.97 500 545 54.5 1.33
550 120 13.0 1.06 550 575 58.0 1.47
600 127 13.6 1.16 600 608 60.5 1.60
650 133 14.2 1.25 650 640 64.0 1.73
AH-2
700 139 14.9 1.38
AH-7
700 672 67.0 1.91
300 122 13.0 0.51 300 532 53.0 1.00
350 134 14.4 0.62 350 580 59.0 1.21
400 147 15.9 0.75 400 643 64.0 1.39
450 159 17.2 0.87 450 695 69.0 1.56
500 172 18.4 1.00 500 740 75.0 1.82
550 181 19.5 1.11 550 792 79.0 1.97
600 191 20.4 1.21 600 836 83.0 2.14
650 199 21.3 1.33 650 879 88.0 2.38
AH-3
700 208 22.4 1.45
AH-9
700 925 92.0 2.56
300 176 10.0 0.52 300 797 79.5 1.00
350 196 20.0 0.63 350 884 88.5 1.20
400 216 21.5 0.72 400 965 96.5 1.39
450 232 23.5 0.87 450 1042 103.5 1.55
500 248 25.0 0.98 500 1122 112.5 1.81
550 263 27.0 1.13 550 1188 118.5 1.96
600 279 28.5 1.24 600 1255 124.5 2.13
650 294 30.0 1.36 650 1318 132.0 2.37
AH-5
700 308 31.5 1.49
AH-
11
700 1388 138.0 2.56
300 248 25.0 0.98 500 1495 114.0 1.81
350 277 28.0 1.21 550 1584 158.0 1.96
400 305 31.0 1.47 600 1672 165.0 2.13
450 326 33.0 1.65 650 1758 175.0 2.36
500 350 35.0 1.82
AH-
12
700 1850 184.0 2.54
550 370 37.0 2.04
600 389 39.0 2.30
650 410 41.0 2.52
AH-6
700 430 43.0 2.73
NOTE
Capacity for conditions not above can be obtained by multiplying the BTU/Hr rating
on the chart by the proper HOT WATER BTU CONSTANT (Table-9)
BTU/Hr
Temperature rise =
1.08 x CFM
SOURCE :VOLTAS HANDBOOK-1977
SECTION: TABLE
TCE.M6-ME-811-304
SHEET 49 OF 49
ISSUE
R2
TABLE-11 STEAM HEATING COIL CAPACITIES
(1 ROW LOW RISE AND HIGH RISE AND 2 ROW COILS)
COIL AIR FACE VELOCITY
FPM
COIL AIR FACE VELOCITY
FPM
400 500 600 700 400 500 600 700
ENT.
AIR
TEMP.
0
F
STE-
AM
PRES-
SURE
PSI
ROWS
OF
HEAT
-ING
COIL
UNIT
SIZE
1000 BTU/HR
UNIT
SIZE
1000 BTU/HR
1 LR 44 50.6 56.5 62.3 190 217.5 244 268
1 HR 97 106 105 121 413 456 494 527 70 2
2 122 143 157 171 532 622 683 748
1 LR 54.4 62.5 69.8 77 234.5 275 300.5 332
1 HR 119 131 142 149 512 568 609 650 35 2
2
AH-
2
151 175 195 214
AH-
7
859 762 852 932
1 LR 66 75 84.8 92.3 252.5 292 333 355
1 HR 145 160 171 183 547 602 652 694 70 2
2 181 215 232 254 716 837 922 1008
1 LR 81.5 93.2 105.2 114 312 370 406 440
1 HR 178 196 214 207 678 743 807 858 35 2
2
AH-
3
224 259 287 316
AH-
9
886 1025 1148 1254
1 LR 96 109.2 123.5 136 385 440 495.5 547
1 HR 211 233 249 266 843 932 1013 1059 70 2
2 262 307 337 369 1068 1250 1373 1502
1 LR 117 135.5 153 168 476 548 612 675
1 HR 259 185 311 332 1040 1144 1245 1305 35 2
2
AH-
5
325 376 420 460
AH-
11
1321 1532 1711 1870
1 LR 130 147 166.5 183.5 505 584 666 710
1 HR 285 314 336 358 1094 1204 1304 1388 70 2
2 354 413 455 498 1432 1674 1844 2016
1 LR 160 182.5 206.5 226.5 624 740 812 880
1 HR 354 384 420 447 1356 1486 1614 1716 35 2
2
AH-
6
430 507 567 620
AH-
12
1772 2050 2296 2508
BTU/Hr
Temperature Rise =
1.08 x CFM
SOURCE: VOLTAS HANDBOOK-1977
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET i OF iii
REV. NO. R0 R1 R2
INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN
ISSUE
PPD. BY DSJ/BM/DJ Sd/-/Sd/-/Sd/- HRK Sd/- TPR
CHD. BY SJB Sd/- PRJ Sd/- HRK
APD. BY RRG Sd/- RL Sd/- RL
DATE 21.01.1986 15.02.2000 20.03.2003
R2
TCE FORM NO. 020R2
DESIGN GUIDE FOR DUCT SIZING
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET ii OF iii
TCE FORM NO. 120 R1
ISSUE
R2
CONTENTS
1.0 SCOPE 1
2.0 INPUT DATA 1
3.0 METHODS OF DUCT SIZING 1
4.0 DUCT SIZING BY EQUAL FRICTION METHOD 2
5.0 REFERENCES 8
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET iii OF iii
TCE FORM NO. 120 R1
ISSUE
R2
REVISION STATUS
R0 21.01.1986 ---
TCE.M6-ME-811-307
DESIGN GUIDE FOR DUCT SIZING SHEET 1 OF 8
TCE FORM NO. 120 R1
ISSUE
R2
1.0 SCOPE
This document gives guidelines for duct sizing for air-conditioning, ventilation
and dust extraction systems.
2.0 INPUT DATA
The following data shall be obtained from the preliminary single-line duct
layout drawings:
(a) Proposed duct routing with air flow rates in each individual duct branch
(b) Type, sizes and locations of air outlets and inlets. Orientation of grilles
to be indicated, i.e. location on side or bottom of duct.
(c) Maximum allowable friction drop in the ducting system
(d) Dust or powder loading on the duct. This item is required only for the
dust extraction systems
3.0 METHODS OF DUCT SIZING
The duct sizing is carried out by the following methods:
3.1 EQUAL FRICTION METHOD
In this method the duct sizing is done for a constant pressure loss per unit
length. This implies that the longest air flow path will dictate the maximum
pressure drop in the system. This method is simple to use and made even easier
by the use of ductulators.
3.2 STATIC REGAIN METHOD
In this method the ducts for succeeding duct branches are sized so as to reduce
the duct velocity and effect an increase in the air static pressure. This causes the
duct sizes to be larger increasing the ducting system cost. This method is
therefore, generally not used. For a more detailed description of this method of
ducting system design, ASHRAE Handbook, Fundamentals, 2001 edition may
be referred.
3.3 T-METHOD
This is a computerised method, developed for optimisation of the ducting
system design minimising the total costs considering the plant operation and
installation costs. If required, ASHRAE Handbook, Fundamentals, 2001 edition
may be referred.
TCE.M6-ME-811-307
TCE FORM NO. 120 R1
ISSUE
R2
4.0 DUCT SIZING BY EQUAL FRICTION METHOD
4.1 The equal friction method is generally used in TCE for duct sizing. In this
method the length of the longest branch governs the total static pressure drop in
the system. In case the allowable pressure drop in the system is specified, the
friction drop per unit length of the duct is given by the following expression:
p = [P - ]] / L
Where,
p = Friction drop per unit length of duct (mmWG / M)
P = Allowable friction drop in the system (mmWG)
x
i
= Friction drop across elements in the system like cooling and
heating coils, filters, dampers, supply and return grilles, etc.
(mmWG)
n = Number of elements
L = Equivalent length of the duct (M).
The equivalent length of the duct shall be estimated for each of the fittings
envisaged, from tables and chart listed below. These tables and charts are given
in Part 2, Chapter 2, Handbook of Air-Conditioning System Design, Carrier
Air-Conditioning Company, 1965 edition:
(a) Table 9 Friction of Round Duct System Elements
(b) Table 10 Friction of Rectangular Duct System Elements
(c) Table 11 Friction of Round Elbows
(d) Table 12 Friction of Rectangular Elbows
(e) Table 13 Percent Section Area in Branches for Maintaining Equal
Friction
Losses for round fittings given in Chart 9 and the additional equivalent length of
straight duct given in Table 11 and Table 12 listed above, are in FPS units and
shall be converted to MKS units in the course of the calculations.
The spacing and number of vanes for elbows shall be selected from Chart 6 -
Vane Location for Rectangular Elbows, Part 2, Chapter 2, Handbook of Air-
Conditioning System Design, Carrier Air-Conditioning Company, 1965 edition.
n
x
i
i = 1
TCE.M6-ME-811-307
TCE FORM NO. 120 R1
ISSUE
R2
4.2 DUCT SIZING CRITERIA
4.2.1 The equal friction method is normally used for duct sizing. As per Figure 9,
Chapter 34, ASHRAE Handbook, Fundamentals, 2001 edition, for equal friction
method, the friction drop is selected in the range of 0.06 to 0.5 mmWG per M of
duct length or air velocity in duct between 9.0 to 20.0 M/sec, whichever is more
stringent.
4.2.2 It is recommended that the ducts be sized for a pressure drop of 0.067 mmWG
per M of duct length. The lower of the friction drop per unit length as calculated
from equation given in para 4.1 or 0.067 mmWG per M of duct length as given
above, shall be considered for the duct sizing.
4.2.3 The recommended air velocities for air-conditioning applications may be lower
than the lower limit of 9.0 M/sec indicated in para 4.2.1 from criteria of noise
reduction and application. Refer table 1 for recommendations on air velocity
selection for various applications. In addition to the recommendations given in
table 1, the recommended velocity for installations of indigenous packaged air-
conditioners considering the static pressures achievable is 7.5 M/sec. For
ventilation systems the air velocity may be selected between 7.5 to 9.15 M/sec.
TABLE 1
RECOMMENDED MAXIMUM DUCT VELOCITIES FOR AIR-CONDITIONING AND VENTILATION SYSTEMS
DUCT VELOCITY (M/sec)
CONTROLLING FACTOR
MAIN DUCTS BRANCH DUCTS
SL.
NO.
APPLICATION
NOISE
SUPPLY RETURN SUPPLY RETURN
1. RESIDENCES 3.0 5.0 4.0 3.0 3.0
2. APARTMENTS, HOTEL
BEDROOMS, HOSPITAL
BEDROOMS
5.0 7.5 6.5 6.0 5.0
3. PRIVATE OFFICES,
DIRECTORS ROOMS,
LIBRARIES
6.0 10.0 7.5 8.0 6.0
4. THEATRES, AUDITORIUMS 4.0 6.5 5.5 5.0 4.0
5. GENERAL OFFICES, HIGH
CLASS RESTAURANTS, HIGH
CLASS STORES, BANKS
7.5 10.0 7.5 8.0 6.0
6. AVERAGE STORES, CAFETERIAS 9.0 10.0 7.5 8.0 6.0
7. INDUSTRIAL 12.5 15.0 9.0 11.0 7.5
SOURCE: CARRIER, PART 2, CHAPTER 2., TABLE 7
TCE.M6-ME-811-307
TCE FORM NO. 120 R1
ISSUE
R2
TABLE 2
TRANSPORT VELOCITIES FOR DIFFERENT MATERIALS
VELOCITY VELOCITY SL.
NO.
MATERIAL
M/sec FPM
SL.
NO.
MATERIAL
M/sec FPM
1. Abrasive blasting 17.8 - 20.3 3500 - 4000 15. Coal (powdered) dust 20.3 4000
2. Aluminium coarse dust 20.3 4000 16. Cocoa dust 15.2 3000
3. Asbestos carding 15.2 3000 17. Cork (ground) dust 12.7 2500
4. Bakelite moulding
powder dust
12.7 2500 18. Cotton dust 15.2 3000
5. Barrel filling or
dumping
17.8-20.3 3500-4000 19. Crushers 15.2 or
higher
3000 or
higher
6. Belt conveyors 17.8 3500 20. Flour dust 12.7 2500
7. Bins and hoppers 17.8 3500 Foundry, general 17.8 3500
8. Brass turnings 20.3 4000 Sand mixer 17.8-20.3 3500-4000
9. Bucket elevators 17.8 3500 Shakeout 17.8-20.3 3500-4000
10. Buffing and
polishing, Dry
15.2-17.8 3000-3500 Swing grinding
booth exhaust
15.2 3000
11. Buffing and
polishing, Sticky
17.8-22.9 3500-4500
21.
Tumbling mills 20.3-25.4 4000-5000
12. Cast iron boring dust 22.9 4000 22. Grain dust 12.7-15.2 2500-3000
Ceramics, general 23. Grinding general 17.8-22.9 3500-4500
Glaze spraying 12.7 2500 24. Portable hand
grinding
17.8 3500
Brushing 17.8 3500 25. Jute Dust 12.7-15.2 2500-3000
Fettling 17.8 3500 26. Jute Lint 15.2 3000
Dry pan mixing 17.8 3500 27. Jute dust shaker waste 16.3 3200
Dry press 17.8 3500 28. Jute pickerstock 15.2 3000
13.
Sagger filling 17.8 3500 29. Lead dust 20.3 4000
14. Clay dust 17.8 3500 30. Lead dust with
small chips
25.4 5000
TCE.M6-ME-811-307
TCE FORM NO. 120 R1
ISSUE
R2
TABLE 2 (CONTD.)
31. Leather dust 17.8 3500 48 Soldering and tinning 12.7 2500
32. Limestone dust 17.8 3500 49. Spray painting 10.2 2000
33. Lint 10.2 2000 50. Starch dust 15.2 3000
34. Magnesium dust,
coarse
20.3 4000 51. Stone cutting and
finishing
17.8 3500
35. Metal turnings 20.3-25.4 4000-5000 52. Tobacco dust 17.8 3500
36. Packaging,
weighing, etc
15.2 3000 Woodworking
37. Downdraft grille 17.8 3500 Wood flour, light dry
sawdust and shaving
12.7 2500
38. Pharmaceutical
coating pans
15.2 3000 Heavy shaving, damp
sawdust
17.8 3500
39. Plastic dust (buffing) 19.3 3800 Heavy wood chips
waste, green shavings
20.3 4000
40. Plating 10.2 2000
53.
Hog waste 15.2 3000
41. Rubber dust, Fine 12.7 2500 54. Wool 15.2 3000
42. Rubber dust, Coarse 22.9 4000 55. Zinc oxide fume 10.2 2000
43. Screens, Cylindrical 17.8 3500 56. Very fine light dusts 10.2 2000
44. Screens, Flat deck 17.8 3500 57. Fine ,dry dusts and
powders
15.2 3000
45. Silica dust 17.8-22.9 3500-4500 58. Average industrial
dusts
17.8 3500
46. Soap dust 15.2 3000 59. Coarse dusts 20.3 - 22.9 4000 - 5000
47. Soapstone dust 17.8 3500 60. Heavy or moist
dust loading
22.9 or
higher
4500 or
higher
SOURCE: ADVANCED DESIGN OF VENTILATION SYSTEMS FOR CONTAMINANT CONTROL BY HOWARD D.
GOODFELLOW, ELSEVIER SCIENCE PUBLISHERS, B. V. 1985, TABLE 4.11, PAGE 320.
4.2.4 The duct velocities for dust extraction systems, however, may be much higher
than the velocity range indicated in table 1, depending on the application. The
recommended duct velocities for dust extraction systems are as given in table 2.
However, for more details of dust or fume extraction system design, the
designer may refer reference number 5.3 indicated at the end of this write-up.
TCE.M6-ME-811-307
TCE FORM NO. 120 R1
ISSUE
R2
4.2.5 The duct sizing may be carried out using ductulators of Trane, Carrier or
SMACNA make, or Chart 7 and Table 6, Part 2, Chapter 2, Friction Loss for
Round Duct, Handbook of Air-Conditioning System Design, Carrier Air-
Conditioning Company, 1965 edition. The chart may be used for systems
handling air from (-)1 to 49
0
C (30 to 120
0
F) and for altitudes upto 600 M
(2000 ft) without correcting for density. Air density correction factors for other
conditions are given in Chart 15, Part 2, Chapter 2, of Handbook of Air-
Conditioning System Design, Carrier Air-Conditioning Company, 1965 edition.
However, correction factors for altitude and temperature for air density other
than 0.075 lb/ft
3
can be read directly using SMACNA make ductulators.
4.3 In case the duct sizing calculations are done manually, the friction drop in the
ducting shall be calculated from following equation:
p =
Where,
p = Friction drop in unit length of duct (mmWG/ M)
f = Friction factor (Dimensionless)
L = Duct length (M)
3
)
=
p
a
= partial pressure of dry air (kPa)
T = Absolute temperature of air (
0
K)
V = Air velocity (M/sec)
D
h
= Hydraulic diameter of duct (mm)
= [4 x Duct cross section area ( mm
2
)] Duct perimeter (mm)
The values for air partial pressure shall be taken from Table 2, Chapter 6,
ASHRAE Handbook, Fundamentals, 2001 edition.
4.4 The friction factor for the manual duct friction drop calculation shall be
calculated from the following equation:
= (-)2 x log [ + ]
Where,
f = Friction factor (Dimensionless)

3.7D
h
f x (100 x L x x V
2
)
2 x D
h
2.51
Re x f
0.5
1 .
f
0.5
p
a
2.871 x 10
5
x T
TCE.M6-ME-811-307
TCE FORM NO. 120 R1
ISSUE
R2
= Material absolute roughness factor (mm). Refer Table 1, Chapter
34, ASHRAE Handbook, Fundamentals, 2001 edition, for duct
roughness factors of various materials of construction.
D
h
= Hydraulic diameter of duct (mm)
Re = Reynolds number
= (D
h
x V) (1000 x )
= 66.4 x D
h
x V (For standard air)
V = Air velocity (M/sec)
= Kinematic viscosity of air (M
2
/sec)
The values for air viscosity shall be taken from Figure 12, Chapter 6, ASHRAE
Handbook, Fundamentals, 2001 edition.
4.5 The equivalent rectangular duct diameter is given by the following equation:
D
e
= 1.3 x
Where,
D
e
= Circular equivalent of rectangular duct for equal length, fluid
resistance and air flow (mm)
a = Length of one side of duct (mm)
b = Length of adjacent side of duct (mm)
Normally, the value of the recommended maximum aspect ratio i.e. (a/b) or
(b/a) is 4.0. However, this limitation may be ignored if the layout requires a
flatter duct having an aspect ratio greater than 4.0.
4.6 For flat oval ducts the formula is modified as follows:
D
e
= 1.55 x
Where,
A = Cross sectional area of flat oval duct (mm
2
)
= (b
2
/ 4) + b(a b)
P = Perimeter (mm)
= b + 2(a - b)
a = Major dimension of oval duct (mm)
A
0.625
P
0.250
(ab)
0.625
(a+b)
0.250
TCE.M6-ME-811-307
TCE FORM NO. 120 R1
ISSUE
R2
b = Minor dimension of oval duct (mm)
4.7 For the criteria given above the round duct diameter shall be obtained from the
equation given in para 4.3. The sizes for the equivalent rectangular ducts shall
be calculated from equation given in para 4.5. Equivalent duct sizes can also be
directly read from Table 6, Part 2, Chapter 2, Handbook of Air-Conditioning
System Design, Carrier Air-Conditioning Company, 1965 edition, or Table 2,
Chapter 34, ASHRAE Handbook, Fundamentals, 2001 edition or from
ductulators. These dimensions shall be decided considering the major criteria
listed below. Refer TCE.M6-ME-811-318 Design Guide for Duct Layout
Drawings for details.
4.7.1 Clear height requirements in the room
4.7.2 Clearances from structures, piping, cable trays or ducts
4.7.3 Access to other facilities
4.7.4 Sizes of equipment to which ducts are connected
4.7.5 Requirements of duct internal lining. The duct size to be enhanced to the extent
of the thickness of the lining and the roughness of the surface in contact with the
air.
5.0 REFERENCES
5.1 ASHRAE Handbook, Fundamentals, 2001 Edition
5.2 Handbook of Air-Conditioning System Design, Carrier Air-Conditioning
Company, 1965 edition.
5.3 Advanced Design of Ventilation Systems for Contaminant Control by Howard
D. Goodfellow, Elsevier Science Publishers, B. V. 1985.
TCE.M6-ME-811-311
DESIGN GUIDE FOR AIR WASHERS SHEET i OF iii
REV. NO. R0 R1 R2
ISSUE
PPD. BY SM/GSJ Sd/-/Sd/- IYM/HRK Sd/-/Sd/- IYM
CHD. BY SJB/SCM Sd/-/Sd/- PRJ Sd/- TPR
APD. BY DHNR Sd/- RL Sd/- RL
DATE 19.12.1980 24.03.2000 20.03.2003
R2
TCE FORM NO. 020R2
DESIGN GUIDE FOR AIR WASHERS
M6ME311R2.DWG
TCE.M6-ME-811-311
DESIGN GUIDE FOR AIR WASHERS SHEET ii OF iii
TCE FORM NO. 120 R1
ISSUE
R2
CONTENTS
1.0 SCOPE 1
2.0 APPLICATIONS 1
3.0 TYPES OF AIR WASHERS 7
4.0 PROCEDURE FOR SIZING 9
5.0 REFERENCES 11
FIGURES
1. RECIRCULATED WATER SPRAY OR EVAPORATIVE AIR
COOLING
2
2. PRE-HEATED AIR WITH RECIRCULATED WATER SPRAY 3
3. HEATED WATER SPRAY 4
4. COOLING AND DEHUMIDIFICATION 6
5. TYPICAL SPRAY TYPE AIR WASHER 12
6 TYPICAL RIGID MEDIA PAD TYPE AIR WASHER 12
TABLE 1. SATURATION EFFICIENCIES AND LENGTHS OF AIR
WASHERS
8
TCE.M6-ME-811-311
DESIGN GUIDE FOR AIR WASHERS SHEET iii OF iii
ISSUE
R2
TCE FORM NO. 120 R1
REVISION STATUS
R0 19.12.1980 ----------------
TCE.M6-ME-811-311
DESIGN GUIDE FOR AIR WASHERS SHEET 1 OF 12
ISSUE
R2
TCE FORM NO. 120 R1
1.0 SCOPE
Air washer is a chamber or enclosed casing where water and air come in direct
contact for applications like humidification, cooling & dehumidification and
air cleaning. This design guide briefly describes these applications, describes
various types of air washers available and gives procedure for sizing of most
commonly used air washers.
2.0 APPLICATIONS
2.1 HUMIDIFICATION
Humidification process increases the specific humidity of the air. Figures 1, 2
and 3 illustrate thermodynamic changes that occur between the air and water
that are in direct contact. Humidification can be achieved in three ways :
(a) Using recirculated water spray
(b) Pre-heating the air and
(c) Using heated water spray
2.1.1 Recirculated Water Spray
Recirculated water spray (also called evaporative air cooling) reduces the air
Dry Bulb Temperature (DBT) by evaporation of water into an air stream.
Figure 1 illustrates thermodynamic changes that occur between the air and
water that are in direct contact. The continuously recirculated water reaches an
equilibrium temperature equal to the Wet Bulb Temperature (WBT) of the
entering air. The heat and mass transfer between the air and water lowers the
air DBT and increases the specific humidity at a constant WBT.
Evaporative air cooling or saturation efficiency (Ec) is given by the relation:
Where,
Ec = Saturation efficiency
T1 = DBT of the entering air
T2 = DBT of the leaving air
T3 = WBT of entering air
Ec = 100 x
T1 T2
T1 T3
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
Evaporative air cooling system is normally provided in areas where wet bulb
depression is more than 11
O
C. In cases where inside heat gain is very high,
irrespective of the wet bulb depression, evaporative cooling is provided as this
will reduce the required air flow rate. Figure 1 represents this schematically on
a psychrometric diagram. Figure 1 also indicates the thermodynamic process
showing the air temperature variation and constant water temperature.
WATER TEMPERATURE T3 (CONSTANT)
AIR WASHER
AIR INLET
CONDITION
WET BULB
TEMPERATURE
AIR WASHER
AIR OUTLET
CONDITION
SATURATION
CURVE
T3 T2 T1
DRT BULB TEMPERATURE (
0
C)
S
P
E
C
I
F
I
C

H
U
M
I
D
I
T
Y
(
g
m

/

K
G

O
F

D
R
Y

A
I
R
)
FIGURE 1
RECIRCULATED WATER SPRAY OR EVAPORATIVE AIR COOLING
INLET AIR
TEMPERATURE T1
OUTLET AIR
TEMPERATURE T2
I
N
I
T
I
A
L

A
I
R
T
E
M
P
E
R
A
T
U
R
E
D
I
F
F
E
R
E
N
C
E
(
T
1

T
3
)
FINAL AIR
TEMPERATURE
DIFFERENCE
(T2 T3)
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
2.1.2 Pre-heating the Air
Air is pre-heated before it enters the air washer. Pre-heating the air increases
both DBT and WBT and lowers Relative Humidity (RH), but does not alter
the specific humidity. At a higher WBT and with the same specific humidity,
more water can be absorbed per unit mass of dry air passing through the air
washer. Process that occurs in the air washer is the same as that for
recirculated water spray. The final preferred conditions are achieved by
adjusting the amount of pre-heating to give the required WBT at the entrance
of air washer. Figure 2 represents this process schematically on a
psychrometric diagram.
2.1.3 Heated Water Spray
Spray water is heated before it is sprayed in the air washer. It is possible to
raise both DBT and WBT above the DBT of the entering air. The leaving air
condition may be controlled by
(a) Bypassing some of the air around the air washer and re-mixing the two
air streams downstream or
(b) Automatically reducing the number of operating spray nozzles.
HEATER ENTRY
AIR CONDITION
AIR WASHER
AIR INLET
CONDITION
WET BULB
TEMPERATURE
AIR WASHER
AIR OUTLET
CONDITION
SATURATION
CURVE
T0 T3 T2 T1
0
C)
S
P
E
C
I
F
I
C

H
U
M
I
D
I
T
Y
(
g
m

/

K
G

O
F

D
R
Y

A
I
R
)
FIGURE 2
PRE-HEATED AIR WITH RECIRCULATED WATER SPRAY
AIR HEATING
EVAPORATIVE
COOLING
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
Figure 3 represents this process schematically on a psychrometric diagram.
Also indicated is the relative variation of the air and water temperature in the
process.
AIR WASHER
AIR INLET
CONDITION
WET BULB
TEMPERATURE
AIR WASHER
AIR OUTLET
CONDITION
SATURATION
CURVE
T3 T1 T2
0
C)
S
P
E
C
I
F
I
C

H
U
M
I
D
I
T
Y
(
g
m

/

K
G

O
F

D
R
Y

A
I
R
)
FIGURE 3
HEATED WATER SPRAY
INLET WATER
TEMPERATURE T3
OUTLET WATER
TEMPERATURE T4
I
N
I
T
I
A
L

A
I
R

T
E
M
P
E
R
A
T
U
R
E

D
I
F
F
E
R
E
N
C
E
(
T
3

T
1
)
FINAL
TEMPERATURE
DIFFERENCE
(T4 T2)
CONTACT TIME
INLET AIR
TEMPERATURE T1
OUTLET AIR
TEMPERATURE T2
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
2.2 COOLING AND DEHUMIDIFICATION
Cooling and Dehumidification reduces the DBT and specific humidity. Figure
4 represents this process schematically on a psychrometric diagram. Also
indicated is the relative variation of the air and water temperature in the
process. Heat and moisture removed from the entering air raises the water
leaving temperature. Dehumidification results if the leaving water temperature
is below the entering dew-point temperature. Moreover, the final water
temperature is determined by the sensible and latent heat pick-up and the
quantity of water circulated.
Air leaving the air washer is substantially saturated. The difference between
DBT and WBT is less than 0.5C. The difference between leaving air and
leaving water temperatures depends on the difference between entering DBT
and WBT and the construction features of the air washer. The rise in water
temperature is usually between 3 to 7
O
C.
The most common air washer arrangement for cooling and dehumidifying air
has two spray banks and is 2,500 to 3,500 mm long. If the air washer can cool
and dehumidify the entering air to a WBT equal to the leaving water
temperature, the performance factor of such an air washer is said to be 1.0.
The actual performance of any air washer is the actual enthalpy change
divided by the enthalpy change in washer having a performance factor of 1.0.
The required performance factor may be calculated by:
Where,
Fp = Performance factor
h1 = Enthalpy at entering air WBT
h2 = Enthalpy at leaving air WBT at actual condition
h3 = Enthalpy at WBT leaving the air washer with Fp = 1.0 i.e. at
WBT equal to leaving water temperature
This type of system was used extensively for applications having large air
flow capacities, e.g. synthetic fibre plants. This is an open system and ingress
of dust and particulate contaminants from the process, which may be absorbed
by the water, may cause clogging of chiller tubes and also the piping system.
This could lead to major maintenance problems, breakdown and loss of
production. Hence this type of system is normally not preferred.
Fp =
h1 h2
h1 h3
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
AIR WASHER
AIR INLET
CONDITION
WET BULB
TEMPERATURE
AIR WASHER
AIR OUTLET
CONDITION
SATURATION
CURVE
T2 T3 T1
0
C)
S
P
E
C
I
F
I
C

H
U
M
I
D
I
T
Y
(
g
m

/

K
G

O
F

D
R
Y

A
I
R
)
FIGURE 4
COOLING AND DEHUMIDIFICATION
INLET AIR
TEMPERATURE T1
OUTLET AIR
TEMPERATURE T2
I
N
I
T
I
A
L

T
E
M
P
E
R
A
T
U
R
E

D
I
F
F
E
R
E
N
C
E
(
T
1

T
3
)
FINAL
TEMPERATURE
DIFFERENCE
(T2 T4)
CONTACT TIME
INLET WATER
TEMPERATURE T3
OUTLET WATER
TEMPERATURE T4
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
2.3 AIR CLEANING
Air washers are also used for removing dust particles etc. before it enters the
process or discharged to atmosphere. The dust removal efficiency of air
washer depends largely on the size, density, wettability and solubility of the
dust particle. Efficiency is higher for the larger and the more wettable
particles, separation being accomplished entirely by impingement on the
wetted surfaces of the eliminator plates. Experience has shown that the spray
itself is relatively ineffective in removing most atmospheric dusts. Air washers
are of little use in removing soot particles because of the absence of an
adhesive effect from the greasy surface. They are also ineffective in
removing smoke because of inadequate inertia of the small particles (less than
1 micron). Rigid media pad type washers, however are efficient air cleaners.
In practice they remove from 70 to 90 % percent by weight of air borne solid
particles which include most of the particles exceeding 5 microns and many
down to size 1 micron. The actual size and arrangement should be verified
based on manufacturers data.
3.0 TYPES OF AIR WASHERS
3.1 SPRAY TYPE AIR WASHERS
Spray type air washer consists of an air-tight chamber or casing containing air
distribution plates, spray nozzle system arranged in a single bank or multiple
banks, a tank for collecting the spray water, eliminators for removing
entrained drops of water from the air, flooding nozzles for cleaning
eliminators and a pump with piping, valves and specialities for recirculating
water at higher rate than the evaporation rate. The tank is provided with drain,
overflow, make-up water and quick-fill connections. Drain sump with suction
screens are provided in tank. Spray type air washers are usually available from
3,500 to 4,25,000 M
3
/Hr capacity. However, there is practically no limit for
specially constructed air washers.
There is no standardisation in air washer sizes. Normally, recirculated water
flow rate is 0.53 M
3
/Hr for a single bank and 1.34 M
3
/Hr for double or
multiple banks per 1,000 M
3
/Hr of air flow rate. Air resistance varies from 6
mmWC to as high as 25 mmWC. Spray nozzle pressure varies from 1.4 to 2.8
Kg/cm
2
g, whereas flooding nozzle operates at 0.2 to 0.3 Kg/cm
2
g pressure.
Generally, specified air face velocity through the air washer internals i.e.
distribution plate, spray nozzles and the eliminators is 2.5 M/sec. Typical
spray type air washer is shown in Figure 5.
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
Tank has a minimum depth of 600 mm with 450 mm water level. The distance
between air distribution plates and spray bank as well as spray bank and
eliminator plates is 400 to 600 mm. The distance between the two spray banks
is 800 to 1,400 mm. Normally, air washer tank is extended beyond eliminators
by 500 mm. An air-tight inspection door is provided on the chamber or casing
along with a marine light and catwalk inside the spray section, to facilitate
cleaning of spray and flooding nozzles during maintenance.
It is recommended that a level switch be provided to safeguard the pump.
However, this is left to the discretion of the designer as the air washer
operation is normally manual and the operator verifies and monitors the
adequacy of the water level in the basin to ensure proper pump operation.
For details and selection of air washers for humidification or cooling and
dehumidification applications, refer Handbook of Air-conditioning System
Design, Carrier Air-Conditioning Company, 1965 edition, Part 6, Chapter 2.
Air washers are available in metallic or Fibre Reinforced Plastic (FRP)
construction for smaller capacities upto about 25,000 M
3
/Hr. For higher
capacity these are normally in masonary construction.
The saturation efficiencies and lengths of air washers are given in table 1
below:
TABLE 1
SATURATION EFFICIENCIES AND LENGTHS OF AIR WASHERS
SL. NO. SPRAY BANK
ARRANGEMENT
SATURATION
EFFICIENCY %
LENGTH OF AIR
WASHER M
1.
Single bank facing downstream
side of air washer
50 to 60 1.2
2.
Single bank facing upstream
side of air washer
65 to 80 1.8
3.
Double bank both facing
downstream side of air washer
80 to 90 2.4 to 3
4.
Double bank with one facing
downstream side and other facing
upstream side of air washer
85 to 95 2.4 to 3
5.
Double bank both facing
upstream side of air washer
90 to 98 2.4 to 3
6.
Multiple bank
90 to 98 3.5
SOURCE : ASHRAE HANDBOOK, HVAC SYSTEMS AND EQUIPMENT, 2000 EDITION, CHAPTER 19, PAGE 19.7
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
3.2 HIGH VELOCITY SPRAY TYPE AIR WASHER
High velocity spray type air washers generally operate at air face velocities in
the range of 6 to 9 M/sec. However, velocity as high as 12 M/sec may also be
used. The reduced cross-sectional area allows air washers to be installed in a
less space.
High velocity spray type air washers are rectangular in cross-section and
except for eliminators are similar in appearance and construction to spray type
air washers. Eliminator blades come in varying shapes, but most are a series of
aerodynamically clean, sinusoidal shapes. Air resistance varies from 15
mmWC to as high as 40 mmWC.
3.3 RIGID MEDIA PAD TYPE AIR WASHER
Rigid media pad type air washer consists of an air-tight chamber or casing of
Galvanised Steel Sheet (GSS) or FRP containing corrugated rigid media pad, a
tank for collecting water and a pump with piping, valves and specialities for
recirculating water.Rigid media pad shall be of cellulose and fibre glass that
have been treated chemically with antirot and rigidifying resins. Details for
these media and fill configurations may be referred from vendor catalogues.
Pad shall be cross-corrugated to maximise mixing of air and water in the
direction of air flow. Depth of pad shall be 300 to 600 mm.
The pad shall be arranged in tiers over which water is distributed. No
atomisation of water is required. Only good distribution of water over the face
of the pad is essential. Nozzles operate under comparatively low pressure as
compared to those in spray type air washer.
It is recommended that fine filters, with a filtering efficiency of 99% down to
a particle size of 5 microns with test dust 2 as per IS 7613, in conjunction with
pre-filters, with a filtering efficiency of 90% with test dust 3 as per IS 7613, be
provided with rigid media type air washers. This is to minimise the clogging
of the media with dust carried by the incoming air flow. However, this aspect
may be examined by the designer with the site conditions in the respective
applications.
Saturation efficiency of this type of air washer is 70 to 95 %. Figure 6 shows a
typical rigid media pad type air washer.
4.0 PROCEDURE FOR SIZING
Procedure for evaporative air cooling application is given below :
4.1 INPUT DATA
DBT of the entering air in
O
C = T1
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
WBT of the entering air in
O
C = T3
Heat load in KCal/Hr (calculated as per = Q
TCE.M6-ME-811-309)
DBT to be maintained inside the space = Ta
4.2 LEAVING AIR TEMPERATURE
The value of saturation efficiency Ec may be referred to from para 3.1.
Knowing the saturation efficiency, T2 can be calculated. Where, T2 is the
DBT of the air leaving the air washer.
4.3 TEMPERATURE RISE DUE TO FAN HEAT GAIN
The temperature rise due to fan heat gain is calculated by:
Where,
P = Static pressure of fan in mmWC (calculated as per TCE.M1-
ME- 811-302)
= Fan static efficiency (normally assumed @ 60%)
a = Air density in Kg/M
3
4.4 AIR FLOW RATE
4.4.1 For draw-through type air washer
4.4.2 For blow-through type air washer
4.5 RECIRCULATING WATER FLOW RATE
In the absence of manufacturers data, para 3.1 above may be referred for
calculating recirculated water flow rate. Knowing the re-circulating water flow
rate, pumps capacity selection and piping sizing may carried out.
Saturation efficiency Ec =
T1 T2
T1 T3
Air flow rate in M
3
/Hr =
Q
0.288 [ Ta - (T2 + T) ]
T =
P x 9.81 x 1.15
x 10 x a
Air flow rate in M
3
/Hr =
Q
0.288 [ (Ta + T) - T2 ]
TCE.M6-ME-811-311
ISSUE
R2
TCE FORM NO. 120 R1
4.6 FACE AREA OF AIR WASHER
Depending on the available space, the height (H) and the width (W) of the air
washer may be arranged such that face area A=WH. It is preferable to arrange
the face area of the air washer such that width and height are equal. The length
of the double bank air washer may be minimum 2.5 M and may be as long as
3.5 M.
4.7 MAKE-UP WATER FLOW RATE
Make-up water flow rate varies from 1 to 1.5 % of recirculating water flow
rate. However, this may be specifically calculated considering evaporation and
blowdown. Blowdown rate shall be calculated considering the upper limit to
be maintained in the concentration of dissolved solids in the recirculated
water. Another criteria for the blowdown water quantity, are the scaling
characteristics of the recirculated water. Generally, the scaling criterion is not
applicable for air washers, as there is no change in the operating temperature
of water for recirculated spray air washers. However, this criterion may be
significant for pre-heated air and heated water spray air washers.
The blowdown quantity and the scaling criteria estimated from the Puckorious
Scaling Index (PSI) shall be calculated from the methods given in para 5.4.1
and para 5.3 respectively of TCE.M1-ME-127-201, Basic Study Guide for
Cooling Tower Make-up System.
5.0 REFERENCES
5.1 ASHRAE Handbook, HVAC Systems and Equipment - 2000 Edition
5.2 Handbook of Air-conditioning System Design, Carrier Air-Conditioning
Company, 1965 edition
5.3 TCE.M1-ME-127-201 Basic Study Guide for Cooling Tower Make-up System
5.4 TCE.M1-ME-811-302 Basic Study Guide for Ventilation System
5.5 TCE.M6-ME-811-301 Design Guide for Air-conditioning Load Calculations
5.6 TCE.M6-ME-811-309 Design Guide for Ventilation Heat Load Calculations
Face area of the air washer in M
2
=
Air flow rate in M
3
/Hr
3600 x air face velocity (M/sec)
TCE.M6-ME-811-313
DESIGN GUIDE FOR
REFRIGERATION LOAD CALCULATIONS FOR
PROCESS COOLING
SHEET i OF iii
ISSUE
PPD. BY SCM Sd/- TPR Sd/- IYM Sd/- RRC
CHD. BY SJB Sd/- PRJ Sd/- PRJ Sd/- TPR
DATE 19.12.1980 10.12.1997 02.03.2001 01.03.2004
R3
TCE FORM NO. 020R2
DESIGN GUIDE FOR
PROCESS COOLING
TCE.M6-ME-811-313
DESIGN GUIDE FOR
PROCESS COOLING
SHEET ii OF iii
TCE FORM NO. 120 R1
ISSUE
R3
CONTENTS
1.0 SCOPE 1
2.0 GENERAL 1
3.0 PROCESS COOLING LOAD 2
4.0 HEAT GAIN DUE TO SUPPLY AND RETURN COOLANT
PIPING
2
5.0 HEAT GAIN DUE TO COOLANT PUMPS AND AGITATORS 4
6.0 HEAT GAIN IN MIXING TANK 5
7.0 REFRIGERATION LOAD 5
8.0 REFERENCES 6
TCE.M6-ME-811-313
DESIGN GUIDE FOR
PROCESS COOLING
SHEET iii OF iii
TCE FORM NO. 120 R1
ISSUE
R3
REVISION STATUS
R0 19.12.1980 - -
R1 10.12.1997 Document number changed. British units deleted and SI
units incorporated. Generally revised.
R3 01.03.2004 Para 8.0 revised and document reformatted.
TCE.M6-ME-811-313
DESIGN GUIDE FOR
PROCESS COOLING
SHEET 1 OF 6
TCE FORM NO. 120 R1
ISSUE
R3
1.0 SCOPE
This design guide describes the method for calculating the refrigeration load on
the refrigeration equipment for process cooling where a secondary coolant like
chilled water or brine is used to remove heat from the various process equipment
in industrial and chemical plants.
2.0 GENERAL
The total load on the refrigeration equipment is the actual process cooling load
plus the heat gain by circulating coolant pumps, supply and return coolant
piping, mixing/storage tank, agitators etc. The following data shall be obtained
from the client or process engineer or process equipment designer before
proceeding with the calculations:
(a) Type of coolant i.e. chilled water or brine such as calcium chloride,
sodium chloride, glycol etc. If client or process engineer or process
equipment designer does not specifically indicate requirement of type of
coolant, it may be recommended by refrigeration system designer and
consent obtained from client or process engineer or process equipment
designer.
(b) Flow rate of coolant through various process equipment
(c) Coolant supply and return temperatures with tolerances at battery limit
or process equipment
(d) Coolant supply and return pressures with tolerances at battery limit or
process equipment
(e) Locations of process equipment and refrigeration equipment (Refer plot
plan and GA drawings)
(f) Routing of supply and return coolant piping from refrigeration
equipment to battery limit or process equipment (Refer piping layout
drawings. In case piping layout drawings are not available, the
refrigeration system designer shall assume the most probable pipe
routing)
(g) Diversity
(h) Special requirements, if any
TCE.M6-ME-811-313
DESIGN GUIDE FOR
PROCESS COOLING
SHEET 2 OF 6
TCE FORM NO. 120 R1
ISSUE
R3
3.0 PROCESS COOLING LOAD
3.1 IN MKS UNITS
Process cooling load in Kcal/Hr = V Cp t
Where, = Density, Kg/M
3
V = Flow rate, M
3
/Hr
Cp = Specific heat, KCal/Kg
O
C
t = Temperature rise,
O
C
3.2 IN SI UNITS
Process cooling load in KW = V Cp t
Where,
= Density, Kg/M
3
V = Flow rate, M
3
/Sec
Cp = Specific heat, KJ/Kg
O
C
t = Temperature rise,
O
C
3.3 For chilled water, value of is 1000 in both MKS and SI units and values of Cp
are 1.0 and 4.1868 in MKS and SI units respectively. However, for brines the
values of and Cp depend upon the type, temperature and concentration of
brines. The values of and Cp for selected brines at various temperatures and
concentrations may be obtained from the references cited in para 8.0. These
properties have to be taken at mean operating temperature.
4.0 HEAT GAIN DUE TO SUPPLY AND RETURN COOLANT PIPING
4.1 IN MKS UNITS
ta - ti
Heat transferred per unit area in KCal/M
2
Hr, q =
R
Total heat transferred in KCal/Hr, Q = q A
L
Where, ta = Ambient air temperature,
O
C
ti = Supply temperature of coolant,
O
C
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R = Overall thermal resistance of the pipe with insulation,
M
2
Hr
O
C/Kcal
A
L
= Pipe outside area with insulation, D
L
L, M
2
D
L
= Outside diameter of pipe with insulation, M
L = Length of pipe, M
4.2 IN SI UNITS
ta ti
Heat transferred per unit area in W/M
2
, q =
R
Total heat transferred in KW, Q = (q A
L
)/1000
Where, ta = Ambient air temperature,
O
C
ti = Supply temperature of coolant,
O
C
R = Overall thermal resistance of the pipe with insulation,
M
2O
K/W
A
L
= Pipe outside area with insulation, D
L
L, M
2
D
L
= Outside diameter of pipe with insulation, M
L = Length of pipe, M
Overall thermal resistance of pipe, R = R
I
+ R
P
+ R
L
+ R
O
D
L
D
L
In (D
O
/D
I
) D
L
In (D
L
/D
O
) 1
R =
h
I
D
I
+
2 k
P
+
2 k
L
+
h
O
Where the abbreviations used are as follows:
ITEM COOLANT PIPE PIPE INSULATION AIR
Diameter, M - -
Inside
D
I
Outside
D
O
Outside
D
L
- -
Thermal conductivity,
Kcal/MHr
O
C (W/M
O
K)
- - k
P
k
P
k
L
- -
Heat transfer coefficient,
Kcal/M
2
Hr
O
C
(W/M
2O
K)
h
I
- - - - - - h
O
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ITEM COOLANT PIPE PIPE INSULATION AIR
Resistance,
M
2
Hr
O
C/KCal
(M
2O
K/W)
R
I
R
P
R
P
R
L
R
O
The resistance of finishing cement layer or any other protective layer for
insulation is neglected. Resistance of inside film, pipe material and outside film
may also be neglected. These neglected components do not significantly affect
the heat gain. For both supply and return piping, tc may be taken equal to the
temperature required at the inlet of battery limit/process equipment.
D
L
In (D
L
/D
O
)
Thus R =
2 k
L
ta - tc
and q =
D
L
ln (D
L
/D
O
)
2 k
L
4.3 Increase the value of Q as calculated by 10% to account for heat gain through
pipe fittings, valves etc.
5.0 HEAT GAIN DUE TO COOLANT PUMPS AND AGITATORS
5.1 The power required to pump the coolant or drive the agitators adds heat to the
system. This may be estimated as follows:
Heat added = BKW 860 KCal/Hr (MKS units)
= BKW (SI units)
Where BKW is the power required to drive the pump/agitator.
5.2 In case the actual power to drive the pump is not available same may be
calculated as given below:
BKW = (V H SG)/(
P
367)
Where, V = Flow rate, M
3
/Hr
H = Total pump head, M
SG = Specific gravity
P
= Pump efficiency
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For small pumps of capacities 4.5 to 22 M
3
/Hr the pump efficiency may be
assumed as 50% and for pumps greater than 22 M
3
/Hr it may be assumed as
70%.
5.3 In the absence of BKW of agitator, heat equivalent of 80% of driver motor rating
for agitator may be taken as heat added to coolant.
6.0 HEAT GAIN IN MIXING TANK
6.1 Surface of the tank through which there is heat transfer shall be considered and
the heat gain shall be calculated by the following formula:
q = (ta - tc)/(Z/k
L
)
Q = q A
L
, Kcal/Hr (MKS units)
= (q A
L
)/1000, KW (SI units)
Where, Z = Insulation thickness, M
A
L
= Total outside surface area with insulation, M
2
6.2 For other symbols and assumptions, refer para 4.0.
7.0 REFRIGERATION LOAD
7.1 The cooling load on the refrigeration equipment is the sum of the process cooling
load (para 3.0) and the heat gain due to piping, pumps and agitators, and mixing
tank (paras 4.0 + 5.0 + 6.0). The diversity factor and special requirements, if any,
shall also be considered.
7.2 Apart from the refrigeration load, the temperatures of coolant required at the
battery limit/process equipment are also important. The heat gain due to pumps,
piping, tank etc. raises the temperature of the coolant. Therefore, the temperature
at the outlet of the chilling unit shall be lower than that required at the inlet of the
battery limit or process equipment. The temperatures at the outlet and inlet of the
chilling unit are calculated or specified as indicated in para 7.3.
7.3 The heat gain in the return coolant piping is a small percentage of the total heat
gain due to pumps, tank and supply piping. Therefore, for calculating the
temperature at the outlet of the chilling unit the entire heat gain is considered to
be on the supply side.
7.4 IN MKS UNITS
Q
T
Temperature rise in
O
C, t =
V Cp
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Where, Q
T
= Heat gain due to piping, pumps, tanks etc. (paras 4.0 +
5.0 + 6.0), KCal/Hr
= Density, Kg/M
3
V = Flow rate, M
3
/Hr
Cp = Specific heat, KCal/Kg
O
C
7.5 IN SI UNITS
Q
T
Temperature rise in
O
C, t =
V Cp
Where, Q
T
= Heat gain due to piping, pumps, tanks etc. (paras 4.0 + 5.0 +
6.0), KW
= Density, Kg/M
3
V = Flow rate, M
3
/Sec
Cp = Specific heat, KJ/Kg
O
C
The temperature to be specified at the outlet of the chilling unit shall be lower by
t than that at the inlet to battery limit or process equipment. The temperature to
be specified at the inlet of the chilling unit shall be the same as that at the outlets
of battery limit or process equipment.
8.0 REFERENCES
8.1 2001 ASHRAE Handbook - Fundamentals
8.2 Handbook of Air Conditioning System Design - Carrier Air Conditioning
Company - 1965 edition.
SECTION: TITLE
TCE.M6-ME-811-314
DESIGN GUIDE FOR
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SHEET OF iii
REV.NO. R0 ISSUE
PPD.BY SS
CHD.BY ST R0
APD.BY RNW/RL
DATE 01.08.16
i
FORM NO. 020R2
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
FILE NAME: M6ME314R0.DOC AND M6ME314R0.DWG
FLOPPY NO :TCE-971-ME-FP-101

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ii
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FORM NO. 120 R1
CONTENTS
SL.NO. TITLE SH.NO.
1.0 SCOPE 1
2.0 AIR TO AIR ENERGY RECOVERY DEVICES 1
3.0 HEAT RECOVERY WHEEL - OPERATING
PRINCIPLE
1
4.0 CONSTRUCTION 2
5.0 PERFORMANCE RATING 7
6.0 PSYCHROMETRIC ANALYSIS 10
7.0 APPLICATIONS 10
8.0 REFERENCES 11
APPENDICES
1. APPENDIX-1 - COMPARISON OF AIR TO AIR
ENERGY RECOVERY DEVICES.
13
2. APPENDIX-2 - SELECTION OF HEAT RECOVERY
WHEEL (WITH TABLE-1)

TABLE-1: TYPICAL MANUFACTURERS
PERFORMANCE DATA FOR HEAT
RECOVERY WHEEL (HRW)
15
22
3. APPENDIX-3 - CONFIGURATION OF HRW & PURGE
SECTION
23
4. APPENDIX-4 - INSTALLATION GUIDE LINES (HRW) 24
5. APPENDIX-5 - PSYCHROMETRIC PROCESS OF HEAT
RECOVERY USING HEAT WHEEL
25
6. APPENDIX-6 - TYPICAL HRW CATALOGUE DATA -
PHYSICAL DIMENSIONS OF A HRW
26
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REVISION STATUS
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1.0 SCOPE
This document describes design and construction features of Heat
Recovery Wheels for air conditioning application and provides
guidelines for their selection.
2.0 TYPES OF AIR TO AIR ENERGY RECOVERY DEVICES
2.1 ASHRAE Equipment Handbook 1996 refers to the following six types
of air-to-air heat exchange devices.
Rotary Energy Exchangers (Enthalpy or Heat Recovery Wheel)
Coil Energy Recovery Loop (Run around coil loop)
Twin-Tower Enthalpy Recovery Loop
Heat Pipe Heat Exchangers
Fixed Plate Exchangers
Thermosyphon Heat Exchangers
2.2 Distinction is made between the sensible only and the total heat
exchangers total heat meaning sensible plus latent heat or enthalpy.
The twin-tower loop is a total heat exchanger. The rotary exchanger,
or heat recovery wheel, may be constructed as either a sensible only or
a total heat device. The rest are essentially sensible heat exchangers in
which transfer of latent heat, if any, is incidental.
2.3 Because of their ability to transfer both sensible and latent heat, the
enthalpy devices are far more effective in energy recovery. It is found
that under summer design conditions, the total heat device typically
recovers nearly three times as much energy as the sensible heat device.
Under winter conditions, it recovers over 25% more (ASHRAE:
Equipment Handbook 1988).
2.4 From the comparison of Air-to-Air Energy Recovery Devices
APPENDIX-1, it is seen that the enthalpy wheel has the highest
effectiveness and the least pressure drop at any face velocity. The
other enthalpy device twin-tower loop has the highest pressure
drop for the same effectiveness.
3.0 HEAT RECOVERY WHEEL OPERATING PRINCIPLE
3.1 A rotary air-to-air energy exchanger, or heat recovery wheel, has a
revolving cylinder filled with an air-permeable medium having a large
inter surface area. Adjacent supply and exhaust airstreams each flow
through one-half of the exchanger in a counterflow pattern
(APPENDIX-3). Heat transfer media may be selected to recover only
sensible heat or total heat.
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3.2 Sensible heat is transferred as the medium picks up and stores heat
from the hot airstream and releases it to the cold one. Latent heat is
transferred as the medium (1) condenses moisture from the airstream
with the higher humidity ratio (either because the medium temperature
is below its dew point) or by means of adsorption for solid desiccants
with a simultaneous release of heat; and (2) releases the moisture
through evaporation (and heat pickup) into the airstream with the lower
humidity ratio. The dessicant coated wheel slowly rotates between the
outdoor and the return air stream. The higher temperature air stream
gives sensible heat to wheel media. The energy is then, given up to the
cooler air stream during the second half of the revolution. The
moisture is captured and released by the dessicant coating which has
an enormous internal surface area and strong attraction to water
vapour. Since the opposing air streams have different temperatures
and moisture contents, their vapour pressures differ. This vapour
pressure differential serves as the driving force which causes the
transfer of water vapour (latent energy). Thus, the humid air is dried
while the dried air is humidified. In total heat transfer, both sensible
and latent heat transfer occur simultaneously. Because heat recovery
wheels have a counterflow configuration and normally use small-
diameter flow passages, they are quite compact and can achieve high
transfer effectiveness.
4.0 CONSTRUCTION
4.1 Air contaminants, dew point, exhaust air temperature, and supply air
properties influence the choice of structural materials for the casing,
rotor structure, and medium of a rotary energy exchanger. Aluminium
and steel are the usual structural, casing, and rotor materials for normal
comfort ventilating systems. Exchanger media are fabricated from
metal or mineral and are classified as providing either random flow or
directionally oriented flow through their structures.
4.2 Random flow media are made by knitting wire into an open woven
cloth or corrugated mesh, which is layered to the desired configuration.
Aluminium mesh, commonly used for comfort ventilation systems, is
packed in pie-shaped wheel segments. Stainless steel and monel mesh
are used for high-temperature and corrosive applications. These media
should only be used with clean, filtered airstreams because they plug
easily. Random flow media also require a significantly larger face area
than directionally oriented media for given values of airflow and
pressure drop.
4.3 Directionally oriented media are available in various geometric
configurations. The most common consist of small 1.5 to 2 mm (0.06
to 0.08 in.) air passages parallel to the direction of airflow. Whether
the manufacturer uses triangular, hexagonal, or other shaped passages,
they are very similar in performance for a given flow passage.
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Aluminium foil, inorganic sheet, treated organic sheet, and synthetic
materials are used for low and medium temperatures. Stainless steel
and ceramics are used for high temperatures and corrosive
atmospheres.
4.4 Media surface areas exposed to airflow vary from 330 sq.m per cubic
meter to 3300 sq.m per cubic meter (100 to over 1000 sq.ft/cu.ft),
depending on the type of medium and physical configurations. Media
may also be classified according to their ability to recover only
sensible or heat or total heat. Media for sensible or total heat recovery
are made of aluminium, copper, stainless steel, and monel and treated
with a desiccant.
4.5 The enthalpy wheel is a cylinder, packed with a heat transfer medium
that has numerous small air passages, or flutes, parallel to the direction
of airflow. The flutes are triangular or semi-circular in cross-section.
The structure, commonly referred to as the honeycomb matrix, is
produced by interleaving flat and corrugated layers of a high
conductivity material, usually aluminium, coated with a desiccant.
Stainless steel, ceramic, and synthetic materials may be used, instead
of aluminium, in specific applications. The flutes in most wheels
measure between 1.5 mm to 2.0mm in height. Typical configuration of
Heat Recovery Wheel is shown in APPENDIX-3.
4.6 In a typical installation, the wheel is positioned in a duct system such
that it is divided into two half moon sections. Stale air from the
conditioned space is exhausted through one half while outdoor air is
drawn through the other half in a counter flow pattern. At the same
time the wheel is rotated slowly (2 to 20 rpm). The rotor is supported
by two pillow block bearings and is driven by an A.C. motor and
permanently lubricated gear reducer. The rotor media is segmented for
ease of field erection or replacement of one sector. The media is
cleanable with low temperature steam, hot water or light detergent,
without degrading the latent recovery. The recovery wheel casing is
manufactured from tubular structure to provide a self supporting rigid
structure complete with access panels, rotor, bearings, seals, drive
mechanism with belt.
4.7 DESICCANT OPTIONS
4.7.1 The desiccant is a key element in the enthalpy wheel technology. It is
relevant, therefore, to discuss briefly on the desiccant options currently
available on wheels and their distinguishing features. A desiccant is a
sorbent having particular affinity for water. Sorbents have been
classified by ASHRAE (Fundamentals Handbook 1997, Chapter 19)
into two basic categories, i.e. Absorbents and Adsorbents. The
absorbents are substances that undergo a physical or a chemical
change in the process of attracting and holding moisture. An example
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of this is table salt, which changes from a solid to a liquid as it absorbs
moisture. Adsorbents, on the other hand, undergo no change except
increase in weight to the extent of moisture adsorbed. However,
absorbents are no more in use on enthalpy wheels.
4.7.2 Adsorbents are primarily solids with internal porosity of such order
that the developed surface area of the pores is several hundred square
meters per gram of the substance. Silica Gel, Activated Alumina, and
Molecular Sieve are the desiccants currently being offered on
enthalpy wheels.
4.7.3 It is observed that molecular sieves have a relatively higher absorption
capacity at low concentration levels of water vapors. However, the
capacity does not increase significantly with increase in relative
humidity. Both silica gel and activated alumina, on the other hand,
have gradually increasing capacities, with silica gel adsorbing almost
twice as much as molecular sieve at 100% RH. The decrease in
adsorption capacity of molecular sieve with increase in temperature is
much smaller compared to the other two desiccants.
4.7.4 These characteristics influence wheel design in terms of its desiccant
mass, flute dimensions, rotational speed, etc., and determine moisture
transfer effectiveness of the wheel at different temperature and
humidity conditions of the two air streams. The overall performance of
a model, however, depends on a number of other factors and must be
established experimentally for each device. Manufacturers normally
have detailed performance data on their equipment which must be
consulted for a given application.
4.7.5 The adsorption behaviour of desiccants is regulated by (a) their total
internal surface area, (b) the total volume of their capillaries, and (c)
the range of their capillary diameters. A wide range of adsorption
characteristics are possible within a single desiccant with variations in
these parameters.
4.7.6 The desiccant is reactivated with building's exhaust air, and the air
reactivates the dessicant adiabatically. No energy apart from what is
contained in the exhaust air stream is required.
4.7.7 The desiccant of sufficient mass is coated with non masking porous
binder adhesive so as to allow quick and easy uptake and release of
water vapour. The weight of desiccant coating and the mass of
aluminium foil (substrate) shall be in a ratio as to ensure equal
recovery of both sensible and latent heat over the operating range.
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4.8 ADVANTAGES OF THE HEAT RECOVERY WHEEL
4.8.1 The Heat Recovery Wheel recovers both sensible and latent energy.
4.8.2 Latent recovery increases the energy savings potential as against
sensible recovery only.
4.8.3 Ideal for applications where large quantities of fresh air are required.
4.8.4 Reduces outdoor air load by about 80%, (depending on inside and
outside conditions) thus reducing first costs in capital equipment like
chillers and boilers.
4.8.5 Unique desiccant surface selectivity eliminates adsorption of
components other than water vapour.
4.8.6 Self-cleaning of rotor.
4.8.7 Better performance, higher efficiencies and lower pressure losses.
4.8.8 Reduced air volume requirements for purge and seal leakage.
4.8.9 Sectionalized media lends itself to a retrofit programme.
4.8.10 Special designs for sensible recoveries and for corrosive environments
are available.
4.9 CROSS CONTAMINATION
4.9.1 Cross contamination or mixing of air between supply and exhaust
airstreams occurs on all rotary energy exchangers by two mechanisms
carryover and leakage. Carryover occurs as air is entrained within
the volume of the rotation medium and is carried into the other
airstream, Leakage occurs because the differential static pressure
across the two airstreams drives air from a higher to a lower static
pressure region. Cross-contamination can be substantially reduced by
placing the blowers so that they promote leakage of outside air to the
exhaust airstream rather than the other way around. Carryover occurs
each time a portion of the matrix passes the seals dividing the supply
and exhaust airstreams. Because carryover from exhaust to supply
may be undesirable, a purge section can be installed on the heat
exchanger to reduce cross-contamination.
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4.9.2 In many applications, recirculating some air is not a concern.
However, critical applications, such as hospital operating rooms,
laboratories, and clean rooms, require stringent control of carryover.
Carryover can be reduced by below 0.1% of the exhaust airflow with a
purge section (ASHRAE SYSTEMS & EQUIPMENT HAND BOOK
1996).
4.9.3 The theoretical carryover of a wheel without a purge is directly
proportional to the speed of the wheel and the void volume of the
wheel media (75 to 95% void, depending on type and configuration).
4.9.4 For example, a 3 m diameter, 200 mm deep wheel with a 90% void and
wheel volume operating at 14 rpm has a carryover volume of
.) ( 1070 60 ) 14 )( 9 . 0 )( 2 . 0 ( ) 2 / 3 (
2
approx CMH
If the wheel is handling a 34,000 CMH balanced flow, the percentage
carryover is
% 15 . 3 100
000 , 34
1070

,
_
The exhaust fan, which is usually located at the exit of the exchanger,
should be sized to include leakage, purge and carryover airflows.
4.9.5 Heat recovery wheels are provided with a purge section as a standard
design to limit trapped exhaust air from being carried over in the
thermal transfer media to supply side. Using a purge section, a small
stream of supply air is diverted, sent back through the wheel media and
exhausted to the outside. By maintaining a pressure difference
between the supply and exhaust ducts, exhaust carry over can be
minimised. The schematic purge operation is shown in APPENDIX-3.
4.9.6 In order to compensate for the outside air being exhausted through the
purge, the exhaust fan capacity should be increased depending on the
pressure differential between the downstream supply side and the
downstream exhaust side.
4.9.7 By utilising the correct fan arrangement, the seal and purge system can
operate at optimum efficiency, virtually eliminating cross
contamination. Installation guidelines are shown in APPENDIX-4.
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5.0 PERFORMANCE RATING
5.1 ASHRAE STANDARD 84, Method of Testing Air-to-Air Heat
Exchangers, establishes rating and testing procedures for commercial
air-to-air heat recovery devices.
5.2 ASHRAE STANDARD 84 defines effectiveness as
E = Actual transfer (of moisture or energy) .. (1)
Max. possible transfer between air streams
Where E = Sensible, latent or total heat effectiveness
Refering to Fig 1,
E = ( ) ( )
( )
( )
1 3
4 3
1 3 1 2
/
X X W
X X We
X X W X X W
MIN
MIN S
(2)
where X = humidity ratio, dry bulb temperature or total enthalpy
respectively at the locations 1,2, 3 & 4.
W
s
= Mass Flow rate of Supply air, kg of dry air.
W
e
= Mass Flow rate of Exhaust Air, kg of dry air.
W
min
= Minimum value W
s
or W
e
.
The leaving supply air condition is ( )
,
_
+
1 3 1 2
X X
W
W
E X X
S
MIN
...(3)
And the leaving exhaust air condition is
( )
,
_

1 3 3 4
X X
W
W
E X X
e
MIN
(4)
(SOURCE : ASHRAE 1996 SYSTEMS & EQUIPMENT HANDBOOK/
CHAPTER 42)
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X
2
X
1
, W
S

2. Supply Air Leaving 1. Supply Air Entering
Energy
Recovery device
W
e
, X
3
X
4

3. Exhaust Air Entering 4. Exhaust Air Leaving
FIG.1 AIR STREAM NUMBERING CONVENTION
5.3 Air flow Arrangements and Effectiveness.
5.3.1 Heat Recovery Wheel effectiveness depends to a great extent on the air
direction and pattern of the supply and exhaust airstreams. Parallel
flow exchangers (Fig.2) have a theoritical max. effectiveness of 50%.
Counterflow exchangers (Fig.3) can have an effectiveness approaching
100% but units designed for typical applications have a much lower
effectiveness. The normal range is 50 to 85%. A median value of 80%
can be assumed for design.
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Outside Air Supply air
Energy
Recovery Device
Return Air Exhaust Air
FIG 2 : PARALLEL HEAT EXCHANGE
Supply Air Outside Air
Energy
Recovery device
Return Air Exhaust Air
FIG .3 : COUNTER FLOW HEAT EXCHANGE
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5.4 PRESSURE DROP
The pressure drop for each air stream through a heat recovery wheel
depends on many factors, including heat exchanger design, mass flow
rate, temperature, moisture and inlet/outlet air. The exchanger pressure
drop must be overcome by fans. However the actual pressure drop
shall be obtained from the manufacturer. Typical pressure drop value
is indicated in APPENDIX-1.
6.0 PSYCHROMETRIC ANALYSIS
In the skeleton Psychrometric Chart shown in APPENDIX-5, outdoor
(fresh) air at 40.4C DB/25.6C WB (15 grams/kg of dry air) (Ab.
Humidity) is drawn through the wheel (F
1
). Heat from return air from
space at 24C/ 9.5 grams /kg of dry air (50% RH) (F
3
) is recovered.
Fresh air entering the space is cooled and dehumidified.
Considering an effectiveness of 80%, supply condition F
2
will be
27.3 C /10.6 gms per kg. of dry air as per calculations shown below.
24 4 . 40
4 . 40
8 . 0
2
X
.
.
. 40.4 X
2
= 0.8 (16.4)
.
.
. X
2
= 27.28C Say 27.3 C
Similarly,
5 . 9 15
15
8 . 0
2
X
or 15 X
2
= 4.4 gms/kg of dry air.
X
2
= 10.6 gms/kg of dry air.
7.0 APPLICATIONS
7.1 With the view to eliminate Sick Building Syndrome created due to
reduced outdoor air (fresh air) quantities, ASHRAE STANDARD
62-1989 for Indoor Air Quality came out with increased ventilation
rates. Reproduced below are the recommended ventilation rates under
the ASHRAE 62-1989 standard for some of the applications :
SECTION:WRITE UP
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26 11
FORM NO. 120 R1
ISSUE
R0
APPLICATION RECOM. VENTILATION
RATE/PERSON (L/S)
Office spaces
Hotel rooms
Hospital rooms
Operating rooms
Auditorium
Smoking Lounge
10 (20 CFM)
15 (30 CFM) per room
12.5 (25 CFM)
15 (30 CFM)
7.5 (15 CFM)
30 (60 CFM)
(Conversion : 1 CFM ~ 0.5 L/SEC.)
7.2 The most widespread application of enthalpy (Heat) wheels is for
PRECONDITIONING fresh outside air before it is introduced to a
building. Because the system is capable of recovering 80% of the
heating or cooling energy that is exhausted from a building, the cost of
fresh air ventilation is reduced. However, an economic analysis has to
be made before recommending HRW for particular application.
7.3 Some typical applications where the Heat Wheel can be employed to
reduce the fresh air load and improve the IAQ are :
Hotels, Restaurants.
Hospitals, Nursing Homes
Conference rooms
Airports
Auditoriums
Offices
Health Clubs, etc.
7.4 A typical calculation procedure for selection of Heat Recovery Wheel
for preconditioning outdoor air for air conditioning application, with a
sample problem has been presented in APPENDIX-2.
8.0 REFERENCES
8.1 ASHRAE Hand Book HVAC SYSTEMS & EQUIPMENT 1996.
8.2 ASHRAE STANDARD 62-1989.
8.3 ECO-Fresh Technical Data, Arctic India.
SECTION:WRITE UP
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26 12
FORM NO. 120 R1
ISSUE
R0
8.4 Carnes Heat Wheel Catalogue.
8.5 ASHRAE JOURNAL OCT 1999 - "Evaluating Active Desiccant
Systems for Ventilating Commercial Buildings" by L.G.Harriman &
Others".
SECTION: APPENDIX-1
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26 OF 13
FORM NO. 120 R1
ISSUE
R0
APPENDIX-1
COMPARISON OF AIR-TO-AIR ENERGY RECOVERY DEVICES
Fixed Plate
Heat
Exchangers
Heat
Recovery
Wheel
Heat Pipe
Heat
Exchangers
Runaround
Coil Loop
Thermosiphon Twin Towers
Enthalpy
recovery loop
Air flow arran
-gements
Counterflow
Crossflow
Parallel flow
Counterflow
Parallel flow
Counterflow
Parallel flow
Counter flow
Parallel flow
Counterflow
Parallel flow
Equipment
Size range,
CMH (cfm)
85 (50) and up 85 to 119000
(50 to 70,000)
170 (100)
and up
170 (100)
and up
170 (100)
and up
Type of heat
transfer
(typical
effectiveness)
Sensible (50
to 80%)
Sensible (50
to 80%) Total
(55 to 85%)
Sensible (45
to 65%)
Sensible (55
to 65%)
Sensible (40 to
60%)
Sensible (40 to
60%)
Face velocity,
m/min (fpm)
(most
common
design
velocity)
30.5 to 305
(61 to 305)
100 to 1000
(200 to 1000)
150 to 305
(500 to 1000)
120 to 240
(135 to 170)
400 to 800
(450 to 550)
90 to 180
(300 to 600)
120 to 240
(135 to 170)
400 to 800
(450 to 550)
90 to 135
(300 to 450)
Pressure drop,
Pa of water
(most likely
pressure) (in.
of water)
5Pa to 450 Pa
(25Pa to 380
Pa)
0.02 to 1.8
(0.1 to 1.5)
100 to 180
(0.4 to 0.7)
100 to 500
(0.4 to 2.0)
100 to 500
(0.4 to 2.0)
100 to 500
(0.4 to 2.0)
180 to 305
(0.7 to 1.2)
Temperature
range C
(F)
-21 to 800
(-70 to 1500
F)
-21 to 800
(-70 to 1500
F)
-4.4 to 35
(-40 to 95 F)
-10 to 480
(-50 to 900
F)
-4.4 to 40
(-40 to 104F)
-4.4 to 46
(-40 to 115F)
Typical mode
of purchase
1.Exchanger
only
2. Exchanger
with
enclosure
or casing
3. Exchanger
and
blowers
Complete
system
1 Exchanger
only
2. Exchanger
with
enclosure
or casing
3. Exchanger
and
blowers
Complete
system
1. Exchanger
only
2.Exchanger
with
enclosure
or casing
1.Coil only
2.Complete
system
1. Exchanger
only
2. Exchanger
with
enclosure
or casing
1. Complete
system
SECTION: APPENDIX-1
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26 OF 14
FORM NO. 120 R1
ISSUE
R0
APPENDIX-1 (CONTD..)
Fixed Plate
Heat
Exchangers
Heat
Recovery
Wheel
Heat Pipe
Heat
Exchangers
Runaround
Coil Loop
Thermosiphon Twin Towers
Enthalpy
recovery loop
Unique
advantages
1. No
moving
parts
2. Low
pressure
drop
3 Easily
cleaned
1. Latent
transfer
2. Compact
large
sizes
3. Low
pressure
drop
1. No
moving
parts
except
tilt .
2. Fan
location
not
critical
3. Allow-
able
pressure
differen-
tial upto
60 in. of
water
1. Exhaust
airstream
can be
separated
from
supply air
2. Fan
location
not
critical
1. No moving
parts.
2. Exhaust
airstream
can be
separated
from
supply air
3. Fan
location not
critical
1. Latent
transfer
from
remote
airstreams
2. Multiple
units in a
single
system.
3. Efficient
micro
biological
cleaning
of both
supply and
exhaust
airstreams.
Limitations Latent avail -
able in hygro-
scopic units
only
Cold climates
may increase
service
Cross air
contam-
ination
possible
Effectiveness
limited by
pressure drop
and cost
Few suppliers
High effective
ness requires
accurate
simulation
model
Effectiveness
may be limited
by pressure
drop and cost.
Few suppliers
Few Suppliers
Cross-leakage 0 to 5% 1 to 10% 0% 0% 0% 0.025%
Heat rate
control (HRC)
schemes
Bypass
dampers and
ducting
Wheel speed
control over
full range
Tilt angle
down to 10%
or maximum
heat rate.
Bypass valve
or pump
speed control
over full
range
Control valve
over full range
Control valve
or pump speed
control over
full range.
SOURCE : ASHRAE 1996 SYSTEMS & EQUIPMENT HANDBOOK CHAPTER 42.
SECTION: APPENDIX-2
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26
15
FORM NO. 120 R1
ISSUE
R0
APPENDIX-2
SELECTION OF HEAT RECOVERY WHEEL
1.0 Selection of Heat Recovery Wheel is normally done using manufacturers data.
However a typical calculation procedure for HVAC system is given below for
guidance.
STEP-1
Determine the Design Conditions (Indoor as well as outdoor temperature/
Humidity and Enthalpy Conditions).
STEP-2
For certain applications, as many as four different wheel sizes may be utilised.
The ultimate selection is based on both performance and economic considerations.
A mid point selection can be made using the following formula :
Nominal wheel area (sq.m) = Supply or Exhaust Volume (CMH)
3600 x (wheel face velocity in m/s)
Manufacturers data furnishes the wheel size which approximates the required
face area. A typical (manufacturers) wheel face area Vs diameter (size) of wheel
is given in APPENDIX-3. A nominal face velocity of 3 to 3.5 m/s. can be
assumed to arrive at the wheel area.
STEP-3
Based on the wheel face velocity and the air flow requirements, the thermal
effectiveness and pressure drop can be determined, using manufacturers data. A
typical wheel selection chart is furnished in TABLE-2. In the absence of such
data, assume a thermal effectiveness of approx. 80% (for total heat recovery) and
a pressure drop of 10 to 18 mm (0.4 to 0.7 inches) of water column (as given in
APPENDIX-1).
STEP-4
Using the following equations, supply air and exhaust air conditions can be
found out.
Effectiveness = W
s
(X
1
X
2
)/W
min
(X
1
X
3
)
Effectiveness = W
e
(X
4
X
3
)/W
min
(X
1
X
3
)
where W
s
= Supply air volume
SECTION: APPENDIX-2
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26
16
FORM NO. 120 R1
ISSUE
R0
APPENDIX-2 (CONTD.)
W
e
= Return air volume/ Exhaust air volume
X
1, 2, 3 & 4
= Dry bulb temperatures, humidity ratios and
enthalpies corresponding to
X
1
= Outdoor air (Entering)
X
2
= Supply air (Leaving)
X
3
= Return air (Entering)
X
4
= Exhaust air (Leaving)
For equal supply volume and exhaust volume
W
x
= W
min
= W
Exhaust
For unequal flow, the air flow to be divided as per the ratio = W
max

W
min
STEP 5
a. Calculate Performance by finding X
1
, X
2
, X
3
& X
4
: temperatures,
humidity ratios and enthalpies at Entering & Leaving conditions.
b. Calculate the potential reduction in plant capacity (Tons of Refrigeration)
using,
Energy recovered = Air flow x density of air x
(Enthalpy in Enthalpy Out)
2.0 EXAMPLE PROBLEM
Building : TCS Sholinganallur SSDC complex
Location : Chennai
Fresh Air
quantity : 15300 CMH (9000 CFM)
To find : Reduction in Refrigeration chiller capacity using HRW.
SECTION: APPENDIX-2
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26
17
FORM NO. 120 R1
ISSUE
R0
APPENDIX-2 (CONTD.)
Sl
No
Conditions
DB C ( F) WB C ( F)
Absolute
Humidity
(kg/kg)/
(gr/lb)
Enthalpy
kJ/kg
(Btu/lb)
1. Outdoor conditions
Summer
Monsoon
Winter
39.4 (103)
28.3(83)
18.3(65)
27.8(82)
26.7(80)
13.9(57)
0.019(133)
0.022(153)
0.0018(56)
89 (45.9)
84 (43.7)
39 (24.5)
2. Inside Conditions 24(75) 17.5(63.5)
(55% RH)
0.01(71.4) 52 (29.1)
1. Heat Recovery Wheel
Nominal Wheel area (sq.m) = 15300 CMH = 1.2 sq.m (13 sq.ft)
3600 x 3.5
where face air velocity across the wheel = 3.5 m/s (700 FPM)
2. From Manufacturers Performance data (TABLE-2)/APPENDIX-2.
For a face velocity of 3.5 m/s (700 FPM).
Model TE3-13 will handle 15580 CMH (9170 CFM) and the size of wheel
= 1930 mm x 1930 mm (76 x 76)
Actual wheel area = 1.2 sq.m (13.1 sq.ft)
3. Effectiveness for the model selected = 78.5%
This can also be found out from manufacturers charts/software
4. Performance
W
s
= Supply (Fresh air) air volume = 15300 CMH
W
min
= 15300 CMH
SECTION: APPENDIX-2
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26
18
FORM NO. 120 R1
ISSUE
R0
Using Equation (3) given in clause 5.0 ( )
,
_
+ 4 . 39 24
15300
15300
4 . 39
2
X 0.785
= 39.4 12.22 = 27.18 Say 27.2C
(81F)
i.e Fresh air (leaving HRW) DBT = 27.2C (81F)
Similarly
X
2
(W) = 0.019 0.785 (0.019 0.01)
= 0.019 - 0.0071 = 0.0119 Say 0.012 kg/kg of dry air
(84 gr/lb)
X
2
(H) = 89 - 0.785 (89-52)
= 59.955 say 60 kJ/kg (32.7 Btu/ lb)
Similarly for exhaust air conditions, using equation (4) as given in clause 5.0.
X
4
= ( )
,
_
4 . 39 24
15300
15300
785 . 0 24 = 36.1C = 97F
i.e. Exhaust air (leaving) DBT = T
DB
= 36.1 C
X
4
(W) = 0.010 + 0.785 (0.019 - 0.010)
= 0.0171 kg/kg of dry air (119.8 gr/lb)
X
4
(H) = 52 + 0.785 (89-52) = 81.045 kJ/kg
Similar calculations can be made for Monsoon and Winter conditions - See
Sh. 19 of 28.
5. Energy Recovered considering supply air entering and leaving conditions.
Summer = 4.5 x 9000 x (45.9 32.7)
= 15300 x 1.2 x (89-60) = 147.9 kW = 42 TR
This is also equal to : 15300 x 1.2(81.1 - 52) = 1484.4 kW or 42.2 TR.,
considering exhaust air entering and leaving conditions.
SECTION: APPENDIX-2
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26
19
FORM NO. 120 R1
ISSUE
R0
APPENDIX-2 (CONTD.)
SITE DATA
ABSOLUTE
HUMIDITY
ENTHALPY
OUTSIDE
COND.
DBT C
( F)
WBT C
( F) kg/kg OF DRY
AIR (GR/LB)
kJ/kg
(BTU//LB)
SUMMER 39.4(103) 27.8(82) 0.019 (133) 89.0(45.9)
MONSOON 28.3(83) 26.7(80) 0.022 (153) 84.0(43.7)
WINTER 18.3(65) 13.9(57) 0.008(56) 39.0(24.5)
INSIDE
COND.
24(75) 17.5C(63.5)
55 % RH
0.01(71.4) 52.0(29.1)
FRESH AIR
QTY
15300 CMH (9000 CFM)
DESIGN PARAMETERS (From TABLE-2)
DESIGN EFFECTIVENESS : 78.5%
FACE VELOCITY : 3.5 m/sec (700 FPM)
WHEEL DIA SELECTED : 1930 mm (76")
PR. DROP SUPPLY : 17 mm wc (0.67)
PR. DROP EXHAUST : 17 mm wc (0.67)
WHEEL MODEL SELECTED : HRW TE3-13 OF ECO-FRESH
(ARCTIC INDIA)
NOTE :
DBT : DRY BULB TEMPERATURE (C)
WBT : WET BULB TEMPERATURE (C)
SECTION: APPENDIX-2
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26
20
FORM NO. 120 R1
ISSUE
R0
APPENDIX-2 (CONTD.)
HEAT RECOVERY WHEEL MODEL NO. HRW 1800
SUPPLY AIR ENTERING
AIR QTY : 15300 CMH + (Purge air) [(9000 CFM + Purge Air)]
ABS.
HUMIDITY
ENTHALPY DBT
C ( F)
WBT
C ( F)
kg/kg (gr/lb) kJ/kg (Btu/1b)
SUMMER 39.4 (103) 27.8 (82) 0.019 (133.0) 89.0 (45.9)
MONSOON 28.3 (83) 26.7 (80) 0.022 (153.0) 84.0 (43.7)
WINTER 18.3 (65) 13.9 (57) 0.008 (56.0) 39.0 (24.5)
SUPPLY AIR LEAVING
AIR QTY : 15300 CMH (9000 CFM)
ABS. HUMIDITY ENTHALPY DBT
C ( F)
WBT
C ( F)
SUMMER 27.2 (81) 20.5 0.012 (84.6) 60.0 (32.7)
MONSOON 25 (77) 20.0 0.0127 (88.9) 59.0 (32.3)
WINTER 22.8 (73) 17.2 0.0097 (68.1) 47.5 (28.1)
EXHAUST AIR LEAVING
AIR QTY : 15300 CMH + Purge Air [(9000 CFM + (Purge Air))]
C ( F)
WBT
C ( F)
SUMMER 36.1 (97) 26 0.017 (1119.8) 81.1 (42.3)
MONSOON 26.7 (80) 24.8 0.019 (135.5) 76.0 (40.6)
WINTER 19.4 (67) 14.8 0.0085 (59.3) 43.5 (25.5)
SECTION: APPENDIX-2
TCE.M6-ME-811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26
21
FORM NO. 120 R1
ISSUE
R0
APPENDIX-2 (CONTD.)
EXHAUST AIR ENTERING
AIR QTY : 15300 CMH (9000 CFM)
C ( F)
WBT
C ( F)
RH%
kg/kg (gr/lb) kJ/ kg (Btu/lb)
SUMMER 23.9 (75) 18C
(64.4)
55 0.010 (71.4) 52 (29.1)
MONSOON 23.9 (75) 18C
(64.4)
55 0.010 (71.4) 52 (29.1)
WINTER 23.9 (75) 18C
(64.4)
55 0.010 (71.4) 52 (29.1)
ENERGY RECOVERED
SUMMER : 147.9 kW or = 42 TR
MONSOON : 127.4 kW or = 36.2 TR
WINTER : - - = 43.4 kW
NOTE 1 : The calculations shown above are typical and values approximate for the
purposes of illustration. Similar procedure could be used for preliminary
estimation. Actual reduction in Refrigeration Capacity (or Heating Capacity)
or energy recovered shall be obtained by Equipment Vendor.
NOTE 2 : Purge air quantities will be determined by manufacturer.
NOTE 3 : Calculation of Enthalpy
Enthalpy values could be obtained from a Psychrometric chart. However
Enthalpy Values can be calculated. ASHRAE Fundamentals Volume (S.I.
Units) 1997 gives formulae for calculation of Enthalpy for a given Dry Bulb
Temperature (C) and Humidity Ratio (Kg/Kg of dry air) (Refer Table 1 in
Chapter 6 of ASHRAE FUNDAMENTALS-1997)
IN S.I. UNITS
Moist air enthalpy = t + w (2501 + 1.805t) kJ/kg of dry air -- (1)
Where t = dry bulb temperature (saturated air)
W = Humidity Ratio.
W can be calculated using W = 0.622
1
]
1
Pw P
Pw
Where Pw = partial pressure of water vapour at tC (kPa)
and P = Atmospheric pressure (kPa).
SECTION: TABLE-2
TCE.M6-ME-
811-314
DESIGN GUIDE FOR
HEAT RECOVERY WHEEL
SHEET OF 26 22
FORM NO. 120 R1
ISSUE
R0
APPENDIX-2 (CONTD.)
TABLE-1
TYPICAL MANUFACTURERS PERFORMANCE DATA
HEAT RECOVERY WHEEL (HRW)
MODEL NUMBERS
TE3-
03
TE3-
05
TE3-
09
TE3-
13
TE3-
18
TE3-
24
TE3-
28
TE3-
35
TE3-
43
TE3-
46
TE3-56 TE3-70
Velocity
FPM
M/S
Effic.
%
Press
Drop
IN
MM
MODEL/
AREA
(SQ.FT)
2.8 5.3 8.6 13.1 18.1 23.8 28.3 35.2 42.9 46.4 56 70.4
300
1.53
88.0 0.29
7.4
SCFM
CMH
840
1430
1590
2700
2580
4380
3030
6680
5430
9230
7140
12130
8490
14430
10560
17940
12870
21870
13920
23650
16800
28540
21120
35880
400
2.03
86.0 0.37
9.4
SCFM
CMH
1120
1900
2120
3600
3440
5850
5240
8900
7240
12300
9520
16170
11320
19230
14080
23920
17160
29160
18560
31530
22400
38060
28160
47840
500
2.54
82.5 0.45
11.4
SCFM
CMH
1400
2380
2650
4500
4300
7310
6550
11130
9050
15380
11900
20220
14150
24040
17600
29900
21450
36440
23200
39420
28000
47570
35200
59810
600
3.05
80.5 0.56
14.2
SCFM
CMH
1680
2850
3180
5400
5160
8770
7860
13350
10860
18450
14280
24260
16980
28850
21120
35880
25740
43730
27840
47300
33600
57090
42240
71770
700
3.56
78.5 0.67
17.0
SCFM
CMH
1960
3330
3710
6300
6020
10230
9170
15580
12670
21530
16660
33660
19810
33660
24640
41860
30030
51020
32480
55180
39200
66600
49280
83730
800
4.06
77.0 0.79
20.1
SCFM
CMH
2240
3810
4240
7200
6880
11690
10480
17810
14480
24600
19040
32350
22640
38470
28160
47840
34320
58310
37120
63070
44800
76120
56320
85690
900
4.57
76.0 0.94
23.9
SCFM
CMH
2520
4280
4770
8100
7740
13150
11790
20030
16290
27680
21420
36390
25470
43270
31680
53820
38610
65600
41760
70950
50400
85630
63360
107650
1000
5.08
74.5 1.05
26.7
SCFM
CMH
2800
4760
5300
9010
8600
14610
13100
22260
18100
30750
23800
40440
28300
48080
35200
59800
42900
72890
46400
78830
56000
95140
70400
119610
1100
5.59
73.5 1.18
30.0
SCFM
CMH
3080
5230
5830
9910
9460
16070
14410
24480
19910
33830
26180
44480
31130
52890
38720
65790
47190
80180
51040
86720
61600
104660
77440
131570
DIMENSIONS AND WEIGHTS
Height and Width A In
mm
40
1016
52
1321
64
1626
76
1930
88
2235
100
2540
112
2845
124
3150
136
3454
141
3581
154
3912
172
4369
Depth in Flow Direction
B
In
mm
19
483
19
483
19
483
19
533
21
533
21
533
21
533
23
584
23
584
23
584
23
584
23
584
Net Weight lb
Kg
380
173
520
236
700
318
1070
486
1300
590
1640
745
2640
1199
3000
1362
3390
1540
3570
1621
4030
1830
4680
2125
SOURCE : ECO-FRESH HEAT WHEEL BY ARCTIC INDIA (FOR REFERENCE ONLY)

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