Air Conditioning of an Industrial Warehouse using a Chilled Water System: A case study

 

Welcome to our blog dedicated to the comprehensive design of chilled water handling unit systems for the air conditioning of industrial warehouses! In this article, we will explore in detail the technical aspects, design considerations and proposed solutions for a specific project. It is important to note that some data regarding the original project have been modified for the purposes of this exercise.

ok, Project Context!

In this project we face the challenge of air conditioning an extension (zone 2) of a large industrial warehouse, where controlled temperature is crucial for the optimal functioning of the equipment and the comfort of the workers. For this project, let's consider installing air handling units (AHUs) to achieve this goal.

In Area 1 we have the production area of our industrial warehouse, due to the increase in demand it was decided to create an expansion and this resulted in the inclusion of an additional air unit (AHU3) and change of the duct system.

Let's start:

Project specifications

Air Units:

AHU-01: 25 tons, 10,350 CFM, 81.8 GPM (existing)

AHU-02: 25 tons, 10350 CFM, 81.8 GPM (existing)

AHU-03: 31 tons, 8230 CFM, 69.4 GPM (new unit installed)

Total air flow to supply: 28,950 CFM

Water flow: 2.4 GPM/TON

Air Distribution: Through a metal duct connected to 12 textile ducts.

Extractor (IN-1): 2 HP, providing 4,662 CFM to the machine room.

Chiller: Connection to a 100 Tons Chiller with a flow rate of 240 GPM.

Important note: highlight that by adding this additional unit to the chiller system we are integrating an over-demand from 235 GPM to 309 GPM, we will be seeing this information throughout this blog.

Design details

1. Balance of water flow

One of the challenges identified in the original project was the imbalance between the water flow demanded and that delivered by the existing pump. In UMA-03, the installation of a 2-way proportional valve has been proposed to modulate the water flows in the different sections of the system. This solution ensures equal distribution of water flow and improves system efficiency.

This diagram shows the composition of the system integrating the Chiller together with the 3 AHUs in our case + 2 AHUs from outdoor areas.

2. Replacement of Hydronic Accessories

To ensure optimal system performance, replacement of all hydronic accessories such as filters, shut-off valves, electric valves, thermometers, circuits, pressure gauges and thermostats is recommended. These components play a crucial role in controlling and regulating water flow, ensuring reliable and efficient performance.

AHUs installation details:

Note: in the cases of AHU-1 and AHU-2 used 3 ways valves.

Temperature control installation diagram:

3. Connection to the cooler and air distribution.

The air units will be connected to a 100-tons chiller, which will also serve two other units in a neighboring industrial warehouse (see 1st point). The air flow generated by the units will be distributed equally through a system of metal and textile ducts, guaranteeing a uniform temperature throughout the industrial warehouse.

3D design distribution of units and metal duct system:

Cut-off view of duct system:

Textile ducts:

Conclusions

The design of a system of chilled water treatment units for the air conditioning of an industrial warehouse is a complex process that requires a comprehensive and careful approach. By properly addressing issues such as water flow balance, hydronic fixture replacement, and efficient air distribution, we can ensure a comfortable and productive indoor environment for all occupants of the home.

In future posts, we will continue to explore topics related to the design, installation and maintenance of industrial HVAC systems, with the goal of providing valuable information and practical solutions to our readers.

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Disclaimer:

The information provided in this blog post is for informational purposes only. Any actions taken based on the content of this post are at the reader's own risk.

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