Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1

23/02/2012

2-STAGE EVAPORATIVE COOLING AIR-CONDITIONING

DESIGN GUIDELINES with Example

PART 1: SINGLE DUCT VARIABLE VOLUME WITH TERMINAL REHEAT

LOAD CALCULATIONS
As for a conventional variable volume air-conditioning system.
Room design conditions: It is the intention to design a 2-stage evaporative cooling
system for the same internal conditions as we would for
conventional air-conditioning, lets go for:
23.5 oC max / 21.0 oC min
Supply air temperature (Pretoria): Variable volume relies on a constant supply air temperature. In
the case of 2-stage evaporative cooling, this temperature is
determined by the local climate conditions. For Pretoria, we
know that we can get the way, most of the time, with:
17.5 oC unit leaving / 18.5 oC room entering (constant)
Note that this temperature is only there to get a first-pass idea
of the required air quantity. The final equipment capacities will
be simulated through simulation, as will be demonstrated later,
Use peak climate data for ever month. September to May for cooling and June to August for heating.
First pass calculations: subdivide building into areas according to orientation (North-, East-, South-,
West perimeter, Interior, ) and calculate peak air quantity and heating load for every area (room,
zone) plus the peak air quantity for every air handling unit.

Example:
Results for rooms
ROOM AREA AIR HEATING
m2 l/s l/s-m2 W W/m2

CB_NO 903 6 912 7.7 36 306 40.2

CB_EA 1 073 24 716 23.0 93 340 87.0
CB_SO 948 10 455 11.0 56 255 59.3
CB_WE 1 108 13 789 12.4 54 760 49.4
CB_INT 1 954 8 248 4.2 32 265 16.5
SB_NO 2 868 46 035 16.1 193 088 67.3
SB_EA 1 200 8 594 7.2 40 666 33.9
SB_SO 2 992 25 832 8.6 134 833 45.1
SB_WE 1 200 9 834 8.2 42 732 35.6
SB_INT 4 623 19 457 4.2 73 801 16.0
NB_NO 1 515 22 995 15.2 99 146 65.4
NB_EA 743 5 098 6.9 24 574 33.1
NB_SO 1 344 12 401 9.2 66 605 49.6
NB_WE 743 5 585 7.5 25 385 34.2
NB_INT 66 281 4.3 1 119 17.0

TOTAL 23 280 220 232 9.5 974 874 41.9

Page 1 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

Results for (total of) Air Handling Units (= 2-Stage Evaporative Cooling Units):

AIR HANDLING UNIT CAPACITY

ROOM LIST
Name No. Name No.

CB_NO 1 NB_NO 1
CB_EA 1 NB_EA 1
CB_SO 1 NB_SO 1
CB_WE 1 NB_WE 1
CB_INT 1 NB_INT 1
SB_NO 1
SB_EA 1
SB_SO 1
SB_WE 1
SB_INT 1
Total area: 23 280 m2
Climate data used: PEAK Weather for PRETORIA
The plant starts at 7 hr and stops at 19 hr
Unit leaving Dry bulb temperature 17.5 oC
Wet bulb temperature 16.5 oC

Peak air quantity occurs at Month 1

Hour 14
Peak Air Quantity 190.0 m3/s
8.2 l/s-m2

Note the Unit air quantity: 190 m 3/s (and this includes 5% leakage). Compare with the sum of the room
peak air quantities: 220 m3/s. Because of the different orientations, the rooms peak at different times.

SIMULATION
The above data are now entered as equipment capacities into a simulation model.
As we have no means of knowing how the space is used from hour to hour, we let the computer
decide. This is done by means of random fluctuations of the occupancy level and of the use of lights,
equipment and shading devices. Because of this, no two consecutive runs of the same simulation are
ever identical, but it is surprising how consistent the results are.
The climate data are now real, typical hourly weather data. Originally, 7 consecutive days were used
per month, to represent the full month. Now, computers are so powerful and fast that there is no
reason not to use the full 365 days of a typical reference year. We now go even one step further:
instead of a reference year, we use several real years and compare the results. From those, a
judgement decision has to be made. There is however little difference from year to year.

Page 2 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

As a minimum, the following climate data are required for every hour: drybulb temperature, relative
humidity and cloud cover. From those, the following type of climate files are derived:

MNTH DAY HR Alt Azim Direct Rad Sky Rad Drybulb Wetbulb
(deg) (deg) (W/m2) (W/m2) (oC) (oC)
.. .. .. .. .. .. .. .. ..
3 4 16 26 285 777 85 27.0 18.2
3 4 17 13 277 531 58 27.8 18.4
3 4 18 0 0 0 0 25.8 19.9
3 4 19 0 0 0 0 22.3 19.7
3 4 20 0 0 0 0 20.3 18.6
3 4 21 0 0 0 0 19.3 17.6
3 4 22 0 0 0 0 18.2 17.0
3 4 23 0 0 0 0 17.5 16.7
3 4 24 0 0 0 0 17.4 16.8
3 5 1 0 0 0 0 16.5 16.1
3 5 2 0 0 0 0 16.3 15.8
3 5 3 0 0 0 0 15.7 15.3
3 5 4 0 0 0 0 15.6 15.0
3 5 5 0 0 0 0 15.5 15.1
3 5 6 0 0 0 0 15.5 15.3
3 5 7 13 83 478 74 17.9 16.0
3 5 8 26 75 466 205 19.4 16.6
3 5 9 39 66 702 220 21.9 18.7
3 5 10 51 52 925 102 24.0 19.5
3 5 11 60 31 946 104 25.6 19.8
3 5 12 64 0 667 362 25.7 19.6
3 5 13 60 329 946 104 27.2 19.9
3 5 14 51 308 832 190 27.6 19.8
3 5 15 39 294 263 301 26.7 19.5
3 5 16 26 285 0 128 22.0 19.6
3 5 17 13 277 0 53 20.7 19.6
3 5 18 0 0 0 0 21.0 19.0
3 5 19 0 0 0 0 20.1 18.9
3 5 20 0 0 0 0 19.6 18.8
3 5 21 0 0 0 0 18.8 17.6
3 5 22 0 0 0 0 19.6 15.6
3 5 23 0 0 0 0 18.6 15.1
3 5 24 0 0 0 0 17.6 15.1
3 6 1 0 0 0 0 16.9 15.3
Etc. .. .. .. .. .. .. .. ..

Page 3 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

Supply air temperature

A constant supply air temperature was used for the load calculation. Now, for simulation, the real
achievable supply air temperature must be used
Try to control the supply air temperature at 17.0 oC. As long as the outside air drybulb is above 17.0
oC, the 2 steps of evaporative cooling are switched in sequence. When the outside temperature drops

below 17.0 oC, return air is introduced and mixed with outside air to achieve the required 17.0 oC.
Typical summer day:
MNTH DAY HR OADB OAWB SAT %DIR %INDIR %OA %RA

1 1 8 20.3 16.8 17.0 100% 0% 100% 0%

1 1 9 22.6 18.1 17.1 100% 100% 100% 0%
1 1 10 23.9 18.2 17.0 100% 100% 100% 0%
1 1 11 25.2 18.8 17.5 100% 100% 100% 0%
1 1 12 25.9 18.5 17.0 100% 96% 100% 0%
1 1 13 27.0 19.0 17.3 100% 100% 100% 0%
1 1 14 28.0 19.1 17.2 100% 100% 100% 0%
1 1 15 28.6 19.4 17.5 100% 100% 100% 0%
1 1 16 29.1 19.5 17.5 100% 100% 100% 0%
1 1 17 25.6 16.9 17.0 100% 14% 100% 0%
1 1 18 20.2 15.6 17.0 73% 0% 100% 0%
1 1 19 20.8 15.8 17.0 80% 0% 100% 0%

Typical Intermediate Season:

MNTH DAY HR OADB OAWB SAT %DIR %INDIR %OA %RA

4 5 8 14.4 11.6 17.0 0% 0% 62% 38%

4 5 9 17.3 13.6 17.0 9% 0% 100% 0%
4 5 10 19.4 14.1 17.0 48% 0% 100% 0%
4 5 11 21.1 13.9 17.0 60% 0% 100% 0%
4 5 12 22.0 13.5 17.0 62% 0% 100% 0%
4 5 13 22.5 13.7 17.0 66% 0% 100% 0%
4 5 14 22.8 13.4 17.0 65% 0% 100% 0%
4 5 15 22.5 13.0 17.0 61% 0% 100% 0%
4 5 16 22.9 12.9 17.0 62% 0% 100% 0%
4 5 17 22.3 13.2 17.0 61% 0% 100% 0%
4 5 18 20.0 12.7 17.0 43% 0% 100% 0%
4 5 19 17.1 12.4 17.0 2% 0% 100% 0%

Typical winter day:

MNTH DAY HR OADB OAWB SAT %DIR %INDIR %OA %RA

6 1 8 9.1 4.6 17.0 0% 0% 32% 68%

6 1 9 12.7 7.0 17.0 0% 0% 47% 53%
6 1 10 15.6 8.5 17.0 0% 0% 75% 25%
6 1 11 17.6 9.9 17.0 8% 0% 100% 0%
6 1 12 18.2 8.7 17.0 13% 0% 100% 0%
6 1 13 17.7 7.6 17.0 7% 0% 100% 0%
6 1 14 17.8 7.5 17.0 8% 0% 100% 0%
6 1 15 17.5 7.2 17.0 5% 0% 100% 0%
6 1 16 16.8 7.0 17.0 0% 0% 96% 4%
6 1 17 14.4 5.9 17.0 0% 0% 62% 38%
6 1 18 12.7 5.2 17.0 0% 0% 49% 51%
6 1 19 10.7 4.5 17.0 0% 0% 39% 61%

Page 4 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

The target supply temperature is not always achievable. For Pretoria, the distribution is as follows:
Operating hours 3 432 hrs

No. of hours SAT >17.0 oC 344 hrs 10.0%

No. of hours SAT >17.5 oC 238 hrs 6.9%
No. of hours SAT >18.0 oC 136 hrs 4.0%
No. of hours SAT >18.5 oC 82 hrs 2.4%
o
No. of hours SAT >19.0 C 24 hrs 0.7%
No. of hours SAT >19.5 oC 0 hrs 0.0%

For 10% of the time, the supply temperature will be above 17.0 oC and this will affect the room
temperature.
Investigating this is part of the simulation process.

Room temperatures.
During simulation, the room temperatures are (must be) calculated, both during operating hours and
after hours.
The room temperature is controlled at 22.0 oC 1.0 degC.
Here is an example:
MNTH DAY HR TSA CB_NO CB_EA CB_SO CB_WE CB_INT UNIT

12 4 1 22.0 21.6 21.7 22.2 21.9 OFF

12 4 2 21.9 21.4 21.5 22.1 21.9 OFF
12 4 3 21.9 21.4 21.5 22.1 21.9 OFF
12 4 4 21.6 20.9 21.1 21.8 21.8 OFF
12 4 5 21.5 20.7 21.0 21.7 21.7 OFF
12 4 6 21.7 25.0 22.2 22.0 21.8 OFF
12 4 7 22.4 28.2 23.6 22.8 22.5 OFF
12 4 8 17.8 21.6 23.7 21.7 21.4 21.4 ON
12 4 9 17.9 22.2 23.3 22.1 22.2 22.5 ON
12 4 10 17.7 22.3 22.5 22.4 22.1 22.2 ON
12 4 11 17.7 22.7 22.2 22.7 22.0 22.6 ON
12 4 12 17.4 22.6 22.1 22.9 22.1 22.2 ON
12 4 13 17.3 22.6 22.0 22.3 22.2 22.5 ON
12 4 14 17.0 22.3 21.9 22.7 22.0 22.5 ON
12 4 15 17.0 22.2 21.4 22.0 22.0 22.2 ON
12 4 16 17.0 22.1 21.5 21.8 21.8 22.3 ON
12 4 17 17.0 22.1 21.5 22.0 21.8 22.5 ON
12 4 18 18.3 21.8 21.2 21.6 21.5 21.6 ON
12 4 19 17.0 21.4 21.0 21.1 21.1 21.3 ON
12 4 20 22.4 22.2 22.2 22.4 22.6 OFF
12 4 21 22.0 21.6 21.6 22.0 22.0 OFF
12 4 22 22.0 21.6 21.6 22.0 22.0 OFF
12 4 23 22.1 21.8 21.7 22.0 22.0 OFF
12 4 24 21.9 21.6 21.6 21.9 22.0 OFF

As can be seen, a supply temperature above 17.0 oC does not necessarily have a proportional effect
on the room temperatures.
As it is not practical to study the full model simulation output for every room for every hour of the year,
we have to call on statistics to make sense of the results.
This is shown below.

Page 5 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

An example of the room temperature distribution for a number of rooms:

CB_NO CB_EA CB_SO CB_WE CB_INT

(During operating hours) 3 432 hrs

Maximum room temperature (oC) 23.2 24.6 23.7 23.2 23.4
Minimum room temperature (oC) 21.0 21.0 21.0 21.0 21.0
Average room temperature (oC) 21.7 21.4 21.5 21.4 21.8

Room temperature >23.0 3 hrs 44 hrs 17 hrs 7 hrs 7 hrs

>23.5 0 hrs 24 hrs 3 hrs 0 hrs 0 hrs
>24.0 0 hrs 14 hrs 0 hrs 0 hrs 0 hrs
>24.5 0 hrs 3 hrs 0 hrs 0 hrs 0 hrs
>25.0 0 hrs 0 hrs 0 hrs 0 hrs 0 hrs

Room temperature <21.0 0 hrs 0 hrs 0 hrs 0 hrs 0 hrs

In percentages
Room temperature >23.0 0.10% 1.29% 0.50% 0.20% 0.20%
>23.5 0.00% 0.69% 0.10% 0.00% 0.00%
>24.0 0.00% 0.40% 0.00% 0.00% 0.00%
>24.5 0.00% 0.10% 0.00% 0.00% 0.00%
>25.0 0.00% 0.00% 0.00% 0.00% 0.00%

Room temperature <21.0 0.00% 0.00% 0.00% 0.00% 0.00%

Although the target supply temperature is exceeded for 10% of the time, there is little effect on the
room temperatures. Even the worst room (CB_EA) exceeds 23 oC for only 1.29% of the time.
However, room CB_EA stands out for its high loads and high temperature. See also the load
calculation results on page 1. It is clear that the faade needs to be looked at again. (Remember, this
was only the first pass calculation.)
One can also see from the average temperatures that, most of the year, there is more than sufficient
cooling capacity. Maybe move the setpoint up by a degree and see what happens.

Relative humidity
Relative humidity is of concern with evaporative cooling and should be checked as part of the
simulation process.
Average for the building on a typical summer day:
MNTH DAY HR Temp (oC) Hum (kg/kg) RH (%)

12 4 8 22.3 0.0151 75%

12 4 9 22.5 0.0151 74%
12 4 10 22.4 0.0148 73%
12 4 11 22.4 0.0148 73%
12 4 12 22.5 0.0145 71%
12 4 13 22.4 0.0144 71%
12 4 14 22.4 0.0140 69%
12 4 15 22.3 0.0132 65%
12 4 16 22.2 0.0143 71%
12 4 17 22.2 0.0141 70%
12 4 18 22.0 0.0155 78%
12 4 19 21.9 0.0140 71%

Page 6 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

A day in October:
MNTH DAY HR Temp (oC) Hum (kg/kg) RH (%)

10 3 8 21.3 0.0079 41%

10 3 9 21.5 0.0087 45%
10 3 10 21.6 0.0089 46%
10 3 11 21.5 0.0096 50%
10 3 12 21.6 0.0105 54%
10 3 13 21.6 0.0107 55%
10 3 14 21.6 0.0107 55%
10 3 15 21.7 0.0112 57%
10 3 16 21.7 0.0111 57%
10 3 17 21.7 0.0109 56%
10 3 18 21.4 0.0101 53%
10 3 19 21.4 0.0094 49%

Average building relative humidity distribution:

Operating hours 3 432

Humidity >60% 1 553 hrs

>65% 1 229 hrs
>70% 657 hrs
>75% 123 hrs
>80% 17 hrs

The impact of humidity on comfort is discussed in detail in a separate article Comfort with 2-Stage
Evaporative Cooling, which can be found on this website.

Central Plant Capacity (exceeded?)

Installed fan capacity: 190.0 m3/s of which 181.0 m3/s reaches the air terminals
Installed air terminal air capacity: 220.0 m3/s 122%
Equivalent full load operating hours 2 258 hrs
Maximum air demand: 212.1 m3/s
Number of operating hours: 3 432 hrs
Number of hours when demand exceeds fan capacity: 99 hrs 2.9%

Installed air terminal heating capacity: 975 kW

Maximum heating demand: 664 kW 68%
Equivalent full load operating hours: 217 hrs

The air demand exceeds the fan capacity for 99 hours (2.9%). The duct pressure might not be
maintained during those periods.
The maximum heating demand is only 68% of the installed capacity.
NOTE: No heating is required in the air handling units.

Page 7 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

Fresh Air
A 2-stage evaporative cooling system is basically an all-outside air system, except when the outside
air drybulb drops below 17.0 oC. Return air is then introduced to mix with outside air in order to
achieve the required supply temperature. There are no heaters in the air handling units and we rely
solely on the heat in the return air. It is therefore necessary to check if the outside air does not drop
below acceptable levels.
Here is a typical example (from the simulation process).
Fresh air statistics
Air-conditioned area: 23 280 m2
Occupation density: 17 m2 per person
Number of people: 1 369
@ 5.0 l/s-person (norm) 6.8 m3/s
No. of hrs exceeded 3 432 100%
@ 7.5 l/s-person (+50%) 10.3 m3/s
No. of hrs exceeded 3 432 100%
@ 10.0 l/s-person (+100%) 13.7 m3/s
No. of hrs exceeded 3 432 100%
@ 12.5 l/s-person (+150%) 17.1 m3/s
No. of hrs exceeded 3 408 99%
@ 15.0 l/s-person 20.5 m3/s
No. of hrs exceeded 3 391 99%
@ 17.5 l/s-person 24.0 m3/s
No. of hrs exceeded 3 378 98%
@ 20.0 l/s-person 27.4 m3/s
No. of hrs exceeded 3 255 95%
@ 25.0 l/s-person 34.2 m3/s
No. of hrs exceeded 3 279 96%
@ 30.0 l/s-person 41.1 m3/s
No. of hrs exceeded 3 197 93%
@ 35.0 l/s-person 47.9 m3/s
No. of hrs exceeded 3 112 91%
@ 40.0 l/s-person 54.8 m3/s
No. of hrs exceeded 3 027 88%
@ 45.0 l/s-person 61.6 m3/s
No. of hrs exceeded 2 962 86%

Maximum outside air 190.0 m3/s

Per person 138.7 l/s
Minimum outside air 14.9 m3/s
Per person 10.9 l/s

As can be seen, there is no problem in this case.

ENERGY AND WATER CONSUMPTION

The power demand of all items of equipment is calculated on an hourly basis as part of the simulation
run. The results are combined to give us the kWh consumption and the kVA maximum demand.
The same is done for the water consumption.
The results are summarized on the next page.

Page 8 of 9
Toon Herman 2-Stage Evaporative Cooling Design Guidelines Part 1
23/02/2012

BUILDING EXAMPLE Location PRETORIA 1369 m above sea level

Standard operating times 859 mbar Atm pressure
5.5 days/week - 52 weeks per year - 3432 operating hrs/year 1.01 kg/m3 specific mass

Air-conditioned Area 23 280 m2

System 2-Stage Evaporative Cooling system (ACTUAL SUPPLY TEMPS)
Supply temperature controlled at: 17.0 oC

Equipment

SA Fans 190 m3/s 8.2 l/s-m2 190 kW 211 kVA

CT Fans 95 kW 106 kVA
Spray pumps 24 kW 27 kVA
Heating 975 kW 41.9 W/m2 975 kW 975 kVA

Unit Consumption kWh p.a. kWh/m2 EFLRH

SA Fans 428 965 18.4 2258 hrs

CT Fans 65 288 2.8 687 hrs
Spray pumps 47 063 2.0 1961 hrs
Heating 211 402 9.1 217 hrs
752 718 32.3

Maximum Demand - kVA SA Fans CT Fans Sprays Heating Total

January 230 106 27 0 362

February 247 106 27 0 380
March 246 106 27 0 379
April 91 0 0 218 310
May 91 0 0 426 517
June 91 0 0 654 745
July 91 0 0 664 755
August 91 0 0 496 587
September 96 0 0 362 458
October 91 0 0 283 374
November 165 106 27 0 297
December 205 106 27 0 338

Totals 1 737 528 133 3 104 5 502 kVA p.a.

0.07 0.02 0.01 0.13 0.24 kVA/m2
EFDM 8.2 5.0 5.0 3.2
Maximum drawn 755 kVA
Energy Costs 32 VA/m2

Units 752 718 kWh @ R 0.3573 = R 268 946 p.a.

Maximum Demand 5 502 kVA @ R 132.55 = R 729 230 p.a.
Service charge 12 months @ R 257.08 (Proport.) = R 3 085 p.a.

Total R 1 001 261 p.a.

R 43.01 /m2

Water Consumption Cooling Tower 4 125 kl p.a. 177 l/m2

Spray system 5 347 kl p.a. 230 l/m2

Total 9 472 kl p.a. 407 l/m2

@ R 10.00 /kl = R 94 720 p.a.
R 4.07 /m2

Page 9 of 9