Examples of

HOSPITAL OPERATING THEATRE

Air Handling Unit, Cooling coils



Prof. Dr. Essam E. Khalil
Professor of Mechanical Engineering, Mechanical Power Engineering Department
Faculty of Engineering, Cairo University, Cairo, Egypt
Chairman of the Consulting Engineering Bureau, CEB
Chairman of the Egyptian Air Conditioning and Refrigeration Code, HBRC
Chairman of the Energy Efficiency of Buildings Code of Egypt EEBC, HBRC


1

3.1 Introduction
An AHU (Air Handling Unit) is a piece of equipment through which air
passes and undergoes different processes in order to deliver air with specific
conditions such as; temperature, pressure, moisture content, size of
suspended particles and dust, air velocity and air quantity.
The AHU has certain components of different arrangement according to the
application in hand. But generally, AHU serves one zone with single or
multiple spaces.
The outer casing may be made of heavy gauge pre-galvanized sheet steel,
folded to form sturdy side, top and bottom panels and a self-supporting
structure. The supply air ducts may either be directly connected to the unit or
may be connected to the unit using a flexible adapter piece, in order to
reduce vibration transmission from AHU to air duct.
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3.2 Specifications
3.2.1 Construction
Table 0-1 AHU Construction options
Type Description Options
1. Frames Frames are made of high quality
extruded aluminum profile. The frame
rigidity is achieved through the use of
unique constructions.


2. Panels Panels utilize corrosion resistance
galvanized steel that is usually available
as double skin panels.

1) Single skin panels
2) Aluminum panels
3) Stainless steel panels
4) epoxy paint for panels
5) Polyester epoxy powder
electrostatic paint oven baked
panels.

3. Base frame Base frame is constructed from steel
channels of heavy gauge galvanized
steel depending on the unit size and the
number of sections the air handling unit
is composed of.
The length and width of the base
frame depends on the unit size
and length.

4. Access
panels and
doors
Double skin door with same panel
construction clamped from the
construction by four bridge clamps to
introduce fully removable access panels
furnished with one or two handles for
easy release. To achieve air tightness,
rubber seal between doors and aluminum
frame is provided
1) Access door with inspection
window
2) Access door with handles and
hinges
3) Access doors with bridge
clamps and hinges
5. Insulation For best thermal and acoustical
performance, panels and frames are
internally insulated with 25 mm thick
injected foam (polyurethane) insulation
with 40-kg/m- density .

1) 25 mm thick fiberglass with
48 kg/m
3
density
2) 50 mm thick fiberglass with
48 kg/m
3
density
3) rubber insulation


3.2.2 Fan section
Fans are used to force the air flow in a determined direction. Fans are either axial
(propeller type, tube axial type and vane axial type), or radial (centrifugal).
Centrifugal fans (forward, backward and airfoil fans) are belt driven, and must be
statically and dynamically balanced.
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Different fan motor arrangements can be provided. Standard fans are forward curved
selected for optimum outlet velocities and low sound levels. They may be supplied with a
flexible connection between the fan discharge
outlet and the unit casing. This will minimize the
vibration and accordingly the sound level and
completely isolate the fan motor assembly from the
rest of the unit structure.
Fan selection depends on the application in hand,
amount of air needed, and noise level limitations.
Options:
1. Inlet guide vanes for backward curved
fans and airfoil fans to control air flow rate
2. Belt guard
3. Wire mesh on the fan inlet





Figure 0-1 Fan section
Fan motor:
The fan motors are mounted on a galvanized steel base which is isolated from the AHU
casing with rubber mounts. Motors with 5.5 kW or less are provided with variable pitch
pulley for the motor and fixed for the fan. Motors are usually Totally Enclosed Fan
Cooled (TEFC).
Options:
1) Explosion proof motors
2) Two speed motors
3) Standby motors with manual or automatic change over
4) Spring vibration isolators
5) Frequency inverters
6) Circuit breaker (loose item)
7) External overload (loose item).


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Table 0-2Fan types
Fan type Curves & Layout Description
1.Forward curved
fan



Runs at a relatively low speed
compared to other types
for the same capacity.
Smaller fan for a
given duty, excellent-for
fan coil units.
2.Radial fan


Self cleaning.
Can be designed for high structural
strength to achieve high speed and
pressures
3.Backward
curved fan




More efficient
Power curve has a flat peak so that the
motor may be sized to
cover the complete
range of operation from
0% to 100% air flow for
a single speed, non-
overloading.
Pressure curve is generally steeper
than that of the forward curved fan. This
results in a smaller change in air volume
for any variation in system pressure for
selections at comparable percentages of
free delivery.
Point of maximum efficiency is to the
right of the pressure peak, allowing
efficient fan selection with a built in
pressure reserve.
Quieter than other types.
3.2.3 Coils
A variety of coils including chilled water, hot water, steam coils and direct expansion
coils are available. Coils are designed to deliver their respective duties at optimum
performance at all design condition. Coils are manufactured from seamless copper tubes,
mechanically expanded into aluminum fins. Coils are usually tested at 3140 kPa air
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pressure in a water bath. They also undergo dry chemical cleaning after coil
manufacturing for optimum system cleanliness. Airtight gaskets are used where coil pipes
exit the unit casing. The sealing around the coil prevents air by pass. Coils are arranged in
staggered or in line form in the direction of airflow. Coils are provided with copper
headers within the coil section. They are provided with a manual air vent accessible from
outside the casing for quick venting.
Coils are available from 1-12 rows for both chilled water and DX- systems and from 1-4
rows for heating coils. Because of the variety of coil input conditions these coils are
selected through a computer selection program to match the required conditions.
Coil circuiting
Water coils can be provided with various types of coil circuiting (half, full and double
circuiting) depending on the water flow rate and water pressure drop inside the coil.
Direct expansion coils are equipped with suitable size distributor to ensure equal
refrigerant fed to all circuits depending on the heat transfer and the refrigerant pressure
drop. Other circuiting types can be made when required.
Coil connection
Coil connections can be provided on either right or left hand side facing air return
Options
1) Copper tube/Copper fin coil
2) Protective coating on coil
3) Various outside pipe diameter
4) Expansion valve for direct expansion coils

Figure 0-2 Coil arrangement
Drain pan
Drain pan is supplied as standard under the cooling coil. Drain pan is made of 1.5 mm
thick painted galvanized steel with a connection from either side. The drain pan is
insulated on the sides and underside to prevent condensation.
Options:
1) Stainless steel drain pan
2) Double wall insulated drain pan
3) Drain pan connection from both sides
6

Figure 0-3 Coil Connections and drain pan
3.2.4 Droplet eliminator
To avoid water carry over at high velocity, it is recommended to use a droplet eliminator
in the unit. Eliminator blades are manufactured from reinforced polypropylene, encased
within a galvanized steel frame, and designed to completely eliminated water carry over
from cooling coils with minimal air pressure drop. In most cases droplet eliminators are
fitted within the cooling coil module, but droplet eliminator could be fitted anywhere
inside the air handling unit if required.

Figure 0-4 Droplet eliminator
3.2.5 Filters
Filters are used for trapping undesired objects that may be sucked in to the AHU. The
nature and size of these objects may vary from relatively large objects such as; plastic
bags, bird feathers, or even whole birds, to relatively small objects such as; specific range
of dust particles size.

The selection of filters depends on indoor air quality required.
Different types of filters and their descriptions are illustrated in the table below.





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Table 0-3 Filter Types
Type Material Comment
Flat filter & V-filter Washable aluminum and
synthetic.
V-type is used when face
velocity is to be reduced.
Bag filter Synthetic media Used when higher level of
filtration is required.
Efficiency reaching 95%.
HEPA filter High efficiency particulate
filters are used when a very
high degree of filtration is
required such as hospitals.
Efficiency reaching 99.99%



Figure 0-5 Air filters
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3.2.6 Mixing Box & Exhaust Box
The mixing box module combines fresh air with the circulated return air from the
conditioned space. A mixing box may be supplied with fresh and return air dampers,
which may or may not be motorized. While the exhaust box function is to exhaust some
of the circulated air and return the rest to the supply air stream.
Certain filters may be included in the mixing box module. Also an economizer section is
optional.

Figure 0-6 Mixing box
Table 0-4 Mixing Box Types
Type Function Contents Options
Mixing box Combines fresh air
with circulated return
air.
Pre-filter and/or
bag filter.
Manual dampers.

Motorized dampers.
Economizer
section.
Insulation.
Exhaust box Exhaust some of the
circulated air and return
the rest to the supply
air stream.

Manual dampers.

3.2.7 Inlet accessories
1. Insect screen.
2. Rail grill.
3. Rain hood.
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3.2.8 Dampers
It is a metallic louver that is mounted on different sections of a duct or AHU and
positioned manually or electrically to control the volume of air flowing through this
section.

Figure 0-7 Dampers
Table 0-5 Damper Material Options
Material options Comment Option
Rigid aluminum
frame with multi airfoil
blades.
Opposed galvanized
steel blades.
To reduce pressure drop and
sound generated when air
passes through the blades.
Driven through geared
linkage with sealed for life
lubrication bearings.
Designed for minimized air
leakage.
They may be linked for
motorized operation.
May be supplied with a
manually adjustable lever
that can be located on either
side of the damper.
3.2.9 Sand trap louver
Heavy gauge galvanized steel with U-shape plates mounted and encased in a galvanized
steel frame. These plates prevent the large particles from entering the AHU with the fresh
air, and thus help in the prolonging filter life and the cleanliness of the air stream.

Figure 0-8 Sand tap louver
3.2.10 Sound attenuators
Sound attenuators can be supplied in the supply and return airside. These attenuators can
be of different lengths depending on the required sound level.
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3.2.11 Heat Recovery sections
This custom module includes an energy recovery device that depends on ambient
conditions, and uses the exhaust air stream to control the entering out door air conditions.
Various types of heat recovery systems are shown in table 3-6.
Table 0-6 Types of Heat Recovery Sections
Type Components Theory of
operation
Uses
Energy wheel.






A rotating
wheel coated
with a special
material suited
for energy
transfer.
The supply air
flows through
one half of the
rotary wheel
and the
exhaust air
flows in the
counter
direction
through the
other half.
Energy wheel
heat
exchangers
are used in
double deck
units.
Cross flow heat exchanger.




Consists of
small,
separated and
sealed
alternating
layers of
plates.
Relies on
thermal
conduction for
energy
recovery. This
type is limited
to sensible
energy
recovery.
Cross flow
heat
exchanger are
used in double
deck units
Run around coils.

Consists of
two finned-
tube coils (air
to water heat
exchanger)
piped
together.
One coil in
the out door
stream and the
other in the
exhaust air
stream.
This type is
limited to
sensible
energy heat
transfer.
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3.2.12 Diffuser plate
This plate is provided when high face velocities exist, especially when final filters are
provided in the AHU. It is made of heavy gauge galvanized steel perforated plate.

Figure 0-9 Diffuser plate
3.2.13 Humidifiers
They are used to increase or control the moisture content of the air. Their types vary
according to each application.
Table 0-7 Humidifiers Theory of Operation
Type Theory of operation Auxiliaries
Electric pan humidifier. Air is humidified by
evaporating water in a
painted galvanized sheet
metal tank using electric
element heater.
The humidifier tank is
provided with a float valve,
drainage output, quick-fill
opening and a water level
switch.
Steam type. By using immersed electrodes, steam cylinder and stainless
steel steam distribution pipe complete with electronic
controls for water level regulation and automatic flushing.
Wetted media type. Water is sprayed over the pad area. Air is humidified and
cooled while passing through the wetted pad media.
Air washer type. Water droplets are
sprayed in the air thus
increasing its moisture
content until saturation
levels if required. The
excess water is
condensed and
collected to be drained
away.
-Bolted galvanized sheet metal
panels internally sealed for water
tightness.
-PVC plates specially shaped to
for droplet eliminators.
-Water sump equipped with the
following openings:-
Drain connection
Supply connection
Suction connection
Overflow
Quick-fill
-Inspection window and access
door.
-Stand pipes with spray nozzles
supplying fine water mist.

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3.3 Specific design criteria for Surgery and Critical Care
No area of the hospital requires more careful control of the aseptic condition of the
environment than does the surgical suite. The systems serving the operating rooms,
including cystoscopic and fracture rooms, require careful design to reduce to a minimum
the concentration of airborne organisms.
The greatest amount of the bacteria found in the operating room comes from the surgical
team and is a result of their activities during surgery. During an operation, most members
of the surgical team are in the vicinity of the operating table, creating the undesirable
situation of concentrating contamination in this highly sensitive area.
3.3.1 Operating Room
Studies of operating room air distribution systems and observation of installations in
industrial clean rooms indicate that delivery of the air from the ceiling, with a downward
movement to several exhaust inlets located on opposite walls, is probably the most
effective air movement pattern for maintaining the concentration of contamination at an
acceptable level. Completely perforated ceilings, partially perforated ceilings, and
ceiling-mounted diffusers have been applied successfully
In the average, hospital operating rooms are in use no more than 8 to 12 h per day
(excepting emergencies). For this reason and for energy conservation, the air-
conditioning system should allow a reduction in the air supplied to some or all of the
operating rooms. However, positive space pressure must be maintained at reduced air
volumes to ensure sterile conditions. Consultation with the hospital surgical staff will
determine the feasibility of providing this feature.
A separate air exhaust system or special vacuum system should be provided for the
removal of anesthetic trace gases. Medical vacuum systems have been used for removal
of nonflammable anesthetic gases. One or more outlets may be located in each operating
room to permit connection of the anesthetic machine scavenger hose. Although good
results have been reported from air disinfection of operating rooms by irradiation, this
method is seldom used. The reluctance to use irradiation may be attributed to the need for
special designs for installation, protective measures for patients and personnel, constant
monitoring of lamp efficiency, and maintenance. The following conditions are
recommended for operating, catheterization, cystoscopic, and fracture rooms:
1. There should be a variable range temperature capability of 20 to 24.5 !C.
2. Relative humidity should be kept between 50 and 60%.
3. Air pressure should be maintained positive with respect to any adjoining rooms by
supplying 15% excess air.
4. Differential pressure indicating device should be installed to permit air pressure
readings in the rooms. Thorough sealing of all wall, ceiling, and floor penetrations and
tight-fitting doors are essential to maintaining readable pressure.
5. Humidity indicator and thermometers should be located for easy observation.
6. Filter efficiencies should be in accordance with Table 3-8.
7. Entire installation should conform to the requirements of NFPA Standard 99,
Health Care Facilities.
8. All air should be supplied at the ceiling and exhausted or returned from at least
two locations near the floor (see Table 3-9 for minimum ventilating rates). Bottom of
exhaust outlets should be at least 3 inches above the floor. Supply diffusers should be of
the unidirectional type. High-induction ceiling or side wall diffusers should be avoided.
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9. Acoustical materials should not be used as duct linings unless 90% efficient
minimum terminal filters are installed downstream of the linings. Internal insulation of
terminal units may be encapsulated with approved materials. Duct-mounted sound traps
should be of the packless type or have polyester film linings over acoustical fill.
10. Any spray-applied insulation and fireproofing should be treated with fungi growth
inhibitor.
11. Sufficient lengths of watertight, drained stainless steel duct should be installed
downstream of humidification equipment to assure complete evaporation of water vapor
before air is discharged into the room.
Control centers that monitor and permit adjustment of temperature, humidity, and air
pressure may be located at the surgical supervisor"s desk.

Table 0-8 Filter Efficiencies for central Ventilation and Air conditioning systems in general hospitals
Minimum
number of
filter beds
Area designation
Filter efficiencies, %
Filter bed
No. 1
a

Filter bed
No. 2
a

Filter bed
No. 3
b

3
Orthopedic operating room
Bone marrow transplant operating
room
Organ transplant operating room
25 90 99.97
c

2
General procedure operating rooms
Delivery rooms
Nurseries
Intensive care units
Patient care rooms
Treatment rooms
Diagnostic and related areas
25 90
1
Laboratories
Sterile storage

1
Food preparation areas
Laundries
Administrative areas
Bulk storage
Soiled holding areas
25

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Table 0-9 General pressure relationships and ventilation of Surgery and critical care areas
Space function Pressure
relationshi
p to
adjacent
areas
Minimum
air change
of outdoor
air per hour
Minimum
total air
change per
hour
All air
exhausted
directly to
outdoors
Air
recirculated
within room
units
Operating room
all outdoor air
system
P 15
C
15

Yes No
Operating room
recirculating air
system
P 5 25 Optional No
Delivery room
all outdoor air
system
P 15 15 Optional No
Delivery room
recirculating air
system
P 5 25 Optional No
Recovery room E 2 6 Optional No
Nursery suite P 5 12 Optional No
Trauma room P 5 12 Optional No
Anesthesia
storage
# Optional 8 Yes No
P = Positive
N = Negative
# = Continuous directional control not required
e

a
Ventilation in accordance with ASHRAE Standard 62-1989, Ventilation for Acceptable
Indoor Air Quality, should be used for areas for which specific ventilation rates are not
given.

b
Total air changes indicated should be either supplied or, where required, exhausted.
c
For operating rooms, 100% outside air should be used only when codes require it and
only if heat recovery devices are used.
d
The term trauma room as used here is the first aid room and/or emergency room used
for general initial treatment of accident victims. The operating room within the trauma
center that is routinely used for emergency surgery should be treated as an operating
room.
e
Although continuous directional control is not required, variations should be minimized,
and in no case should a lack of directional control allow the spread of infection from one
area to another. Boundaries between functional areas (wards or departments) should have
directional control.
3.3.2 Operation theatre air flow
The risk of post operative infection is present in all surgical procedures, but can be
particularly serious in certain operations, for example, joint replacement. The National
Institute of Health (NIH), Office of Research Services, Division of Engineering services,
has conducted an extensive study on the issue of operating room ventilation systems and
their effect on the protection of the surgical site.
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Several factors can affect postoperative infection, including patient factors, surgical field
factors, room factors, and HVAC factors (which is our highlighted concern in this part of
the project).
The literature agrees that the primary source of bacteria that causes infection are skin
scales or particles. These particles are about 10 microns in diameter, and are shed from
exposed regions of skin, both from the surgical staff and by the patient.
Suggested standards exist for air-conditioning systems for operating theatres in different
countries. These standards contain some specific details for the design of the operating
room, such as the supply air flow rate. The actual air to be supplied to the room, however,
is defined using two factors, which require experimental measurement to be determined.
The 1999 ASHRAE Handbook Applications suggests that " the delivery of air from the
ceiling, with a downward movement to several exhaust inlets located on opposite walls,
is probably the most effective air movement pattern for maintaining the concentration at
an acceptable level." The handbook suggests that the temperature range should be
between 16.67!C and 26.67!C, and that positive pressurization should be maintained.
It also suggests that the air should be supplied at the ceiling and exhausted or returned
from at least two locations near the floor. It suggests that supply diffusers should be of
unidirectional type, and that high-induction ceiling or side wall diffusers should be
avoided.

Figure 0-10 Typical Operating Theater Set-Up
Generally, the practice of increasing ACH to high levels results in excellent removal of
particles via ventilation, but does not necessarily mean that the percentage of particles
that strike the surfaces of concern continue to decrease.
In a system that provides a laminar flow regime, a mixture of exhaust location levels
works better than either low or high level locations only. However, the difference is not
significant enough that the low- or high-level location systems are not viable options.
Systems that provide laminar flow regimes represent the best option for an operating
room in terms of contamination control, as they result in the smallest percentage of
particles impacting the surgical site. However, care needs to be taken in the sizing of the
laminar flow array. A face velocity of around 30 to 35 fpm (0.15 to 0.18 m/s) is sufficient
from the laminar diffuser array, provided that the array size itself is set correctly.
To expand on the issue of diffuser array size, it appears that the main factor in the design
of the ventilation system is the control of the central region of the operating room. In
particular, the operating lights and surgical staff represent a large heat density in the
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middle of the room. Particulates could become caught in buoyant plumes created by these
heat-dissipating objects, at which point control of them is lost. However, if a laminar
flow type system is employed, the particles are instead driven by the flow to be
exhausted. Ideally then, the array size should be large enough to cover the main heat
dissipating objects. This is illustrated in Figure 3-11 below.




Figure 0-11 Temperature Distribution inside Operating Theater
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3.3.3 Room pressure for critical environments
The method to achieve directional airflow is via the control of the supply and exhaust
airflows within and adjacent to the concerned room.
3.3.3.1 Room Pressurization Fundamentals
Room pressurization depends on the ability of air to build up within a room. The leakage
into or out of room is a key factor. Chapter 26 of the 2001 ASHRAE Handbook-
Fundamentals presents a leakage function relationship that correlates a room or building
envelope air leakage to the differential pressure producing the flow.
ASHRAE defines the leakage function with the presentation of the $power law equation"
as: Q = C (%P)
n

Where:
Q is the volumetric rate of flow through an orifice.
C is a flow coefficient that depends on the geometry of the orifice. It is empirically
determined using a fan pressurization test, similar to the duct leakage test performed by
air balancers.
P is the pressure differential across the orifice
n is the pressure exponent, commonly around 0.65 per ASHRAE the figure 3-12 below
shows the characteristic &infiltration curve' that represents the power law equation.
Thus, if the gaps around a closed door and gaps to adjacent spaces are modeled as an
orifice and you know:
a) The differential pressure you want to obtain.
b) The geometric coefficient of the gaps.
c) The empirical exponent n, you can calculate the differential airflow.

Figure 0-12 Infiltration Curve (Power Law Equation)
However, what is the required differential pressure and related differential airflow to
contain or keep out contaminants, is our main concern.
3.3.3.2 Recommended Differential Pressure
The Centers for Disease Control"s &Guidelines for Preventing the Transmission of
Mycobacterium Tuberculosis in HealthCare Facilities ' states a minimum differential
pressure %P of 0.249 Pa is required to achieve a directional airflow into or out of a room.
However, this value is challenged as insufficient based on potential thermal stratification
in a room, room supply air diffusion, door swings and eddies.
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3.3.3.3 Recommended Differential Airflow
The American Conference of Governmental Industrial Hygienists (ACGIH) industrial
Ventilation, A Manual of Recommended Practice addresses a quantitative design
differential airflow. It states &the proper flow differential will depend on the physical
condition of the area, but a general guideline would be to set a 5% flow difference but no
less than 50 cfm (24 L/s)'
Standard for Laboratory Ventilation takes a position that controls using room differential
air flow set points are preferred over controls that use room differential pressure. A
suggested 10% offset between the supply and exhaust airflows and notes this value has
no general validity. The text focuses on the containment or exclusion requirements of an
open door versus a closed door and the effect on the overall differential airflow to obtain
a 50 fpm (0.254 m/s) velocity through an open door.
An open door design criteria is impractical considering the volume of the makeup air
through the door. Often, most communicating corridors are egress corridors and for
smoke control purposes, most building codes prohibit the communicating corridor from
providing any significant transfer air to adjacent rooms. Therefore, the high air volume
required to contain or keep out contaminants through an open door would violate the
code.
The use of an air lock is suggested for critical applications, thereby obviating the
potential for a continuous open door path from the room to the communication corridor.
3.3.3.4 Room Pressure for a Protective Environment
The airlock protects a contained area against building pressure fluctuations. In a hospital
patient"s rooms are recommended to have the following; The walls and floor penetrations
are to be sealed to best of general construction standards that can be from excellent to
sufficient. Two access panels, later sealed, penetrate the corridor-to-room wall above the
ceiling. The toilet exhaust should be common to other toilet exhausts. A special sink in
the patient room (not bathroom) had an open gap drain to another space below for
sanitation purposes.
The room supply should be via a pressure independent primary air HEPA filtered fan-
powered series box. The return to the fan-powered box may be in the room. The house
exhaust for the room is served by a pressure independent exhaust box. The supply and
exhaust airflows are to be measured with an air volume hood. The differential pressures
are measured by placing the static probe in the middle of the room, routing the tube
through the door undercut and connecting the probe to the digital manometer out side the
room. An airflow direction indicator should be placed above the entry door to show
whether the room was under positive pressure.
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3.3.3.5 Door Swings and Anterooms
For a positive pressure room it is recommended that the entry doors are to be sealed by a
gasket, with sliding break-away doors. If a standard swing door is used, it is
recommended to swing out of the room for a negative room and swing into the room for a
positive room. This may not always be practical. For example, hospital isolation room
doors that are located off the main corridor cannot swing out into the corridor. In such
cases, it is advised to use an air lock.
An airlock (anteroom) should be used whenever possible. The anteroom traps any
escaped air from a negative room and isolates corridor air from a positive room. Because
the anteroom is a trap, it should incorporate a high air change rate of around 12 ACH or
higher and the differential cfm should be zero or neutral to allow overall desired
directional airflow between the corridor and the concerned room.
3.3.3.6 Comments
Some basic points for designing for proper room pressurization based on differential
airflow settings include:
Seal the room.
Meet or exceed minimum codes for air change rates.
Incorporate industry regulations and practice for minimum air change rates and
room pressure. However, as a minimum, strive for 2.49 Pa to 12.45 Pa differential
pressure.
When designing the HVAC system to obtain the desired room pressurization/directional
air flow for #200 ft
2
(18.58 m
2
) rooms, consider the following points:
Rooms should have a minimum negative or positive pressure of 2.49 Pa where 12.45
Pa or higher is preferred. Codes and industry regulations and practice may dictate specific
limits.
Air balancer specs for positive rooms should be considered.
For negative rooms, the makeup air should be provided via a supply outside the room.
For positive rooms, exfiltration of air should be accommodated by an exhaust outside the
room.
All room penetrations above and below the ceiling and the ductwork should be well
sealed.
The ceiling should be tight as possible, preferably sheetrock or concrete deck.
Specify surface mount or recessed vapor-tight, or non-re turn-air light fixtures.
Each entry door to the room should be sealed on its top and sides (including astragal
vertical joint seal for leaf or double doors) and include an adjustable bottom seal.
A sliding entry door is preferred over a swing door. If a swing door is used, it should
open out of a negative room or open into a positive room.
Anterooms should be used whenever possible with 12 air changes per hour (ACH)
minimum (codes and industry regulations and practice may dictate higher values) and a
neutral pressure where the supply and exhaust airflow quantities are equal.
An airflow direction indicator should be installed to visually see the dynamics of the
room pressurization.
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3.4 Example of Operating Theater Load Estimation
3.4.1 General Zone Data
Typical operating rooms arrangement is shown in appendix D, the largest room was
found to be 52 m
2
area with a ceiling height of 3 m. There are no walls facing outside
areas. The partitions to adjacent operating rooms should represent no load on the air
conditioning facility. While the partitions to corridors and antiseptic storage represent a
load due to temperature variations with respect to the operating room.
Also the ceiling and floor will participate in the load due to difference in temperatures.
Floor area : 52 m
2

Building weight : Medium
Lighting
Fluorescent light : 640 watts
Fixture type : Rec., Not vented
Operating theatre lighting fixture : 100 Watts
Total watts : 740 watts
Wattage Multiplier. : 1.25
Total wattage : 925 watts
Other Electric
Electrocardiogram (monitor) : 130 watts
X-ray screen: 200 Watts
Pulse measuring machine: 160 Watts
Operation spot light: 2500 Watts
Dialysis machine : 480 Watts
Portable sterilization machine : 670 Watts
Ultrasonography: 110 Watts
Computer and monitors for laser and endoscope systems: 325 Watts
DC shock: 200 Watts
Total wattage: 4450 Watts
People
Number of people : 10 people
Activity level : medium work
Sensible gain : 86.5 W/Person
Latent gain : 133.3 W/Person
Miscellaneous loads
Sensible : 1000 Watts
Latent: : 500 Watts
Reheater Power: 8131 Watts

Required room conditions
Dry bulb temperature: 21!C
Relative humidity: 50 %
Weather data
The weather data collected by the meteorological authority in Egypt as shown in
appendix A state that the extreme weather conditions occurs in July with 43.33 !C dry
bulb temperature and a 27.66 % relative humidity with air enthalpy of 83.35 kJ/kg this
condition is extreme in the sense of dry bulb temperature while if revising the July
21
average weather condition it is shown that the air enthalpy is as high as 86.89 kJ/kg. This
leads us to take the July average conditions to run the load calculation on the operating
room.
But as stated in the AIAA paper (AIAA 4199 - 2003), By Dr. E. E. Khalil, the weather
extreme conditions should be modified to 40 !C dry bulb temperature and 50 % relative
humidity, in order to account for global warming as the weather conditions in Cairo
deteriorates each year. Thus we have concluded the recommended weather conditions in
Appendix B.
As such the weather conditions taken in the cooling coil design are;
Dry bulb temperature: 40!C
Relative humidity: 50 %
Air flow rate
As stated before, the dominating factor in the design of Operating rooms air conditioning
is the air quality. The air quality is dominated by the air change per hour. The minimum
air change per hour advised by the ASHRAE is 15 ACH per hour for operating rooms
with all outdoor air. For extra safety we have chosen it to be 25 air changes per hour.
The 25 ACH per hour will lead to an air flow rate of 1.085 m
3
/s.
The air velocity should be kept at the lower boundary in order to avoid water drift with
air flow. The air velocity should be within the range from 1 to 3 m/s.
Refrigerant
Choosing chilled water system for cooling, the chilled water would be the refrigerant.
Refrigerant: Chilled water
Inlet conditions: 6!C
outlet conditions: 12!C
The water velocity inside tubes should be in the range of 0.5 to 1.5 m/s

3.4.2 Room sensible load:
Solar heat gain
There is no solar heat gain through glass or fenestration as there are no exterior walls. As
well there is no solar heat gain through walls . Also assuming there is a conditioned space
above, there would be no solar heat gain through the roof.
22
Transmission gain except walls and roof
The adjacent room air conditions are so close to the inside room conditions and the
variation are so small and could not be computed as the CLTD (cooling load temperature
difference) factor is zero referring to the CARRIER HANDBOOK for load estimation.
Internal heat
People:
7 * 86.5 = 605.5W
Electric equipment:
4450 Watts
Lights:
740 * 1.25 = 925 W
Miscellaneous load
1000 W
Total room sensible heat ( RSH):
RSH = 605.5 + 4450 + 925 + 1000 = 6980.5 W
3.4.3 Room latent load:
Infiltration
The infiltration doesn't exist as the operating theater should be positively pressurized to
maintain higher indoor air quality. That is why the infiltration would not be accounted for
in the room latent load.
People
7 * 133.3 = 933.1 W
Steam and other appliances
There are no appliances that would generate steam or any source of latent load inside the
operating theater.
Miscellaneous load
500 W
Total room latent heat (RLH):
RLH = 933.1 + 500 = 1433.1 W
3.4.4 Room sensible heat factor (RSHF)
RSHF = (6980.5)/(6980.5 + 1433.1) = 0.83
3.4.5 Supply air temperature
But the supply air temperature is constrained by the following equation:
air p air
t C V RSH


thus the supply air temperature would be,
tc = tr
02 . 1 085 . 1 2 . 1
5 . 6980

p air
C V
RSH

= 21-5.25 = 15.74 !C

3.4.6 Psychrometric Processes

23
Figure 0-13 Psychrometric Represaentation of Load Estimation
Investigating the psychrometric chart shown in figure 3-13, we have found the following:
Air mass flow rate 1.3 kg/s
On coil conditions: 40 !C dbt and 50 % RH.
Off coil conditions: 9.41 !C dbt and 99.41 % RH.
3.4.7 Results
Room effect
Supply air conditions: 15.56 !C dbt and 66.37 % relative humidity.
Room air conditions: 21 !C dbt and 50% relative humidity.
Room sensible heat: 6.98 kW.
Room latent heat: 1.433 kW.
Air conditioning apparatus
Total cooling capacity: 92kW.
Moisture removal: 20.4 g/s.
On coil air conditions: 40!C dbt and 50% relative humidity.
Off coil air conditions: 9.3!C dbt and 99.4% relative humidity.

24

3.4.8 Computer assisted load estimation programs:


Using Carrier load estimation program, the E20.II as shown in appendix C, the load came
to be about 93 kW and the leaving dry bulb, wet bulb was 9.3/9.3 !C. While when using
advanced versions of load estimation programs the load was 94 kW and the dry bulb/wet
bulb temperatures were 9.9/9.9 !C, when a return air plenum was installed. When using
the same advanced software but without the installation of a return air plenum the load
calculated was 109.6 kW and the dry bulb/wet bulb temperatures were 9.9/9.9 !C, as
shown in appendix D and E.
The existence of return air plenum reduces the coil load greatly as the return air is not
exhausted directly to the atmosphere, but rather passed through a space above the
conditioned room to remove first some of the load. When the air passes through the
return air plenum it carries some of the lighting load (in case of recessed not vented
fixtures), as well as part of the external load.
25
3.5 Example of Cooling Coil Design
3.5.1 Theoretical background
The cooling coil is the major part of the air handling unit as it is responsible of cooling
air. When we talk about air treatment we happen to stress more on the cooling coil and
methods of reducing the air's temperature due to the nature of the region we are living in.

The majority of the equipment used today for cooling and dehumidifying an airstream
under forced convection incorporates a coil section that contains one or more cooling
coils assembled in a coil bank arrangement. Such coil sections are used extensively as
components in room terminal units; larger factory-assembled, self-contained air
conditioners; central station air handlers; and field built-up systems. The applications of
each type of coil are limited to the field within which the coil is rated. Other limitations
are imposed by code requirements, proper choice of materials for the fluids used, the
configuration of the air handler, and economic analysis of the possible alternatives for
each installation.
3.5.1.1 Coil Construction and Arrangement
In finned coils, the external surface of the tubes is the primary surface, and the fin surface
is the secondary surface. The primary surface generally consists of rows of round tubes or
pipes that may be staggered or placed in line with respect to the airflow. Flattened tubes
or tubes with other nonround internal passageways are sometimes used. The inside
surface of the tubes is usually smooth and plain, but some coil designs have various
forms of internal fins or turbulence promoters to enhance performance. The individual
tube passes in a coil are usually interconnected by return bends to form the serpentine
arrangement of multipass tube circuits. Coils are usually available with different circuit
arrangements and combinations offering varying numbers of parallel water flow passes
within the tube core as shown in Figure 3-14.
Cooling coils of water, aqueous glycol, brine, or halocarbon refrigerants usually have
aluminum fins on copper tubes, although copper fins on copper tubes and aluminum fins
on aluminum tubes (excluding water) are also used. Adhesives are sometimes used to
bond header connections, return bends, and fin-tube joints, particularly for aluminum-to-
aluminum joints. Certain special-application coils feature an all-aluminum extruded tube-
and-fin surface.
Common core tubes outside diameters are 5/16, 3/8, 1/2, 5/8, 3/4, and 1 inch, with fins
spaced 4 to 18 per inch. Tube spacing ranges from 0.6 to 3.0 inch on equilateral
(staggered) or rectangular (in line) centers, depending on the width of individual fins and
on other performance considerations. Fins should be spaced according to the job to be
performed, with special attention given to air friction; possibility of lint accumulation;
and frost accumulation, especially at lower temperatures.
Tube wall thickness and the required use of alloys other than copper are determined
mainly by the coil"s working pressure and safety factor for hydrostatic pressure. Fin-type
and header construction also play a large part in this determination.
3.5.1.2 Water Coils
Good performance of water-type coils requires both the elimination of all air and water
traps within the water circuit and the proper distribution of water. Unless properly vented,
air may accumulate in the coil tube circuits, reducing thermal performance and possibly
causing noise or vibration in the piping system. Air vent and drain connections are
26
usually provided on the coil water headers, but this does not eliminate the need to install,
operate, and maintain the coil tube core in a level position. Individual coil vents and drain
plugs are often incorporated on the headers (Figure 3-14).

Figure 0-14 Typical water circuit arrangement
Depending on performance requirements, the water velocity inside the tubes usually
ranges from approximately 0.3 to 2.5 m/s, and the design water pressure drop across the
coils varies from about 1.5 to 15 m of water head.
The core tubes of properly designed and installed coils should feature circuits that
1. Have equally developed line length;
2. Are self-draining by means of gravity during the coil"s off cycle;
3. Have the minimum pressure drop to aid in water distribution from the supply
header without requiring an excessive pumping head;
4. Have equal feed and return by the supply and return header. Design for the proper
in-tube water velocity determines the circuitry style required.
Multirow coils are usually circuited to the cross-counterflow arrangement and oriented
for top-outlet/ bottom-feed connection.
3.5.1.3 Flow Arrangement
In the air-conditioning process, the relation of the fluid flow arrangement within the coil
tubes to the coil depth greatly influences the performance of the heat transfer surface.
Generally, air-cooling and dehumidifying coils are multirow and circuited for
counterflow arrangement. The inlet air is applied at right angles to the coil "s tube face
(coil height), which is also at the coil "s outlet header location. The air exits at the
opposite face (side) of the coil where the corresponding inlet header is located.
Counterflow can produce the highest possible heat exchange within the shortest possible
(coil row) depth because it has the closest temperature relationships between tube fluid
and air at each side of the coil.
3.5.1.4 Applications
Figure 0-15 shows a typical arrangement of coils in a field built-up central station system.
All air should be filtered to prevent dirt, insects, and foreign matter from accumulating on
the coils. The cooling coil (and humidifier, when used) should include a drain pan under
27
each coil to catch the condensate formed during the cooling cycle (and the excess water
from the humidifier). The drain connection should be on the downstream side of the coils,
be of sufficient size, have accessible cleanouts, and discharge to an indirect waste or
storm sewer. The drain also requires a deep-seal trap so that no sewer gas can enter the
system. Precautions must be taken if there is a possibility that the drain might freeze. The
drain pan, unit casing, and water piping should be insulated to prevent sweating.
Factory-assembled central station air handlers incorporate most of the design features
outlined for field built-up systems. These packaged units can generally accommodate
various sizes, types, and row depths of cooling and heating coils to meet most job
requirements. This usually eliminates the need for field built-up central systems, except
on very large jobs.



Figure 0-15 Cooling Coil assembly inside Typical Application
The design features of the coil (fin spacing, tube spacing, face height, type of fins),
together with the amount of moisture on the coil and the degree of surface cleanliness,
determines the air velocity.

Generally, condensate water begins to be blown off a plate fin coil face at air velocities
above 3 m/s. Water blow-off from the coils into air ductwork external to the air-
conditioning unit should be prevented. However, water blow-off from the coils is not
usually a problem if coil fin heights are limited to 1.1 m. and the unit is set up to catch
and dispose of the condensate. When a number of coils are stacked one above another,
the condensate is carried into the airstream as it drips from one coil to the next. A
downstream eliminator section could prevent this, but an intermediate drain pan and/or
condensate trough to collect the condensate and conduct it directly to the main drain pan
is preferred. Extending downstream of the coil, each drain pan length should be at least
one-half the coil height, and somewhat greater when coil airflow face velocities and/or
humidity levels are higher.
When water is likely to carry over from the air-conditioning unit into external air
ductwork, and no other means of prevention is provided, eliminator plates should be
installed on the downstream side of the coils.
28
Air-cooling and dehumidifying coil frames, as well as all drain pans and troughs, should
be of an acceptable corrosion-resistant material suitable for the system and its expected
useful service life. The air handler"s coil section enclosure should be corrosion-resistant;
be properly double-wall insulated; and have adequate access doors for changing air
filters, cleaning coils, adjusting flow control valves, and maintaining motors.
3.5.1.5 COIL SELECTION
When selecting a coil, the following factors should be considered:
Job requirements; cooling, dehumidifying, and the capacity required to properly
balance with other system components
Temperature conditions of entering air
Available cooling media and operating temperatures
Space and dimensional limitations
Air and cooling fluid quantities, including distribution and limitations
Allowable frictional resistances in air circuit (including coils)
Allowable frictional resistances in cooling media piping system (including coils)
Characteristics of individual coil designs and circuitry possibilities
Individual installation requirements such as type of automatic control to be used;
presence of corrosive atmosphere; design pressures; and durability of tube, fins, and
frame material.
Air quantity is affected by such factors as design parameters, codes, space, and
equipment. The resistance through the air circuit influences the fan power and speed.
This resistance may be limited to allow the use of a given size fan motor, to keep the
operating expense low, or because of sound level requirements. The air friction loss
across the cooling coil; in summation with other series air pressure drops for such
elements as air filters, water sprays, heating coils, air grilles, and ductwork; determines
the static pressure requirement for the complete airway system. The static pressure
requirement is used in selecting the fans and drives to obtain the design air quantity under
operating conditions.
The conditioned air face velocity is determined by economic evaluation of initial and
operating costs for the complete installation as influenced by
1. Heat transfer performance of the specific coil surface type for various
combinations of face areas and row depths as a function of the air velocity;
2. Air-side frictional resistance for the complete air circuit (including coils), which
affects fan size, power, and sound-level requirements;
3. Condensate water carryover considerations.
The allowable friction through the water or brine coil circuitry may be dictated by the
head available from a given size pump and pump motor, as well as the same economic
factors governing the air side made applicable to the water side. Additionally, the adverse
effect of high cooling water velocities on erosion-corrosion of tube walls is a major factor
in sizing and circuitry to keep tube velocity below the recommended maximums. On
larger coils, water pressure drop limits of 4.5 to 6 m water usually keep such velocities
within acceptable limits of 0.183 to 0.366 m/s, depending on circuitry design.
Coil ratings are based on a uniform velocity. Design interference with uniform airflow
through the coil makes predicting coil performance difficult as well as inaccurate. Such
airflow interference may be caused by the entrance of air at odd angles or by the
inadvertent blocking of a portion of the coil face. To obtain rated performance, the
29
volumetric airflow quantity must be adjusted on the job to correspond to that at which the
coil was rated and must be kept at that value.
In the case of dehumidifying coils, it is important that the proper amount of surface area
be installed to obtain the ratio of air-side sensible-to-total heat required for maintaining
the air dry-bulb and wet-bulb temperatures in the conditioned space. This is an important
consideration when preconditioning is done by reheat arrangement.
The same room air conditions can be maintained with different air quantities (including
outside and return air) through a coil. However, for a given total air quantity with fixed
percentages of outside and return air, there is only one set of air conditions leaving the
coil that will precisely maintain the room design air conditions. Once the air quantity and
leaving air conditions at the coil have been selected, there is usually only one
combination of face area, row depth, and air face velocity for a given coil surface that
will precisely maintain the required room ambient conditions. Therefore, in making final
coil selections it is necessary to recheck the initial selection to ensure that the leaving air
conditions, as calculated by a coil selection computer program or other procedure, will
match those determined from the cooling load estimate.
Coil ratings and selections can be obtained from manufacturers" catalogs. Most catalogs
contain extensive tables giving the performance of coils at various air and water
velocities and entering humidity and temperatures. Most manufacturers provide
computerized coil selection programs to potential customers. The final choice can then be
made based on system performance and economic requirements.

3.5.1.6 AIRFLOW RESISTANCE
A cooling coil"s airflow resistance (air friction) depends on the tube pattern and fin
geometry (tube size and spacing, fin configuration, and number of in-line or staggered
rows), the coil face velocity, and the amount of moisture on the coil. The coil air friction
may also be affected by the degree of aerodynamic cleanliness of the coil core; burrs on
fin edges may increase coil friction and increase the tendency to pocket dirt or lint on the
faces. A completely dry coil, removing only sensible heat, offers approximately one-third
less resistance to airflow than a dehumidifying coil removing both sensible and latent
heat.
For a given surface and airflow, an increase in the number of rows or number of fins
increases the airflow resistance. Therefore, the final selection involves the economic
balancing of the initial cost of the coil against the operating costs of the coil geometry
combinations available to adequately meet the performance requirements.
The aluminum fin surfaces of new dehumidifying coils tend to inhibit condensate
sheeting action until they have aged for a year. Recently developed hydrophilic
aluminum fin surface coatings reduce the water droplet surface tension, producing a more
evenly dispersed wetted surface action at initial start-up. Manufacturers have tried
different methods of applying such coatings, including dipping the coil into a tank,
coating the fin stock material, or subjecting the material to a chemical etching process.
Tests have shown as much as a 30% reduction in air pressure drop across a hydrophilic
coil as opposed a new untreated coil.
3.5.1.7 HEAT TRANSFER
The heat transmission rate of air passing over a clean tube (with or without extended
surface) to a fluid flowing within it is impeded principally by three thermal resistances.
30
The first, from the air to the surface of the exterior fin and tube assembly, is known as the
surface air-side film thermal resistance. The second is the metal thermal resistance to the
conductance of heat through the exterior fin and tube assembly. The third is the in-tube
fluid-side film thermal resistance, which impedes the flow of heat between the internal
surface of the metal and the fluid flowing within the tube. For some applications, an
additional thermal resistance is factored in to account for external and/or internal surface
fouling. Usually, the combination of the metal and tube-side film resistance is
considerably lower than the air-side surface resistance.
For a reduction in thermal resistance, the fin surface is fabricated with die-formed
corrugations instead of the traditional flat design. At low airflows or wide fin spacing, the
air-side transfer coefficient is virtually the same for flat and corrugated fins. Under
normal comfort conditioning operation, the corrugated fin surface is designed to reduce
the boundary air film thickness by undulation of the passing airstream within the coil; this
produces a marked improvement in heat transfer without much airflow penalty. Further
fin enhancements, including the louvered and lanced fin designs, have been driven by the
desire to duplicate throughout the coil depth the thin boundary air film characteristic of
the fin"s leading edge. Louvered fin design maximizes the number of fin surface leading
edges throughout the entire secondary surface area and increases the external secondary
surface area, as through the multiplicity of edges.
The transfer of heat between the cooling medium and the airstream across a coil is
influenced by the following variables:
) Temperature difference between fluids
) Design and surface arrangement of the coil
) Velocity and character of the airstream
) Velocity and character of the in-tube coolant
With water coils, only the water temperature rises. With coils of volatile refrigerants, an
appreciable pressure drop and a corresponding change in evaporating temperature
through the refrigerant circuit often occur. The rating of direct-expansion coils is further
complicated by the refrigerant evaporating in part of the circuit and superheating in the
remainder.
31
3.5.1.8 PERFORMANCE OF SENSIBLE COOLING COILS
The performance of sensible cooling coils depends on the following factors.
1. The overall coefficient U
o
of sensible heat transfer between airstream and
coolant fluid
2. The mean temperature difference *t
m
between airstream and coolant fluid
3. The physical dimensions of and data for the coil (such as coil face area A
face

and total external surface area A
o
) with characteristics of the heat transfer surface
The sensible heat cooling capacity q
s
of a given coil is expressed by the following
equation:
q
s
= U
o
F
s
A
face
N
r
*t
m
(1a)
with
Fs = A
o
/(A
face
* N
r
) (1b)
Assuming no irrelevant heat losses, the same amount of sensible heat is lost from the
airstream:
) (
1 a ao pair air s
t t C m q

(2a)
with
o
air face face air
A V m * *

(2b)
The same amount of sensible heat is absorbed by the coolant; for a nonvolatile type, it is
) ( *
in r out r water water
t t C m qs

(3)
For a nonvolatile coolant in thermal counterflow with the air, the mean temperature
difference in Equation (1a) is expressed as

,
_

in r a
out r ao
in r a out r ao
m
t t
t t
t t t t
t
1
1
(
ln
) ( ) (
(4)
These calculations are based on various assumptions; among them that U for the total
external surface is constant. While this assumption is generally not valid for multirow
coils, the use of cross-flow temperature differences is preferable to Equation (4), which
applies only to counterflow. However, the use of the log mean temperature difference is
widespread.
The overall heat transfer coefficient U
o
for a given coil design, whether bare-pipe or
finned-type, with clean, non-fouled surfaces, consists of the combined effect of three
individual heat transfer coefficients:
1. The film coefficient h
c
of sensible heat transfer between air and the external surface of
the coil
2. The unit conductance 1/R
md
of the coil material (i.e., tube wall, fins, etc.)
3. The film coefficient h
r
of heat transfer between the internal coil surface and the coolant
fluid within the coil.
For a bare-pipe coil, the overall coefficient of heat transfer for sensible cooling (without
dehumidification) can be expressed by a simplified basic equation:
) / ( 2 / ) ( ) / 1 (
1
r oi i o c
o
h A k D D h
U
+ +
(5a)
When pipe or tube walls are thin and made of material with high conductivity (as in
typical heating and cooling coils), the term (D
o
- D
i
)/2k in Equation (5a) frequently
becomes negligible and is generally disregarded. (This effect in typical bare-pipe cooling
32
coils seldom exceeds 1 to 2% of the overall coefficient.) Thus, the overall coefficient for
bare pipe in its simplest form is
) / ( ) / 1 (
1
r oi c
h A h
Uo
+
(5b)
For finned coils, the equation for the overall coefficient of heat transfer can be written
) / ( ) / 1 (
1
r oi c
h A h
Uo
+

(5c)
Where the fin effectiveness + allows for the resistance to heat flow encountered in the
fins. It is defined as
o p s
A A EA / ) ( + (6)
Where E is the fin efficiency.
For typical cooling surface designs, the surface ratio A
oi
ranges from about 1.03 to 1.15
for bare pipe coils and from 10 to 30 for finned coils.
Estimation of the air-side heat transfer coefficient h
c
is more difficult because well-
verified general predictive techniques are not available. Hence, direct use of experimental
data is usually necessary.
With a given design and arrangement of heat transfer surface used as cooling coil core
material for which basic physical and heat transfer data are available to determine U
o

from Equation (5a), Equation (5b), and Equation (5c), the selection, sizing, and
performance calculation of sensible cooling coils for a particular application generally
reduces to the heat transfer surface area A
o
or the coil row depth N
r
for a specific coil size
is required and initially unknown. The sensible cooling capacity q
s
, flow rates for both
the air and the coolant, entrance and exit temperatures of both fluids, and mean
temperature difference between fluids are initially known or can be assumed or
determined from Equation (2a), Equation (3), and Equation (4). The required surface area
A
o
or coil row depth N
r
can then be calculated directly from Equation (1a).
3.5.1.9 PERFORMANCE OF DEHUMIDIFYING COILS
A dehumidifying coil normally removes both moisture and sensible heat from entering
air. In most air conditioning processes, the air to be cooled is a mixture of water vapor
and dry air gases. Both lose sensible heat when in contact with a surface cooler than the
air. The removal of latent heat through condensation occurs only on the portions of the
coil where the surface temperature is lower than the dew point of the air passing over it.
As the leaving dry-bulb temperature is lowered below the entering dew-point
temperature, the difference between the leaving dry-bulb temperature and the leaving
dew point for a given coil, airflow, and entering air condition is lowered.
When the coil starts to remove moisture, the cooling surfaces carry both the sensible and
latent heat load. As the air approaches saturation, each degree of sensible cooling is
nearly matched by a corresponding degree of dew-point decrease. The latent heat
removal per degree of dew-point change is considerably greater.
The potential or driving force for transferring total heat q
t
from the airstream to the tube-
side coolant is composed of two components in series heat flow:
(1) An air-to-surface air enthalpy difference (h
a
- h
i
)
(2) A surface-to-coolant temperature difference (t
i
- t
r
).
Figure 3-16 is a typical thermal diagram for a coil in which the air and a nonvolatile
coolant are arranged in counterflow. The top and bottom lines in the diagram indicate,
33
respectively, changes across the coil in the airstream enthalpy h
a
and the coolant
temperature t
r
. To illustrate continuity, the single middle line in Figure 3-16 represents
both surface temperature t
i
and the corresponding saturated air enthalpy h
i
, although the
temperature and air enthalpy scales do not actually coincide as shown. The differential
surface area dA
w
represents any specific location within the coil thermal diagram where
operating conditions are such that the air-surface interface temperature t
i
is lower than the
local air dew-point temperature. Under these conditions, both sensible heat and latent
heat are removed from the airstream, and the cooler surface actively condenses water
vapor.

Figure 0-16 Two-component Driving Force Between Dehumidifying Air and Coolant
Neglecting the enthalpy of the condensed water vapor leaving the surface and any
radiation and convection losses, the total heat lost from the airstream in flowing over dA
w

is
a air t
dh m dq *

(7)
This same total heat is transferred from the airstream to the surface interface through both
sensible and latent processes.
) ( * *
i a o c s
t t dA h dq
fg cond l
h dm dq *
.

) ( * *
. i a o D cond
dA h dm
fg i a o D i a o c t
h dA h t t dA h dq * )) ( * * ( ) ( * * + (8)
but for a Lewis number of unity the following is valid
) _ (
/
air wet p c D
C h h
and moist air enthalpy could be calculated as follows
)) ( * ) _ ( ( * * ti ta vapor water Cp hfg a ta Cp h
a
+ +
) _ (
* * ) (
air wet p
c o i a
t
C
h dA h h
dq

(9)
hi
ti
hi
ti
hi
34
The total heat transferred from the air-surface interface across the surface elements and
into the coolant is equal to that given in Equation (7) and Equation (9):
) ( * *
r i i r t
t t dA h dq (10)

The same quantity of total heat is also gained by the chilled water in passing across dA
w

) ( *
r water water t
dt C m dq

(11)
If Equation (9) and Equation (10) are equated and the terms rearranged, an expression for
the coil characteristic R
cf
is obtained:
i a
r i
i r p
o c
cf
h h
t t
dA h C
dA h
R

(12)
Equation (12) shows the basic relationship of the two components of the driving force
between air and coolant in terms of two principal heat transfer coefficients. For a given
coil, these tow heat transfer coefficient of air, and combined metal in-tube fluid can be
determined for the particular application, which gives a fixed value for R
cf
. Equation (12)
can then be used to determine point conditions for the interrelated values of airstream"s
enthalpy h
a
coolant temperature t
r
; surface temperature t
i
and the enthalpy h
i
of saturated
air corresponding to the surface temperature. When both t
i
and h
i
are unknown, a trial-
and-error solution is necessary.
Figure 3-17 shows a typical thermal diagram for a portion of the coil surface when it is
operating dry. The illustration is for counter flow with chilled water as a refrigerant. The
diagram at the top of the figure 3-17 illustrates a typical coil installation in an air duct
with tube passes circuited countercurrent to airflow. Locations of the entering and leaving
boundary conditions for both air and coolant are shown.
The thermal diagram in Figure 3-17 is of the same type as that in Figure 3-16, showing
three lines to illustrate local conditions for the air, surface, and coolant throughout a coil.
The dry-wet boundary conditions are located where the coil surface temperature t
ib
equals
the entering air dew-point temperature dpt
o
; Thus, the surface area A
d
to the left of this
boundary is dry, with the remainder A
w
of the coil surface area operating wet.
When using fluids or halocarbon refrigerants in a thermal counter flow arrangement as
illustrated in Figure 3-17, the dry-wet boundary conditions can be determined from the
following relationships:
water water
air
a ao
in r out r
C m
m
h h
t t
y

1
(13)
y R
h R h y t dpt
h
cf
Dpt cf ao rout o
ab
o
+
+ +
(14)
35

Figure 0-17 Thermal Diagram for General Case When Coil Surface Operates Partially Dry

The value of h
ab
from Equation (14) serves as an index of whether the coil surface is
operating fully wetted, partially dry, or completely dry, according to the following three
limits:
If h
ab
, h
ao
the surface is fully wetted.
If h
ao
> h
ab
> h
a1
, the surface is partially dry.
If h
ab
- h
a1
, the surface is completely dry.
Other dry-wet boundary properties are then determined:
o ib
Dpt t (15)
p ab ao ao ab
c h h t t / ) ( (16)
) (
ab ao p rout rb
t t c y t t (17)
The dry surface area A
d
required and capacity q
td
are calculated by conventional sensible
heat transfer relationships, as stated before in section 6.5.1.8.
) / ( ) / 1 (
1
r oi c
h A h
Uo
+

(18)
With
o p s
A A EA / ) ( + (19)
The mean difference between air dry bulb temperature and coolant temperature, using
symbols from Figure 3-18, is

( ) ( )
( ) ( ) [ ]
rb ab ro ao
rb ab a ao
m
t t t t
t t t t
t



/ ln
1
(20)
36

The dry surface area required is

m o
td
d
t U
q
A

(21)
The air-side total heat capacity is
( )
ab ao p
a
td
t t c m q

(22a)
From the coolant side,
( )
rb rout water
water
td
t t c m q

(22b)
The wet surface area A
w
and capacity q
tw
are determined by the following relationships,
using terminology in Figure 3-18.
The air-side total heat capacity is
( ) [ ]
fw a ao
a
tw
h h h m q +

1
(23a)
The enthalpy h
fw
of condensate removed is
( )
2 2 1 a pw fw
t c h (23b)
Note that h
fw
for normal air-conditioning applications is about 0.5% of the air stream
enthalpy difference (h
ao
. h
a1
) and is usually neglected.
The coolant-side heat capacity is
( )
rin rb r
water
tw
t t c m q

(23c)

Figure 0-18 Thermal Diagram for General Case When Coil Surface Operates Partially Dry
The coil surface is divided into n segments, which results into ( n + 1 ) station. The heat
transfer through each element can be described as follows:
1
1
1
1
1
]
1

,
_

+
+

,
_

+

+ +
+ +

+
p
j i j i j a j a
j j c j a j a air i i
C
h h h h
A h h h m q
2 2
* ) (
) 1 ( , , ) 1 ( , ,
1 ) 1 ( , , 1
(24)
For each element, we may assume constant heat transfer rate which is equal to the total
heat transfer rate divided by the number of elements. This assumption will allow us to
1 2
3
3 4 n
n+1
Condensate
Air
flow
Chilled
water flow
Surface
temperature
ti
37
calculate the air enthalpy, refrigerant temperature, surface temperature, and enthalpy of
air at surface temperature.
Thus the element area can be calculated as:
Cp
h h h h
h
h h m
A
j i j i j a j a
c
j a j a air
j j
/
2 2
*
) (
) 1 ( , , ) 1 ( , ,
) 1 ( , ,
1

,
_

,
_

,
_

+ +
+

+
(25)
then the total required outside surface area required is

The total surface area requirement of the coil is
A
o
= A
d
+A
w
. (26)
The total heat capacity for the coil is
q
t
= q
td
+ q
tw
(27)
Now it is required to check the value of the off coil dry bulb temperature, this is done
using the following relations:

,
_

+ +
+ +

+
2 2
* * ) ( * *
) 1 ( , , ) 1 ( , ,
1 ) 1 ( , , 1 ,
j i j i j a j a
j j c j a j a p air j j s
t t t t
A h t t C m q (28)
thus the dry bulb temperature is calculated at each station until we reach the final stage.
The exit dry bulb temperature should satisfy the required design, if not some of the
assumed parameters during design which would affect the convection heat transfer
coefficients and the surface temperature.
3.5.2 Cooling coil design strategy:
The cooling coil design should be designed based on the following conditions:
1. Air inlet conditions.
2. Air outlet conditions.
3. Air flow rate.
The available data for the Operating theater were:
1. Air inlet conditions.
Dry bulb temperature: 40 !C.
Relative Humidity : 50 %
2. Air outlet conditions.
Dry bulb temperature: 9.3 !C.
Relative Humidity : 99.41 %
3. Air flow rate.
1.085 m
3
/s.

Now we have to choose the coil configuration from the manufacturer data which are
summarized in Table 3-10 and attached figure 3-19.
Table 0-10 Surface Area Data
Data Surface 1 Surface 2
Dimensions, (nomenclature according to figure 3-19)
A, tube outside diameter, mm 10.2108 17.1704
B, tube spacing across face, mm 25.4 381
C, tube spacing between rows, mm 22 44.45
1 +

j j o
A A
38
D, spacing of fins, center to center, mm 3.175 3.2766
E, thickness of aluminum fins,mm 0.3302 0.4064
Flow passage hydraulic diameter, 4r
h
(D
h
) 0.302768 0.322072
Area Data
F
s
, External surface area /(Face area) (No. of rows) 12.92 22.86
A
oi,
, ratio of external surface area to the internal surface area 12.27 19.31
A
nff
, net flow area per face area 0.534 0.497
A
fo
, Fin surface area per external surface area 0.839 0.905




Figure 0-19 Correlated external surface heat transfer data for surfaces of table 3-10

From the chosen configuration we can get:
1. The ratio between external surface area and internal surface area (Ao/Ai).
2. The ratio between external surface area and face area per row (Ao/A
f
N
r
).
3. Tube spacing and dimensions.
Design procedure:
1. Assume face velocity to be 1.5 m/s.
Face area = (Air flow rate / face velocity ).
From face velocity and geometry of the coil with air properties at inlet conditions we can
use the Colburn J factor to calculate the outside heat transfer coefficient.
2. Assume water inlet and outlet temperatures,
Water flow rate = ( Q / (C
p,w
(t
out
t
in
)).
Assuming water velocity inside tubes to be 1 m/s, and knowing the dimensions we may
calculate the water side heat transfer coefficient using empirical formulae.
39
Now that we have calculated the inside and outside heat transfer coefficient we can
calculate the coil factor.
Dividing the coil into some twenty elements we can calculate each element's area
assuming each element to have the same capacity.


Station ha
(kJ/kg)
ti (!C) hi
(kJ/kg)
Element ha avg hi avg
(kJ/kg)
ti avg
(!C)
Dbt
(!C)
1 101 ** ** -------- ** ** ** **
2 1-2
.


20 19-20 Outlet


After calculating the outlet air conditions we have to verify that it coincide the required
outlet conditions. If not we have to change some of the assumed values like the inlet and
outlet water temperatures or water velocity inside tubes and repeat until we get the
required outlet conditions.
40
3.5.3 Developed code for coil design
{log J_colburn factor = -0.3559192 * log (Re E-3) - 2.06083}
J_c = 10^((-0.3559192 * Log10(Re_a/1000)) - 2.06083)

{inlet air data = 40 oC dbt with 50 % relative humidity.}
{outlet air data = 8.8 oC dbt with 94 % relative humidity. }
{air flow rate = 1.085 m3/s}

vel_fair = 2
Vdot_air = 1.085

T_o=40
P_=101.325
R_o = 0.5
T_R = 21
R_R = 0.5
T_1 =9.3
R_1 = 1
{assumptions}
t_rin = 6
t_rout = 12
v_water = 1
{air properties}
v_R=volume(AirH2O,T=T_R ,P=P_,R=R_R )
miu_o=VISCOSITY(AirH2O,T=T_o,P=P_,R=R_o)
miu_1 = VISCOSITY(AirH2O,T=T_1,P=P_,R=R_1 )
miu_avg = (miu_o+miu_1)/2
Cp_o = CP(AirH2O,T=T_o,P=P_,R=R_o)
Cp_1 = CP(AirH2O,T=T_1,P=P_,R=R_1)
Cp_avg = (Cp_o+Cp_1)/2
k_o = CONDUCTIVITY(AirH2O,T=T_o,P=P_,R=R_o)
k_1 = CONDUCTIVITY(AirH2O,T=T_1,P=P_,R=R_1 )
k_avg = (k_o+k_1)/2
h_o = ENTHALPY(AirH2O,T=T_o,P=P_,R=R_o)
h_1 = ENTHALPY(AirH2O,T=T_1,P=P_,R=R_1)

mdot_air =Vdot_air /v_R
A_face=Vdot_air/vel_fair
Q_cc = mdot_air *(h_o-h_1)
{G = mass velocity }
G =mdot_air /A_nff/A_face
Re_a=D_h*G/miu_avg
Pr = (miu_avg*Cp_avg*1000/K_avg)
St = J_c/(Pr^(2/3))
{h_c = convection heat transfer coefficient}
h_c = St*G*Cp_avg*1000

t_ravg = (t_rin+t_rout)/2
mdot_water = Q_cc /4.18/(t_rout-t_rin)
roh_ravg = DENSITY(Water,T=t_ravg,P=200)
miu_water = VISCOSITY(Water,T=t_ravg,P=200)
Re_w = roh_ravg*v_water*D_i/miu_water
Pr_w = PRANDTL(Water,T=t_ravg,P=200)
k_f = CONDUCTIVITY(Water,T=t_ravg,P=200)
Nu_D = 0.023*(Re_w^(4/5))*(Pr_w^0.4)
h_r = Nu_D*K_f/D_i
41
{R_cf = Coil factor }
R_cf = h_c*(A_oi)/h_r/Cp_avg

y = (t_rout-t_rin)/(h_o-h_1)
dpt_o = DEWPOINT(AirH2O,T=T_o,P=P_,R=R_o)
hi_dpto =ENTHALPY(AirH2O,T=dpt_o,P=P_,R=1)
h_ab=(dpt_o-t_rout+y*h_o+R_cf * hi_dpto)/(R_cf+y)

{n = no. of stations
x = specific heat transfer through each element.}
n=50
x=(h_o-h_1)/(n-1)
h_a[1]=h_o
DUPLICATE j=2,n
h_a[j]=h_a[j-1] - x
END
t_r[1] = t_rout

DUPLICATE j=2,n
t_r[j]=t_r[j-1] - (x/4.18/mdot_water *mdot_air)
END

DUPLICATE j=1,n
h_i[j] = 9.3625+1.7861*(t_i[j])+0.01135*(t_i[j])^2+0.00098855*(t_i[j])^3
(t_i[j]/R_cf)-(t_r[j]/R_cf)-h_a[j]+h_i[j]=0
END

DUPLICATE j=2,n
mdot_air*(h_a[j-1]-h_a[j])=h_c*A_[j]/(Cp_avg*1000)*((h_a[j-1]+h_a[j])/2-(h_i[j-1]+h_i[j])/2)
END

A_cum[2]=A_[2]
DUPLICATE j=3,n
A_cum[j] = A_[j]+A_cum[j-1]
END

A_tot=A_cum[n]
dbt_[1] = T_o
DUPLICATE j=2,n
mdot_air*1000*Cp_avg*(dbt_[j-1]-dbt_[j])=h_c*A_[j]*((dbt_[j-1]+dbt_[j])/2-(t_i[j-1]+t_i[j])/2)
END
N_r=A_tot/F_s/A_face

side_T=A_face^0.5
N_T=side_T/S_T
N_Tn=round(N_T)
side_Tn=N_Tn*S_T
W=A_face/side_Tn
side_L=round(N_r)*S_L

nooffinperinch = 0.0254/S_f
n_circuits=mdot_water/roh_ravg/

v_water/(pi/4*D_i^2)
n_c=round(n_circuits)
v_watern=mdot_water/roh_ravg/
42
n_c/(pi/4*D_i^2)
3.5.4 Code Output

A_face=0.5425
A_nff=0.497
A_oi=19.31
A_tot=112.3 [m2]
Cp_1=1.02 [kJ/kg-K]
Cp_avg=1.034
Cp_o=1.049 [kJ/kg-K]
D_h=0.003865
D_i=0.01588
D_o=0.01717
dpt_o=27.59 [C]
F_s=22.86
G=4.77
h_1=27.68 [kJ/kg]
h_ab=136.7
h_c=52.13
h_o=100.8 [kJ/kg]
h_r=3768
hi_dpto=87.78 [kJ/kg]
J_c=0.008692
k_1=0.02437 [W/m-K]
k_avg=0.02555
k_f=0.5782 [W/m-K]
k_o=0.02673 [W/m-K]
mdot_air=1.286
mdot_water=3.75
miu_1=0.00001773
[kg/m-s]
miu_avg=0.00001843
miu_o=0.00001913
[kg/m-s]
miu_water=0.001345
[kg/m-s]
n_c=19
n_circuits=18.95
N_r=9.059
N_T=19.33
N_Tn=19
n=50
nooffinperinch=7.753
Nu_D=103.5
P_=101.3
Pr_w=9.743
Pr=0.746
Q_cc=94.05
R_1=1
R_cf=0.2583
R_o=0.5
R_r=0.5
Re_a=1000
Re_w=11802
roh_ravg=1000
[kg/m^3]
S_f=0.003276
S_L=0.04445
S_T=0.0381
side_L=0.4001
side_T=0.7365
side_Tn=0.7239
St=0.01057
T_1=9.3
T_f=0.0004064
T_o=40
T_r=21
t_ravg=9
t_rin=6
t_rout=12
v_R=0.8436 [m^3/kg]
v_water=1
v_watern=0.9972
Vdot_air=1.085
vel_fair=2
W=0.7494
x=1.492
y=0.08205
















Table 0-11 Air Parameters at each station
Station,j ha,j hi,j ti,j tr,j A,j Acum,j Dbt,j
1 100.8 63.41 21.66 12 40
Side_Tn
Side_L
W
43
2 99.31 62.46 21.4 11.88 1.026 1.026 39.27
3 97.82 61.51 21.13 11.76 1.041 2.067 38.55
4 96.33 60.56 20.87 11.63 1.057 3.123 37.84
5 94.83 59.63 20.6 11.51 1.073 4.196 37.14
6 93.34 58.69 20.34 11.39 1.09 5.287 36.44
7 91.85 57.77 20.07 11.27 1.108 6.395 35.75
8 90.36 56.84 19.8 11.14 1.127 7.521 35.07
9 88.86 55.93 19.53 11.02 1.146 8.667 34.39
10 87.37 55.02 19.25 10.9 1.166 9.834 33.72
11 85.88 54.11 18.98 10.78 1.188 11.02 33.05
12 84.39 53.21 18.7 10.65 1.21 12.23 32.4
13 82.9 52.32 18.43 10.53 1.233 13.46 31.74
14 81.4 51.43 18.15 10.41 1.258 14.72 31.1
15 79.91 50.55 17.87 10.29 1.283 16.01 30.45
16 78.42 49.67 17.59 10.16 1.31 17.32 29.82
17 76.93 48.8 17.31 10.04 1.339 18.66 29.18
18 75.43 47.93 17.02 9.918 1.369 20.02 28.56
19 73.94 47.07 16.74 9.796 1.401 21.42 27.93
20 72.45 46.21 16.45 9.673 1.434 22.86 27.31
21 70.96 45.36 16.16 9.551 1.469 24.33 26.7
22 69.46 44.52 15.87 9.429 1.507 25.83 26.08
23 67.97 43.68 15.58 9.306 1.547 27.38 25.47
24 66.48 42.85 15.29 9.184 1.589 28.97 24.87
25 64.99 42.02 14.99 9.061 1.634 30.61 24.26
26 63.5 41.2 14.7 8.939 1.683 32.29 23.66
27 62 40.39 14.4 8.816 1.734 34.02 23.06
28 60.51 39.58 14.1 8.694 1.79 35.81 22.47
29 59.02 38.77 13.8 8.571 1.849 37.66 21.87
30 57.53 37.97 13.5 8.449 1.913 39.58 21.28
31 56.03 37.18 13.2 8.327 1.983 41.56 20.68
32 54.54 36.39 12.89 8.204 2.058 43.62 20.09
33 53.05 35.61 12.59 8.082 2.14 45.76 19.5
34 51.56 34.83 12.28 7.959 2.229 47.99 18.91
35 50.07 34.06 11.97 7.837 2.327 50.31 18.32
36 48.57 33.3 11.66 7.714 2.435 52.75 17.72
37 47.08 32.54 11.35 7.592 2.554 55.3 17.13
38 45.59 31.78 11.03 7.469 2.686 57.99 16.54
39 44.1 31.03 10.72 7.347 2.835 60.82 15.94
40 42.6 30.29 10.4 7.224 3.001 63.82 15.34
41 41.11 29.55 10.09 7.102 3.19 67.01 14.74
42 39.62 28.82 9.769 6.98 3.406 70.42 14.14
43 38.13 28.09 9.45 6.857 3.654 74.07 13.54
44 36.63 27.37 9.129 6.735 3.944 78.02 12.93
45 35.14 26.65 8.806 6.612 4.287 82.3 12.31
46 33.65 25.93 8.483 6.49 4.698 87 11.69
47
32.16 25.23 8.158 6.367 5.199 92.2 11.07
48 30.67 24.52 7.832 6.245 5.824 98.03 10.44
49 29.17 23.82 7.504 6.122 6.626 104.7 9.803
50
27.68 23.13 7.176 6 7.691 112.3 9.158

44
3.5.5 The effect of different variables
3.5.5.1 Effect of face velocity
In this study, the face velocity is being changed from 0.5 to 3 m / s and the effect on the
outside total heat transfer area, and number of rows are plotted.
Table 0-12 Face Velocity Effect on Coil dimensions
Run
Face
velocity
(m/s)
h_c
(W/m
2
K)
Outlet
dry bulb
(!C)
Total
outside
area (m
2)

No.
of
rows
side_L
(m)
Side_tn
(m)
Width
(m)

1 0.5 21.35 9.127 211.6 4.266 0.1778 1.486 1.46
2 0.6 24.01 9.132 192.9 4.666 0.2223 1.334 1.356
3 0.7 26.51 9.135 178.7 5.043 0.2223 1.257 1.233
4 0.8 28.89 9.138 167.5 5.402 0.2223 1.181 1.148
5 0.9 31.17 9.14 158.4 5.747 0.2667 1.105 1.091
6 1 33.36 9.142 150.8 6.081 0.2667 1.029 1.055
7 1.1 35.47 9.144 144.4 6.405 0.2667 0.9906 0.9957
8 1.2 37.52 9.146 138.9 6.722 0.3112 0.9525 0.9493
9 1.3 39.5 9.148 134.1 7.031 0.3112 0.9144 0.9127
10 1.4 41.43 9.15 129.9 7.334 0.3112 0.8763 0.8844
11 1.5 43.32 9.151 126.2 7.632 0.3556 0.8382 0.863
12 1.6 45.16 9.153 122.9 7.925 0.3556 0.8382 0.809
13 1.7 46.95 9.154 119.8 8.214 0.3556 0.8001 0.7977
14 1.8 48.71 9.155 117.1 8.499 0.3556 0.762 0.791
15 1.9 50.44 9.157 114.6 8.781 0.4001 0.762 0.7494
16 2 52.13 9.158 112.3 9.059 0.4001 0.7239 0.7494
17 2.1 53.8 9.159 110.2 9.334 0.4001 0.7239 0.7137
18 2.2 55.44 9.16 108.3 9.607 0.4445 0.6858 0.7191
19 2.3 57.05 9.162 106.5 9.877 0.4445 0.6858 0.6879
20 2.4 58.63 9.163 104.8 10.14 0.4445 0.6858 0.6592
21 2.5 60.19 9.164 103.3 10.41 0.4445 0.6477 0.6701
22 2.6 61.73 9.165 101.8 10.67 0.489 0.6477 0.6443
23 2.7 63.25 9.166 100.5 10.94 0.489 0.6477 0.6204
24 2.8 64.75 9.168 99.18 11.2 0.489 0.6096 0.6357
25 2.9 66.23 9.169 97.97 11.46 0.489 0.6096 0.6137
26 3 67.69 9.17 96.83 11.71 0.5334 0.6096 0.5933

45

Figure 0-20 The Required Coil External Surface Area and No. of Rows Variation with Face Velocity

When making the choice of the face velocity, the number of rows should be considered as
well as the total surface area, a smaller area with larger number of rows is not a favorable
case as the coil would be considered bulky and would thus increase both the air side
pressure drop as well as the water side pressure drop. And thus the initial cost would be
small (smaller surface area and therefore lower material weight), but the running cost
would be larger (higher pressure drop). Finally a compromised solution should be
reached based on economical considerations.
From the plot shown in figure 3-20 it can be easily concluded that as the face velocity
increases, the coil face area decreases but the coil depth increase but the total outside
surface area is being reduced.
From the graph shown in figure 3-20, the chosen air velocity is such that the rate of total
external area change with face velocity is small. That is why we tried to take the face
velocity around 2.2m/s, but this value results in a number of rows of 9.6. this value
couldn't be achieved that is why the choice was for the 2 m/s face velocity which results
in a number of rows of 9.
1 1.4 1.8 2.2 2.6 3
90
100
110
120
130
140
150
160
6
7
8
9
10
11
12
vel
fair

A
t
o
t


[
m
2
]
N
r



46
3.5.5.2 Effect of water velocity
In this study, the water velocity is being changed from 0.5 to 1.5 m / s while the face
velocity is kept constant at 2 m/s.
Table 0-13 Water Velocity Effect on Coil Dimensions and No. of Circuits
Run
Water
velocity
(m/s)
h_r
(W/m
2
K)
Outlet
dry
bulb
(!C)
Total
outside
area
(m
2)

No. of
rows
side_L
(m)
No. of
circuits
1 0.5 2164 9.187 145.9 11.76 0.5334 38
2 0.54 2302 9.183 141.1 11.38 0.489 35
3 0.58 2437 9.18 137 11.04 0.489 33
4 0.62 2571 9.176 133.3 10.75 0.489 31
5 0.66 2703 9.174 130.1 10.49 0.4445 29
6 0.7 2833 9.171 127.2 10.25 0.4445 27
7 0.74 2962 9.169 124.6 10.04 0.4445 26
8 0.78 3089 9.167 122.2 9.853 0.4445 24
9 0.82 3215 9.165 120 9.679 0.4445 23
10 0.86 3340 9.163 118.1 9.521 0.4445 22
11 0.9 3464 9.161 116.3 9.375 0.4001 21
12 0.94 3586 9.16 114.6 9.241 0.4001 20
13 0.98 3708 9.159 113.1 9.117 0.4001 19
14 1.02 3829 9.157 111.6 9.002 0.4001 19
15 1.06 3948 9.156 110.3 8.896 0.4001 18
16 1.1 4067 9.155 109.1 8.796 0.4001 17
17 1.14 4185 9.154 107.9 8.703 0.4001 17
18 1.18 4302 9.153 106.8 8.615 0.4001 16
19 1.22 4418 9.152 105.8 8.533 0.4001 16
20 1.26 4534 9.151 104.9 8.456 0.3556 15
21 1.3 4649 9.15 104 8.383 0.3556 15
22 1.34 4763 9.149 103.1 8.315 0.3556 14
23 1.38 4876 9.149 102.3 8.25 0.3556 14
24 1.42 4989 9.148 101.5 8.188 0.3556 13
25 1.46 5101 9.147 100.8 8.129 0.3556 13
26 1.5 5212 9.146 100.1 8.074 0.3556 13

47
3.5.5.3 Effect of inlet water temperature
In this study, the inlet water temperature is being changed from 5 to 8 !C while the face
and the water velocities is kept constant at 2 and 1 m/s respectively.
Table 0-14 Inlet Water Temperature Effect on Coi l Dimensions
Run
t_rout
!C
t_rin
!C
h_r
(W/m
2
K)
Outlet
dry
bulb
(!C)
Total
outside
area
(m
2)

No. of
rows
side_L
(m)
No. of
circuits
1 12 5 3743 9.113 103 8.305 0.3556 16
2 12 5.12 3746 9.119 104 8.384 0.3556 17
3 12 5.24 3749 9.124 105 8.466 0.3556 17
4 12 5.36 3752 9.13 106 8.55 0.4001 17
5 12 5.48 3755 9.135 107.1 8.638 0.4001 17
6 12 5.6 3758 9.14 108.3 8.729 0.4001 18
7 12 5.72 3761 9.146 109.4 8.823 0.4001 18
8 12 5.84 3764 9.151 110.6 8.922 0.4001 18
9 12 5.96 3767 9.156 111.9 9.024 0.4001 19
10 12 6.08 3770 9.161 113.2 9.13 0.4001 19
11 12 6.2 3773 9.167 114.6 9.241 0.4001 20
12 12 6.32 3777 9.172 116 9.358 0.4001 20
13 12 6.44 3780 9.177 117.6 9.479 0.4001 20
14 12 6.56 3783 9.182 119.1 9.607 0.4445 21
15 12 6.68 3786 9.187 120.8 9.741 0.4445 21
16 12 6.8 3789 9.192 122.6 9.882 0.4445 22
17 12 6.92 3792 9.197 124.4 10.03 0.4445 22
18 12 7.04 3795 9.201 126.4 10.19 0.4445 23
19 12 7.16 3798 9.206 128.4 10.36 0.4445 23
20 12 7.28 3801 9.211 130.6 10.53 0.489 24
21 12 7.4 3804 9.216 133 10.72 0.489 25
22 12 7.52 3807 9.22 135.5 10.93 0.489 25
23 12 7.64 3810 9.225 138.2 11.15 0.489 26
24 12 7.76 3813 9.229 141.2 11.38 0.489 27
25 12 7.88 3816 9.233 144.4 11.64 0.5334 28
26 12 8 3819 9.238 147.9 11.92 0.5334 28

48
3.5.5.4 Effect of ambient air temperature
In this study, all the coil design parameters are being constant except for the outside air
dry-bulb temperature. The results are shown in table 3-15 for an outside temperature
variation from 21 !C to 44 !C.
Table 0-15 Oustide air condition effect on coil capacity
run To Outside RH Atot Qcc Nr
Exit dry
bulb
1 21 0.5 75.71 16.83 6.105 9.541
3 22 0.5 76.79 19.76 6.192 9.525
5 23 0.5 78.43 22.79 6.324 9.502
7 24 0.5 80.32 25.91 6.477 9.476
9 25 0.5 82.33 29.13 6.638 9.45
11 26 0.5 84.38 32.47 6.804 9.424
13 27 0.5 86.46 35.91 6.972 9.399
15 28 0.5 88.53 39.48 7.139 9.375
17 29 0.5 90.6 43.17 7.305 9.352
19 30 0.5 92.64 46.99 7.47 9.33
21 31 0.5 94.68 50.96 7.634 9.309
23 32 0.5 96.69 55.06 7.797 9.289
25 33 0.5 98.69 59.32 7.958 9.269
27 34 0.5 100.7 63.74 8.117 9.251
29 35 0.5 102.6 68.32 8.276 9.234
31 36 0.5 104.6 73.08 8.434 9.217
33 37 0.5 106.5 78.02 8.591 9.201
35 38 0.5 108.5 83.16 8.747 9.186
37 39 0.5 110.4 88.5 8.903 9.172
39 40 0.5 112.3 94.05 9.059 9.158
41 41 0.5 114.3 99.82 9.214 9.145
43 42 0.5 116.2 105.8 9.37 9.132
45 43 0.5 118.1 112.1 9.525 9.12
47 44 0.5 120.1 118.6 9.681 9.109

Weather Condition effect on Coil Capacity and No. of Rows
0
20
40
60
80
100
120
140
21 23.5 26 28.5 31 33.5 36 38.5 41 43.5
Outside Dry-Bulb Temperature (deg.C)
C
o
i
l

C
a
p
a
c
i
t
y

(
k
W
)
6
6.5
7
7.5
8
8.5
9
9.5
10
N
o
.

O
f

R
o
w
s
Coil
Capacity
No. of
rows
49

50
3.6 DDC Control System For Total Fresh Air AHU
3.6.1 Sequence of Operation

The AHU consists of filter section including pre and bag filters, cooling coil, electric
heater, steam humidifier and supply fan with variable speed drive.

1. Start of the supply fan according to a programmable time program with the
possibility of exception programs for holidays, maintenance, etc..

2. Supply fan start interlocks fresh air damper to open to preset location.

3. supply fan flow, indicated by differential pressure switch interlocks control
system start so that control functions are not performed if fan is not in normal operation.
Flow failure will initiate an alarm at the control system.

4. Temperature and humidity is measured by sensor mounted on supply air duct.

5. Temperature and humidity are then compared to the previously adjusted set points
& controller signals 3-way cooling valveto modulate for cooling or dehumidification, or
current valve mounted on electric heater to modulate for heating or reheat, and steam
humidifier to modulate for humidification upon deviation from the adjusted set point.

6. Overheat thermostat is mounted downstream of the electric heater. An alarm will
be issued in case of overheat sensed.

7. Status , and trip alarm of supply fan will be monitored through control system.
Failure to give a status after a start signal was issued will signal an alarm after a
dedicated time delay.
8. Differential pressure switch mounted across filterbanks will issue an alarm in case
of filter dirty.

9. Pressure sensor mounted on supply air duct measures supply air pressure, in case
of pressure drop due to absolute filter being dirty, variable speed drive will be signaled to
increase the fan motor speed to ensure a constant pressure of air flow to the controlled
zone. This is to avoid cross contamination between the controlled zone and surrounding
zones due to infiltration, doors opening etc..

10. Smoke detector mounted on supply air duct will issue an alarm in case of smoke
sensed. Control system will be signaled to stop immediately. In case of exhaust fan
available, exhaust fan will be signaled to start immediately to purge smoke from the
controlled zone
51
3.7 Nomenclature
D
o
Tube's outside diameter, m
D
i
Tube's inside diameter, m
S
T
Tube spacing across face, m
S
L
Tube spacing between rows, m
S
f
Fin spacing center to center, m
T
f
Thickness of aluminum fins, m
D
h
Flow passage hydraulic diameter, m
F
s
External surface area per face area per row
A
oi
External surface area per internal surface area
A
nff
Net flow area per free flow area
A
fin
Fin area, m
2

A
o
External surface area (air side heat transfer area), m
2
A
face
Face area, m
2

Jc Colburn J factor (S
t
*P
r
^(2/3))
vel
fair
Air face velocity, m/s
o
air
V Air flow rate, m
3
/s
T
o
On coil dry bulb air temperature, !C
R
o
On coil relative humidity
T
r
Room dry bulb air temperature, !C
R
r
Room relative humidity
T
1
Off coil dry bulb air temperature, !C
R
1
Off coil relative humidity
P Air pressure, kPa
t
rin
Inlet refrigerant temperature (chilled water), !C
t
rout
outlet refrigerant temperature (chilled water), !C
v
water
Water velocity inside tubes, m/s
v
R
Specific air volume at room conditions, m
3
/kg
/
o
On coil viscosity, Ns/m
2

/
1
Off coil viscosity, Ns/m
2

/
avg
Average viscosity, Ns/m
2

Cp
o
On coil air heat capacity, kJ/kg K
Cp
1
On coil air heat capacity, kJ/kg K
Cp
avg
Average Air heat capacity, kJ/kg K
k
o
On coil air conductivity, W/m K
k
1
Off coil air conductivity, W/m k
k
avg
average air conductivity, W/m k
h
o
On coil air enthalpy, kJ/kg K
h
1
Off coil air enthalpy, kJ/kg K
m
o
air
Air mass flow rate, kg/s
Q
cc
Cooling coil capacity, kW
G mass velocity, kg/m
2
s
Re
a
Air side Reynolds number
Pr Air side Prandtl number
St Air side Stanton number
h
c
Air side convection heat transfer coefficient, W/m
2
K
52
t
ravg
Average refrigerant temperature, !C
m
o
water
Water mass flow rate, kg/s
0
ravg
Average refrigerant density, kg/m
3

/
water
Average water viscosity, Ns/m
2

Re
w
Average water side Reynolds number
Pr
w
Average water side Prandtl number
k
f
Average water conductivity, W/m K
Nu
D
Average Nusselt number
h
r
Air side convection heat transfer coefficient, W/m
2
K
R
cf
Coil factor
dpt
o
On coil dew point temperature, !C
h
i
Saturated air enthalpy, kJ/kg
n Number of stations
x Specific heat transfer through each element, kJ/kg
side
T
Coil height, m
side
Tn
Corrected coil height according to transverse tube spacing, m
W Coil width across face, m
side
L
Coil depth, m
n
circuits
Number of water circuits


53
3 Air Handling Unit, Cooling coils ................................................................................... 0
3.1 Introduction ............................................................................................................. 1
3.2 Specifications .......................................................................................................... 2
3.2.1 Construction .................................................................................................... 2
3.2.2 Fan section ...................................................................................................... 2
3.2.3 Coils ................................................................................................................. 4
3.2.4 Droplet eliminator ........................................................................................... 6
3.2.5 Filters ............................................................................................................... 6
3.2.6 Mixing Box & Exhaust Box........................................................................... 8
3.2.7 Inlet accessories .............................................................................................. 8
3.2.8 Dampers........................................................................................................... 9
3.2.9 Sand trap louver .............................................................................................. 9
3.2.10 Sound attenuators............................................................................................ 9
3.2.11 Heat Recovery sections ................................................................................ 10
3.2.12 Diffuser plate................................................................................................. 11
3.2.13 Humidifiers ................................................................................................... 11
3.3 Specific design criteria for Surgery and Critical Care ........................................ 12
3.3.1 Operating Room ............................................................................................ 12
3.3.2 Operation theatre air flow ............................................................................ 14
3.3.3 Room pressure for critical environments .................................................... 17
3.4 Operating Theater Load Estimation ..................................................................... 20
3.4.1 General Zone Data ........................................................................................ 20
3.4.2 Room sensible load:...................................................................................... 21
3.4.3 Room latent load: .......................................................................................... 22
3.4.4 Room sensible heat factor (RSHF) .............................................................. 22
3.4.5 Supply air temperature ................................................................................. 22
3.4.6 Psychrometric Processes .............................................................................. 22
3.4.7 Results ........................................................................................................... 23
3.4.8 Computer assisted load estimation programs: ............................................ 24
3.5 Cooling Coil Design ............................................................................................. 25
3.5.1 Theoretical background ................................................................................ 25
3.5.2 Cooling coil design strategy:........................................................................ 37
3.5.3 Developed code for coil design ................................................................... 40
3.5.4 Code Output .................................................................................................. 42
3.5.5 The effect of different variables................................................................... 44
3.5.6 Cooling Coil Production............................. Error! Bookmark not defined.
3.6 DDC Control System For Total Fresh Air AHU ................................................ 50
3.6.1 Sequence Of Operation ................................................................................ 50
3.7 Nomenclature ........................................................................................................ 51

Table 3-1 AHU Construction options..................................................................................... 2
Figure 3-1 Fan section ............................................................................................................. 3
Table 3-2Fan types .................................................................................................................. 4
Figure 3-2 Coil arrangement .................................................................................................. 5
Figure 3-3 Coil Connections and drain pan ........................................................................... 6
Figure 3-4 Droplet eliminator ................................................................................................. 6
54
Table 3-3 Filter Types ............................................................................................................. 7
Figure 3-5 Air filters ................................................................................................................ 7
Figure 3-6 Mixing box ............................................................................................................ 8
Table 3-4 Mixing Box Types .................................................................................................. 8
Figure 3-7 Dampers ................................................................................................................. 9
Table 3-5 Damper Material Options ....................................................................................... 9
Figure 3-8 Sand tap louver ...................................................................................................... 9
Table 3-6 Types of Heat Recovery Sections ........................................................................ 10
Figure 3-9 Diffuser plate ....................................................................................................... 11
Table 3-7 Humidifiers Theory of Operation ........................................................................ 11
Table 3-8 Filter Efficiencies for central Ventilation and Air conditioning systems in
general hospitals .................................................................................................................... 13
Table 3-9 General pressure relationships and ventilation of Surgery and critical care areas
................................................................................................................................................. 14
Figure 3-10 Typical Operating Theater Set-Up ................................................................... 15
Figure 3-11 Temperature Distribution inside Operating Theater ....................................... 16
Figure 3-12 Infiltration Curve (Power Law Equation) ........................................................ 17
Figure 3-13 Psychrometric Represaentation of Load Estimation ...................................... 23
Figure 3-14 Typical water circuit arrangement ................................................................... 26
Figure 3-15 Cooling Coil assembly inside Typical Application ........................................ 27
Figure 3-16 Two-component Driving Force Between Dehumidifying Air and Coolant .. 33
Figure 3-17 Thermal Diagram for General Case When Coil Surface Operates Partially
Dry .......................................................................................................................................... 35
Figure 3-18 Thermal Diagram for General Case When Coil Surface Operates Partially
Dry .......................................................................................................................................... 36
Table 3-10 Surface Area Data............................................................................................... 37
Figure 3-19 Correlated external surface heat transfer data for surfaces of table 3-10 ...... 38
Table 3-11 Air Parameters at each station ........................................................................... 42
Table 3-12 Face Velocity Effect on Coil dimensions ........................................................ 44
Figure 3-20 The Required Coil External Surface Area and No. of Rows Variation with
Face Velocity ......................................................................................................................... 45
Table 3-13 Water Velocity Effect on Coil Dimensions and No. of Circuits ..................... 46
Table 3-14 Inlet Water Temperature Effect on Coi l Dimensions .................................... 47
Table 3-15 Oustide air condition effect on coil capacity .................................................... 48
Figure 3-21 copper drum roll .............................................. Error! Bookmark not defined.
Figure 3-22 Cutting the tube coils ...................................... Error! Bookmark not defined.
Figure 3-23 The tube coil after being cut ........................... Error! Bookmark not defined.
Figure 3-24 Rolled aluminum sheet ................................... Error! Bookmark not defined.
Figure 3-25 Fins coming out from the other side of the machine. ... Error! Bookmark not
defined.
Figure 3-26 This is how the aluminum sheet looks like after punching and before the
cooling coils are fitted in the holes. .................................... Error! Bookmark not defined.
Figure 3-27 Coil Assembly. ................................................ Error! Bookmark not defined.
Figure 3-28 This is how the cooling coil looks like after assembly . Error! Bookmark not
defined.
Figure 3-29 Mechanical welding of Copper tubes ............ Error! Bookmark not defined.
55
Figure 3-30 Casing Assembly. ............................................ Error! Bookmark not defined.
Figure 3-31 ........................................................................... Error! Bookmark not defined.
Figure 3-32 ........................................................................... Error! Bookmark not defined.
Figure 3-33 Water and sodium hydroxide bath ................. Error! Bookmark not defined.
Figure 3-34) Water bath ...................................................... Error! Bookmark not defined.
Figure 3-35 Painting station. ............................................... Error! Bookmark not defined.
Figure 3-36 Placing the coil inside the AHU .................... Error! Bookmark not defined.