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Calculation methods for a complete air conditioning study: Case study of an

industrial installation

Article  in  Structural Survey · November 2012

DOI: 10.1108/02630801211288224

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Charisis G Vrellas Theoklitos Karakatsanis

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SS
30,5
Calculation methods for a
complete air conditioning study
Case study of an industrial installation
460 Charisis G. Vrellas
Department of Business Administration, University of Macedonia,
Thessaloniki, Greece, and
Theoklitos S. Karakatsanis
Production & Management Engineering, Democritus University of Thrace,
Alexandroupolis, Greece

Abstract
Purpose – The purpose of this paper is to describe and categorize calculation methods for conducting
a complete air conditioning study. More specifically, this paper is a general review of cooling loads
calculation methods, psychrometric calculations for installing a central air conditioning unit, ways of
fan coil units connection and air duct calculation methods.
Design/methodology/approach – This paper was based on two pillars: a dissertation for an
industrial facility and technical information found after methodical research.
Findings – After a brief reference of the calculation methods and the air conditioning systems
installed in this industrial facility, this paper concludes with the most appropriate calculation methods
for this industrial facility.
Research limitations/implications – This study describes some calculation methods. Thus, future
research could be addressed toward the analysis of more methods.
Practical implications – This paper includes implications for choosing the most appropriate
calculation method according to the air conditioning system installed.
Originality/value – The originality of this paper lies in the fact that, except for the theoretical part,
there are some examples taken from a case study, thus it can be used as a future guide for selecting
methods and systems of industrial air conditioning.
Keywords Structural analysis, design and theory, Design calculations, Air conditioning, Cooling,
Psychrometry, Fan coil unit, Duct, Industrial application
Paper type Technical paper

Acronyms:
VRV – Variable Refrigerant Volume
FCU – Fan Coil Unit
CAU – Central Air Conditioning Unit
RF – Radiation Factor
BF – Bypass Factor

1. Introduction
Conducting an air conditioning study is a complicated and difficult procedure
including many different stages. This derives from the nature and the differentiation of
the numerous calculations needed for the completion of this study. Unlike a heating
Structural Survey installation study, in which the basic stage is the calculation of thermal losses, an air
Vol. 30 No. 5, 2012
pp. 460-474 conditioning study primarily requires the calculation of cooling loads.
r Emerald Group Publishing Limited
0263-080X
By completing the cooling loads calculation, the engineer conducting the study can
DOI 10.1108/02630801211288224 instantly understand the needs for cooling and air conditioning of each building space.
The next stage is choosing the most appropriate air conditioning system for each Calculation for
space. Different kinds of spaces require different kind of air conditioning and air conditioning
ventilation. Subsequently, the right choice of the system must be done under certain
criteria. In order to install each air conditioning system, certain calculations and
measurements need to be done. The installation study for each system must be as
accurate as possible; otherwise, the final installation will have certain miscalculation
problems and functional or economic drawbacks. 461
The aim of this paper is to explain certain calculation methods for a complete air
conditioning study. This is accomplished in two stages: first through the theoretical
part, where certain air conditioning systems calculations methods are categorized,
and second through applied examples, which are taken from a diploma thesis. More
specifically, the systems referred are: floor fan coil units (FCUs), ceiling FCUs, air duct
network with central air conditioning units (CAUs) and variable refrigerant volume
(VRV) system. Finally, this qualitative research aims to highlight the differences of
each calculation method conducted for the above systems and to give certain examples
using a case study of an industrial installation.

2. Literature review
As mentioned before, this paper is based on an air conditioning study for an industrial
facility (Vrellas, 2009). This study is the planning process in theoretical level as far as
concerning the practical application and calculations required for a study from
beginning to completion. Some information was taken from two other similar diploma
dissertations, with the title “air conditioning and ventilation study of an industrial
facility” (Seretoudi, 2005) and “heating study of an industrial facility” (Kiriakou, 2008).
From the last, valuable information was taken about air conditioning and heating
systems.
Furthermore, certain software was used when conducting the air conditioning study
to give the measurements and the vital data for drawing the conclusions of this paper.
The software used was Adapt Manager and Auto Fine. The technical data about the
orifices were taken by the Aerogrammi (2008). Finally, while compiling the study,
the following regulations were taken into account:
. ASHRAE, 1977 Fundamentals Handbook: For the Calculation of Cooling Loads
. ASHRAE, Handbook of Systems
. ASHRAE, Handbook of Applications
. ASHRAE, Handbook of Equipment
. ASHRAE, Standards for Natural and Mechanical Ventilation
. Carrier Handbook of Air Conditioning System Design

3. Cooling loads calculation

Space thermal/heat loss is the rate at which heat leaves the building during a time
interval. On the contrary, space heat gain is the rate at which heat enters a space, or
heat is generated within a space during a time interval. Thus, space cooling load is
defined as the rate that heat is removed from the conditioned space in order to maintain
a constant space air temperature. The difference between space heat gain and space
cooling load is due to the storage of a portion of radiant heat in the structure. The
convective component is converted to space cooling load instantaneously.
SS 3.1 Cooling loads calculation methods
30,5 The methods of calculating cooling loads are based on equations of thermal
equilibrium between the space components and heat sources. The two basic methods
for calculating the cooling loads are: the CARRIER method and the ASHRAE method.
Generally, these two methods follow the same basic principles.
The ASHRAE methods are:
462 . cooling load temperature difference (CLCD): this is a hand calculation method
based on representative results from the transfer function method;
. transfer function method (TFM): this method uses heat accumulation factors to
convert the heat gain into cooling load; and
. radiant time series (RTS): this is the most accurate method, because it calculates
the delayed heat gain result during a 24-hour cycle in the current cooling load.
3.2 Cooling load categorization
According to ASHRAE, the space cooling load is classified into three categories:
(1) the external cooling loads, comprising of:
. solar heat gain through fenestration areas (Qfes);
. conduction heat gain through fenestration areas (Qfe);
. conduction heat gain through roofs (Qrs) and external walls (Qws); and
. conduction heat gain through interior partitions, ceilings and floors
(Qic).
(2) the internal cooling loads, comprising of:
. electric lighting (sensible load only);
. people (sensible heat and latent heat); and
. power equipment and appliances (either sensible or latent loads, and
sometimes both).
(3) loads from infiltration and ventilation (both sensible and latent cooling loads).
Respectively, CARRIER classifies the cooling loads in the same minor categories,
without using the major categories.

4. Phychrometry
In the general case of air conditioning the challenge is maintaining stable conditions
within a space or even a pre-definite comfort condition. The conductor for transferring
appropriate amounts of sensible and latent heat is the air. Thus, central air
conditioning in its general form consists of the following air components:
. Fresh air: it is the air coming from the outer environment. Its input in the space is
necessary to control air quality, i.e. the content of polluting agents.
. Recirculation air: it is the amount of air that has been recollected from the space,
is being mixed with fresh air and used from the beginning by the central unit.
Its temperature and humidity are those of the conditioned space. The optimal
location from which it can be collected is the lower space, inside the living zone.
 . Air input: it is the mixture of fresh and recirculation air, which after Calculation for
treatment from the provisions of the air conditioner unit, is brought into the air conditioning
room within the appropriate conditions in order to achieve the convenience
conditions.
. Air discharged: it is the amount of air, which after has been recollected from the
space, is discharged to the outer environment as being inferior. The optimal
location from which it can be collected is the higher space, above the living zone, 463
where most pollutants gather.
The general case of air conditioning (Figure 1) represents the all air system, i.e. the
system in which the air input fully confronts both sensible and latent space cooling
load, ensuring the desired air quality. Some of the concepts below are:
. RSHF: room sensible heat factor;
. GSHF: great sensible heat factor; and
. ESHF: effective sensible heat factor.
The slope of the RSHF straight equals the rate of sensible heat and is calculated by
Equation (1):

RSH
RSHF ¼ ð1Þ
RLH

where RSH is the room sensible load and RLH is room latent load.

Figure 1.
Psychometric chart
for the general case
of air conditioning
SS The slope of the GSHF straight equals the rate of active device heat is calculated by
30,5 Equation (2):

TSH
GSHF ¼ ð2Þ
GTH

464 where TSH is the total sensible heat and GTH is total heat load of the device.
The slope of the straight ESHF equals the effective rate of sensible heat and is
calculated by Equation (3):

RSH þ BFOASH
ESHF ¼ ð3Þ
RLH þ BFOATH
where OASH is the sensible load of fresh air, RTH ( ¼ RSH þ OALH) the room total
load, OATH ( ¼ OASH þ OALH) the total load of fresh air, BF the bypass factor
(related with cooling element of the unit & air speed).

5. FCUs connection
The FCUs can be connected with one of the following ways:
(1) two-pipe system;
(2) four-pipe system;
(3) three-pipe or Tichelmann or reverse – return system; and
(4) one-pipe system.
5.1 Two-pipe system
The two-pipe system network consists of two parallel major branches, of equal (or
almost equal, for the corresponding branches) cross sections, flow and return. Each
FCU connects its inlet to the flow branch and its outlet to the return branch. The return
branch begins from the last fan coil and the cross section increases as it is connected
with the rest of the network. Once the first fan coil is connected, the return is driven to
the collector. In this system the units have one coil.

5.2 Four-pipe system

The four-pipe system is actually two independent two-pipe systems. In this system the
units can have two coils. Thus, it can be realized that this option is far more expensive
and it is used in cases where simultaneous heating and cooling are required in different
zones or humidity control is desired using the hot water coil as terminal reheat.

5.3 Three-pipe system

The three-pipe system also consists of two major branches for flow and one for return.
The return, however, starts from the first FCU and the cross section increases as it is
connected with the rest of the network. Once the latter is connected, the return of the
final section goes back to the return collector. For this very reason, this system is
chosen in networks where a fast turnaround between heating and cooling could be
made. So that the system can be depressurized, and issues like changing over from
cooling to heating too fast that cause thermal shock to the boiler can be avoided. It is
most typically used with hot water heating systems (radiators).
5.4 One-pipe system Calculation for
The single pipe system is the simplest system of all. In this system there is no return, air conditioning
so all FCUs are connected with a single flow pipe. Due to circulation the cooling
performance is decreasing from unit to unit, so this system is rarely used for large
installations. Thus, it is particularly used for small and low-pressure networks with a
small number of fan coils.
465
6. Air duct calculation methods
The calculation of air duct network is often performed according to three basic
methods:
(1) constant pressure loss method (or equal friction method);
(2) static pressure recovery method; and
(3) velocity method.
6.1 Constant pressure loss method
In this method, air vents are dimensioned for constant pressure loss per length meter. A
proper speed is selected in the main duct close to the fan. The pressure loss in the main
duct is then used as a template for the rest of the system. The pressure (or friction) loss
is kept at a constant level throughout the system. The method gives an automatic velocity
reduction through the system. The method may add more cross sectional changes in the
main duct and can increase the number of system components compared to other methods.
Specifically, this method involves the following steps:
(1) the desired air flow is calculated according to the cooling load system or the air
rotations;
(2) the speed at the beginning of the air duct network is set according to the
desired noise level;
(3) given the desired flow rate and speed, the cross section of the main duct
outcomes with a simple division;
(4) the cross sections of all branches are calculated depending on the flow rate
percentage of each branch related to the main duct;
(5) the total pressure loss is calculated according to the longest network part; and
(6) in the rest of the parts, air duct sizes are calculated, so that all the branches will
have the same total pressure loss.
Moreover, in most air duct networks the last step does not take place during the
designing, but certain regulatory diaphragms are placed at the branches. These are set
after the stoking of the network with air in order to accomplish the best network
balancing. The last step is planning the network design that can be self-balanced. The
concept of self-balancing does not mean that all network branches will have equal
pressure loss; something that happens to all networks regardless the way they have been
dimensioned. Self-balancing means that the network will work according to the designed
conditions (speed calculated at all branches), and will not require regulatory intervention.

6.2 Static pressure recovery method

With the static pressure recovery method the secondary ducts are selected to achieve
more or less the same static pressure in front of all outlets or inlets. The major
SS advantage of this method is the common conditions created for outlets and inlets. This
30,5 method is the most complicated and therefore is seldom used.
Specifically, this method comprises the following steps:
(1) The desired air flow is calculated according to the system cooling load or the
air rotations.

466 (2) The speed at the beginning of the air duct network is set according to the
desired noise level.
(3) Given the desired flow rate and speed, the cross section of the main duct
derives from a simple division.
(4) Except for the terminal branches of the network, the rest of the branches are
calculated on a repetitive basis. The criterion used is that of dividing each duct
into several ducts, the point of bifurcation has the same static pressure.
(5) The terminal branches are calculated again so as to produce the “required
static pressure” on them. The term “required static pressure” of terminal
branch is understood as the pressure that reaches the flow rate and the design
range for the orifice given for the chosen branch. The static pressure just
outside an input or output orifice is taken equal to zero for normal applications.
(6) The total pressure loss in the longest part of the network is calculated.
From the above it is concluded that the method takes into account the actual behavior
of the network making it more accurate and resulting in more well-balanced networks.
Compared with the method of constant pressure loss method, it creates larger air duct
networks and leads to rapid speed fluctuations along the different branches.

6.3 Velocity method

This method is used in air duct installations dealing with air dedusting systems and
transport of particles through the air in general. Maintaining air speed on these
networks is essential for preventing sedimentation of the particles within the networks.
Specifically, this method uses the following steps:
(1) the value of air speed for the entire network is chosen;
(2) the cross section of each part of the network is calculated, so that the speed will
remain constant; and
(3) the pressure loss of the network is calculated for a specific geometry and
speed.

7. Case study of an industrial installation

The air conditioning systems referred in this paper (Section 7.3) are meant to be
installed in an industrial facility in the region of Alexandroupolis, in Greece.
Consequently, all results and conclusions were taken from the study which was
conducted for that building (Vrellas, 2009).
As mentioned before the aim of this paper is to give the basic fundamentals of
compiling an air conditioning study. This is fulfilled through some examples that are
taken from the study referred earlier (Vrellas, 2009). Formulas and math types that
are widely known are avoided for practical reasons. This paper is mainly interested in
the methods in which the certain calculations were done.
 Before choosing a calculation method, different methods were compared according Calculation for
to their difficulty of applying, effectiveness, accuracy, complexity and other factors that air conditioning
concern an engineer performing that kind of study.

7.1 Building description

The following application study is regarding an industrial facility located in
Alexandroupolis. The building examined consists of three levels. 467
The basement, where there are: the production space 249.4 m2 (816.93 ft2), the
warehouse of raw materials and the boiler room along with the cooling room.
The ground floor, where there are: the assembly space 285.6 m2 (935 ft2) and the area
of 135.9 m2 (442.91 ft2) for finished products.
The first floor which houses the offices: the sales room 20.4 m2 (65.62 ft2), the
accounting room 19.7 m2 (62.34 ft2), the secretary’s office 24.2 m2 (78.74 ft2), the manager’s
office 30.4 m2 (98.43 ft2), the conference room 52.5 m2 (170.6 ft2) and the exhibition room
69.3 m2 (226.38 ft2) with a hall of 25.1 m2 (82.02 ft2) and the essential WCs. WCs also exist
in the other two levels.
The concept of the study conducted was the air conditioning and the ventilation of
the building and the proposal of alternative air conditioning solutions.

7.2 Cooling loads calculation

The cooling loads in the study were calculated according to the ASHRAE RTS method,
because it is the most accurate. The thermal conductivity factors k were calculated
from the structural elements of the building, based on the data generated by the
architectural design. The cooling loads were calculated for the months July-August
(the most demanding season). While performing the calculation the below conditions
were taken into account:
. the desired internal summer temperature of 271C (80.61F);
. the desired humidity of 60 percent; and
. the required air exchange.
The ventilation is correlated with space air renewals. The recommended air renewals
for each space have been calculated according to the type of space and the number of
people working inside the space. Thus, for the production and assembly spaces eight
air renewals per hour are required, for the finished goods spaces six air renewals are
required, and for the offices and boardroom four air renewals per hour are required.
While calculating the cooling loads the below requirements were also taken into
account:
. lighting;
. number of people;
. equipment and machinery; and
. ventilation losses.
The calculation of the installation was made in accordance with the following external
conditions which represent the city of Alexandroupolis (Table I):
The facility is operational from 8 a.m. to 6 p.m., thus the cooling loads were
estimated for this time zone.
SS The basic example is about the basement of the facility and more specifically the
30,5 production space. This space was chosen because it combines all factors (such as many
people, machinery) which affect a space that must be ventilated and conditioned, thus
it is the most demanding space of the building (from the cooling load perspective).
The figure below shows the production space after the completion of the study. We can
notice the necessary air duct network along with one CAUs supporting the network
468 (see Case B2). The drawing (Figure 2) is the outcome of Auto Line, a mechanical design
software that works with the same principals as Auto Cad.
The drawing below (Figure 2) shows two CAUs. Both CAUs are part of Case B2,
where all facility areas are conditioned by air duct networks along with CAUs.
Furthermore, central unit 1 (yellow color) is for the production space (basement), while
central unit 2 is for the assembly and finished goods space (ground floor) which cannot
be seen in the drawing.
7.2.1 External cooling loads for production area. The first task for calculating the
external cooling loads is finding the surfaces of the examined space. This is done by
the architectural design of the building. The procedure is simple (Table II):
. the type of wall and its orientation is set;

Temperature Humidity (%)

Table I.
External conditions for Summer 33.21C (91.761F) 47
Alexandroupolis Winter 01C (321F) 68

Central unit 1 Central unit 2

Figure 2.
The production space
with the air duct network
and the central
air conditioning unit
(Case B2)
 Total
Calculation for
Surface k (kcal/ Height or Surface surface Abstracted Calculation air conditioning
type Orientation m2 hc) Length width (m2) (m2) surface (m2) surface (m2)

T2 W 0.6 1.50 3.20 4.80 4.80 0.45 4.35

T7 W 0.56 1.50 0.30 0.45 0.45 – 0.45
E1 E 1.5 1.70 3.20 5.44 5.44 – 5.44 469
E1 E 1.5 6.65 3.20 21.28 21.28 – 21.28
E1 E 1.5 0.80 3.20 2.56 2.56 – 2.56
E1 E 1.5 5.00 3.20 16.00 16.00 – 16.00 Table II.
E1 E 1.5 2.50 3.20 8.00 8.00 – 8.00 Calculation surfaces for
T2 W 0.6 6.80 3.20 21.76 21.76 3.60 18.16 the production space

. the factor k of thermal conductivity of the wall is set;

. the dimensions of the wall (length, height or width), so that its surface is
estimated; and
. the openings are abstracted from the final surface.
For example, T2 wall is shown in the drawing above is first oriented west. Its k factor is
0.6 kcal/m2 hc, its length is 1.50 m and its height 3.20 m. So, the total surface of T2
western wall is 4.80 m2. If the openings are abstracted (0.45 m2), the calculation surface
is 4.35 m2. With this procedure all the upper factors such as solar heat gain through
fenestration areas (Qfes) and conduction heat gain through fenestration areas (Qfe) are
estimated by the program.
By completing this task the engineer is able to calculate the cooling loads per
surfaces and hours for the space. The power unit which will be used for the calculation
of the loads is watt (W), because it gives rounded numbers. Other power units that
could be used for cooling loads are: kcal  h1, Btu  h1.
7.2.2 Internal cooling loads for production area. The next task is calculating the
internal cooling loads of the examined area (Table III). As mentioned above the internal
cooling loads consist of:
. Lighting: 2  36 fluorescent lamps of 1,300, power 4,988 W, total 5,736 W, Rad. F
59 percent;
. People: 12 workers, mild machine labor, 110 sensible, 185 latent, Rad. F 49
percent; and

Load type 8 a.m. 9 a.m. 10 a.m. 11 a.m. 12 a.m. 1 p.m. 2 p.m. 3 p.m. 4 p.m. 5 p.m. 6 p.m.

Lighting 5,296 5,432 5,499 5,533 5,550 5,584 5,601 5,618 5,635 5,652 5,659
People (sensible) 1,029 1,132 1,184 1,217 1,236 1,249 1,262 1,268 1,275 1,281 1,288
People (latent) 2,220 2,220 2,220 2,220 2,220 2,220 2,220 2,220 2,220 2,220 2,220
People (total) 3,249 3,352 3,404 3,437 3,456 3,469 3,482 3,488 3,495 3,601 3,508
Machines Table III.
(sensible, k) 25 25 25 25 25 25 25 25 25 25 25 Additional loads/hour
Machines (latent, k) 8 8 8 8 8 8 8 8 8 8 8 the production
Machines (total, k) 33 33 33 33 33 33 33 33 33 33 33 space (W)
SS . Machinery: 1 machine of total power 25 kW sensible, 8 kW latent, Rad. F 49
30,5 percent.
Thus, the total cooling loads for the production spaces can be seen in Table IV.
7.2.3 Cooling loads for all facility areas. By following the same methodology, the
cooling loads for the other building areas were calculated (Vrellas, 2009) and are
shown at Table V:
470
(1) Basement level:
. production space – p (already estimated); and
. warehouse – w (not air conditioned, only products inside).
(2) Ground floor level:
. assembly space – as; and
. finished products space – fp.
(3) First floor level:
. sales room – sa;
. accounting room – ac;
. secretary’s office – se;
. manager’s office – ma;

Cooling load
type 8 a.m. 9 a.m. 10 a.m. 11 a.m. 12 a.m. 1 p.m. 2 p.m. 3 p.m. 4 p.m. 5 p.m. 6 p.m.

Table IV. Sensible 30.49 31.05 31.45 31.76 32.05 32.37 32.62 32.77 32.78 32.70 32.50
Total loads/hour for Latent 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22 10.22
production space (kW) Total 40.71 41.27 41.67 41.98 42.27 42.59 42.84 42.99 43.00 42.92 42.72

8 a.m. 9 a.m. 10 a.m. 11 a.m. 12 a.m. 1 p.m. 2 p.m. 3 p.m. 4 p.m. 5 p.m. 6 p.m.

Basement level
p 40.7 41.3 41.7 41.9 42.2 42.6 42.8 42.9 43 42.9 42.7
w – – – – – – – – – – –
Ground floor level
as 10 10.5 10.9 11.1 11.3 11.7 11.9 12 12 11.9 11.6
fp 5.7 7.2 9 10.7 11.9 12.4 11.9 10.7 9.3 8.3 7.3
Table V. First floor level
Total loads/hour for sa 2.1 3.1 3.3 3.3 3.3 3.3 3.2 3.1 2.9 2.9 2.8
each building space ac 1.9 2.9 2.9 2.7 2.6 2.6 2.5 2.5 2.4 2.5 2.5
and for the entire se 1.3 1.7 1.7 1.7 1.6 1.7 1.7 1.7 1.6 1.6 1.5
facility without the ma 1.9 2.9 3 3 3 3.1 3.1 3.1 2.9 3 3
ventilation, estimated co 1.6 2.5 2.8 3 3.1 3.2 3.2 3.1 2.9 3 3.1
for the 23 of ex 1.7 1.8 1.9 1.9 2 2 2.1 2.2 2 2.3 2.4
July (kW) Total 67 74 78 80 82 84 84 83 80 79 78
 . conference room – co; and Calculation for
. exhibition room – ex. air conditioning
From Table V we can realize that we have basically two space types. Those that require
great cooling loads with many air renewals like production space, assembly and those
that require less cooling loads with few or no air renewals.
471
7.3 Proposed air conditioning system solutions
So, two solutions of air conditioning are proposed for each of the two kinds of spaces
having completely different needs in ventilation and air conditioning. First, the air
conditioning of the offices (the first floor) can be accomplished either with floor FCUs
(for cooling and heating) or with multizone air conditioning VRV system, respectively.
While, the air conditioning of the production space (the basement) and the assembly
and finished products areas (ground floor) can be accomplished either with two air
duct systems with two CAUs or with ceiling FCUs (cooling only) with an independent
ventilation system, respectively. Summing up, the above the cases examined are:

A. office area
A1, cooling-heating with floor FCUs
A2, cooling-heating with VRV system
B. production assembly finished products spaces
B1, ceiling FCUs and independent air duct network (ventilation)
B2, air duct networks with CAUs.

7.4 Psychrometry
The psychrometric chart derives from the cooling loads calculated and shows the
individual systems that we have subjectively divided the facility. The psychrometry of
two systems was calculated. The first system involves the production area and the
second system involves the assembly finished products area. This chart is used for
calculating the CAU 1 in B2 case, which can also be seen in Figure 2:
(1) Indoor conditions
Desired temperature – TrdbTrwb: 26.0018.671C
Desired humidity – FrWr: 50.0010.62% (g/kg)
(2) Outdoor conditions
Outdoor temperature – TadbTawb: 33.2023.991C
Outdoor humidity – FaWa: 47.0015.22% (g/kg)
(3) Mixing point conditions
Point temperature mixing – TmdbTmwb: 29.6021.471C
Humidity mixing point – FmWm: 49.1312.92% (g/kg)
(4) Entering unit conditions
Temperature input – TedbTewb: 29.6021.471C
Humidity input – FeWe: 49.1312.92% (g/kg)
(5) Exiting unit conditions
Temperature output – TldbTlwb: 13.8412.891C
Humidity output – FlWl: 90.188.98% (g/kg)
SS (6) Entering room conditions
30,5 Flow temperature – TsadbTsawb: 13.8412.891C
Water supply – FsaWsa: 90.188.98% (g/kg)
More specifically in Figure 3, point 1 shows the conditions inside the room before the
air treatment; point 2 shows the conditions outside the building, from where the central
unit will take air and must change it according to our demands; point 3 shows
472 the conditions inside the central unit; point 4 shows the conditions when the outdoor
air enters the central unit (in this case it coincides with point 3); point 5 shows
the conditions when the treated air exits the unit; and point 6 shows the conditions
when the treated air from the central unit enters the room (in this case it coincides with
point 5).

7.5 FCUs
The two-pipe system was chosen for the FCUs of both cases (A1 and B1). The
advantage of the two-pipe system is that the water in the primary “flow” pipe is only
used in one FCU before being returned to the primary return pipe for reheating/
recooling. This means that it is possible to achieve equal temperature in all cooling
elements unlike the single pipe system. The advantage of a fully pumped two-pipe
system is a fast heating-cooling response and a better heat/cool balanced for all FCUs.

7.6 Air ducts

The air ducts were calculated by the constant pressure loss method. This method is
straightforward and easy to use, while it gives an automatic reduction of the air flow
velocities throughout the system. The reduced velocities are in general within the noise
limits of the application environment. However, this method increases the number of

Figure 3.
Psychometric chart for
production spaces
Air duct Duct Flow Duct Duct Air Friction/ Part Duct Total
Calculation for
network length rate Duct width height speed m (mm friction friction friction air conditioning
part (m) (m3/s) type (mm) (mm) (m/s) Y/m) (mmYS) (mmYS) (mmYS)

1.2 4.75 7,992 REC 2,000 250 6.00 0.05 3.05 0.25 3.34
2.3 4.24 4,303 REC 950 250 6.00 0.08 4.41 0.33 4.74
3.4 3.65 3,689 REC 800 250 5.95 0.08 3.03 0.30 3.34 473
4.5 3.65 3,074 REC 700 250 5.67 0.08 2.76 0.30 3.06
5.6 3.65 2,459 REC 550 250 5.36 0.08 2.46 0.30 2.76
6.7 3.65 1,844 CIR 450 5.02 0.08 2.16 0.30 2.46 Table VI.
7.8 3.00 1,229 CIR 300 4.53 0.08 1.76 0.25 2.01 Air duct network

components compared to other methods, and gives a poorer pressure balance to the
system. This leads to the need for more adjusting dampers that may increase the
system cost compared to other methods. By using this method we prefer quality and
calculation convenience against installation cost.
The application of the method can be noticed in Table VI. The first column shows
the air duct network. The certain network branches are numbered. The main duct is
numbered with 1 and as the network proceeds inside the building, numbers are
increasing. The total flow rate coming from the unit is 7,992 m3/h and is decreasing
while it is being divided into the smaller ducts. Two types of ducts have been used:
rectangular and circular. The air speed is decreasing, but we cannot tell the same about
the friction inside the network.

8. Conclusions
The main core of this paper is the qualitative approach of selecting the right air
conditioning system and the best calculation method for the cases examined. Thus, the
most accurate method for calculating the cooling loads of this industrial facility is the
ASHRAE RTS. The best calculation tool for installing a CAU in this factory is the
psychometric chart, which analyzes every phase of the conditioned air inside and
outside the CAU. While, considering the most efficient FCUs connection pipe system
for this industrial building, the two-pipe system proves to be the one. Regarding the air
duct calculation method, constant pressure loss method seems to be the most suitable
for calculating the air duct network of this building.
Finally, expanding the scope of this paper can lead to a future selection guide for the
best system and calculation method, when conducting an air conditioning study for an
industrial building. In addition to this, it would be interesting to examine if different
results derive from different calculation method application; and furthermore if this
leads to major or minor changes on the final decisions for installing an air conditioning
system in an industrial facility depending on the applied method.

References
Aerogrammi (2008), “Ventilation orifices, technical specifications catalog”, Athens.
Kiriakou, G. (2008), “Heating study of an industrial facility”, diploma thesis, Department of
Production and Management Engineering, D.U.TH, Xanthi.
Seretoudi, N. (2005), “Air conditioning and ventilation study of an industrial facility”, diploma
thesis, Department of Production and Management Engineering, D.U.TH, Xanthi.
SS Vrellas, C. (2009), “Air conditioning study for industrial facility”, diploma thesis, Department of
Production and Management engineering, D.U.TH, Xanthi.
30,5
Further reading
Antonopolos, A. and Kouremenos, D. (1991), Building Elements Thermal Flow for Cooling Loads
in Greece, Foivos Publications, Athens.
474 Asimakopoulos, A. (1975), Refrigeration Technology, Papasotiriou Publications, Athens.
Asimakopoulos, A. (1980), “Air conditioning”.
Dalavigas, A., Kristalidis, L., Ligerakis, A., Paparigakis, K. and Papadakis, D. (1987), “Building
installations: building air conditioning”, T.O.T.E.E 2423/86.
Lefas, K.H. (1992), Ventilation and Air Conditioning, Foivos Publications, Athens.
Papadimitriou, I. (2001), “Introduction to refrigeration and air conditioning”.
Papakostas, K.T. (2005), “Air conditioning systems and energy saving”, Proccedings of 34
Congress of Heating Refrigeration and Air Conditioning, Belgrade.
Papanikas, D., Kafetzopoulos, G. and Logos, G. (1987), “Building installations: cooling loads
calculation elements”, Technical Chamber of Greece Regulstions, T.O.T.E.E 2423/86,
Athens.
Pauleas, T. (2007), “VRV system: the solution for energy saving”, Conference, Athens.
Recknagel, H. and Spenger, E. (1980), Heating – Air Conditioning, Giourdas Publications, Athens.
Sellountos, V.I. (2002a), Heating – Air Conditioning, Vol. A, 3rd ed., ÔeEkdotiki Publications,
Athens.
Sellountos, V.I. (2002b), Heating – Air Conditioning, Vol. B, 3rd ed., ÔeEkdotiki Publications,
Athens.
Sotiropoulos, V.A. (1986), “Elements of industrial refrigeration”, Air Conditioning Conference
Thessaloniki.
Spliter, J. (2000), Overview of the Radiant Time Series Method, School of Mechanical and
Aerospace Engineering, Oklahoma state university, Athens, OK.
4M (2009), “Adapt manager, auto fine calculation program”.

About the authors

Charisis G. Vrellas, Production and Management Engineer (Democritus University of Thrace),
Master in Business Administration (MBA) (University of Macedonia) is a PhD candidate at the
University of Macedonia, Greece. Charisis G. Vrellas is the corresponding author and can be
contacted at: vrellas@uom.gr
Theoklitos S. Karakatsanis, PhD in Electrical Engineering (National Technical University of
Athens) is an Assistant Professor at Democritus University of Thrace, Greece.

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