EF303 - Climate Systems - AHU System

EDMM 210 - Process and equipment
Routine Maintenance and Troubleshooting of AHU Systems

2 Days Training Course ( 2007 )
On : Routine Maintenance and Troubleshooting of AHU Systems.
For : FLM, Nestle Manufacturing (Malaysia) Sdn.Bhd.
By : Mr. N S Loh
PEng
1
Executive Diploma in Manufacturing Management
Routine Maintenance and Troubleshooting of AHU system

Trainer : Mr. N S Loh
Professional Engineer in the Province of Ontario, Canada
Member of ASHRAE.
Managing Director Of Climate Systems Sdn. Bhd.
Long term partner in M&I of Air Conditioning, Refrigeration in NMM factories
Has more than 25 years of extensive & practical experience
in the M&E projects especially in the field of ACMV
Tel No: 03-79570477
Email: nsloh@climatesystems.com.my
2
Module # 1. Basic air principles

At the end of the course , FLM is able to :
a. Explain the basic air properties and its behavior in an airair-conditioned space.
What is dew point, relative humidity, temperature & how to measure
measure them.
b. Explain the use of psychrometric chart & use it to solve fundamental airair-conditioning problems.
Locate the operation point of a few typical applications e.g. Milo filling room, ice cream cold room,
ice cream filling room & explain the problem, limitations, improvements
improvements etc.
c. Explain the concept of sensible and latent heat and :
Relate to typical application in Nestle factories.
Explain the impact to AHU operation and product issues.
d. Explain Nestle requirements of RH and temperature for Milo, cereal, Nescafe, ice cream, mixes,
milk powder.
3
Module # 1.
Basic air principles
4
Composition of Dry Air
1%
21%
78%
Nitrogen
Oxygen
Other Gases
5
Water Vapor in Air

Moist air is a binary mixture of dry air and water vapour
-The amount of water vapour varies from zero (dry) to a maximum that
that depends on
temperature and pressure.
Water Vapor
Dry Air
Air +
Vapor
Mechanical Mixture
Air Sample
In A Unit Volume of Air
7
Section 2 Comfort
Cool Air Sample
Not Saturated
Saturated
no more moisture can be absorbed
70F (21C)
70F (21C)
8
Warm Air Holds More Moisture

Not Saturated
Saturated
92F (33C)
92F (33C)
The warmer air able to hold more moisture

- note, add more dots
9
Basic Air Principles

Dry Bulb Temperature
The temperature of air as registered by an ordinary thermometer.
Wet Bulb Temperature
The temperature registered by a thermometer whose bulb is covered by a wetted wick and
exposed to a current of rapidly moving air.
Dew Point Temperature
The temperature at which condensation of moisture begins when the air is cooled.
Moisture Content (Specific Humidity)
The weight of water vapour in grains (pounds of moisture per pound of dry air or gram of
moisture per kilogram of dry air).
Relative Humidity
Ratio of the actual amount of moisture in the air to the saturated amount of moisture in the
air at the same temperature.
10
10
Psychrometric Chart
Introduction
11
11
Psychrometric Chart
Understand the properties of air and water vapor mixtures
Build the psychrometric chart
Use the psychrometric chart to determine the properties of an air/water

air/water vapor mixture
Use the psychrometric chart to understand the basic air conditioning

conditioning processes
Understand how the processes can be combined into a system using a system plot
diagram and psychrometric chart
12
12
Psychrometric Chart, Normal Temperature, Sea Level
13
13
Sling Psychrometer
Proper Procedure
Avoid adverse conditions that
can affect reading
Moisten wick before procedure
Rotate device at least 2 minutes
Read device immediately after rotation
The sling psychrometer consists of two thermometers mounted in a frame and attached to a
handle by means of a swivel. One thermometer has a wetted cotton wick wrapped around
its mercury bulb. The other thermometer is an ordinary mercury type.
type.
When the apparatus is whirled around, air is moved across the wick
wick and some of the water is
evaporated. This evaporation absorbs heat and causes the thermometer to register
register the
wet bulb temperature.
This piece of equipment provides a direct and instant dry/wet bulb comparison, a
convenient way of determining the humidity condition in the air.
Warning: Mercury instrument/equipment is absolutely prohibited in Nestle

14
Factories.
14
Dry & Wet Bulb Temperatures

How to identify dry & wet bulb from the Psy-chart
The horizontal axis on the chart represents an
ordinary temperature scale called the dry bulb
temperature.
It is the temperature of air as registered by an ordinary
thermometer.
Wet bulb temp is the temperature registered by a
thermometer whose bulb is covered by a wetted
wick and exposed to a current of
rapidly moving air.
Wet bulb temperature

60Fwb (15.5Cwb)
The saturation line on the chart
Represents the wet bulb
temperature.
Saturation Line
Wet Bulb Line F
Dry Bulb Line F
75 Deg. F db ( 24Deg.C Dry bulb)
15
15
Dewpoint
How to identify dew point from the Psy-chart
Assume the air at 75Fdb (24Deg.C dry bulb )
60Fwb (15.5 Deg.C wet bulb),
its dewpoint at this condition is 53F (11.6C).
60Fwb
(15.5Cwb)
Dewpoint = 53F (11.6C)
wb dp F
db F
53F
(11.6C)
75F (24 Deg.C)

16
16
Moisture Content (Specific Humidity)

The vertical scale indicates the amount of water
vapour mixed with each pound of dry air the
specific humidity scale.
Moisture Content Line
Since the amount of water vapour is small, the scale

is plotted in grains of water vapour per pound of dry
air.
Assume the air at 75Fdb and 60Fwb,

its moisture content at this condition is 60 gr.
60Fwb
60 gr
wb dp
F
db F
17
75Fdb
17
Dewpoint and Moisture Content
Assume the air at 75Fdb and 60Fwb, its dewpoint is

53F.
Its moisture content at this condition is 60 grains
60Fwb
Dewpoint = 53F
60 gr
wb dp F
db F
53F
75Fdb
18
18
Dew Point Example

An insulated duct carrying air at 55F and runs through a space
temperature of 95Fdb and 100 grains of water vapour, the
dewpoint of the space is 67F.
That means the 55F duct cools the surrounding air below its 67F
dewpoint, therefore water vapour condenses on the duct..
Outside air 95Fdb

@ 100gr
Dp = 67F
100
gr
Supply air
in Duct 55F
wb dp
F
db F
55
67 dewpoint
95
19
19
Cooling and Dehumidifying

Cooling Coil
Coil Surface Temp
= 10C
Leaving Air
Entering Air
Off Coil Temp = 12C
On Coil Conditions
26C @ 50%RH
Dew Point =14.5C
Supply chilled water

Shall be a 2 to 3C below coil
surface temp
Condensation
occurs when coil surface temperature is
below the dewpoint of the entering air
20
20
Saturation (Wet Bulb) Line
The saturation curve

indicates 100% RH
Saturation Line
wb dp
F
db F
21
21
Saturated Air Air Sample
Not Saturated
Saturated
70F (21C)
55 gr
70F (21C)
110 gr
22
22
How Much Moisture at Saturation?
110
grains
55
grains
Dry Bulb Temperature, F

23
23
Relative Humidity
Relative
55
Humidity = 110 = 50%
Approx.
RH is defined as the amount of
moisture in the air compared to the
maximum amount that could be
present at the same temperature.
110 gr
58.5Fwb
50%
55 gr
wb dp
F
db F
70F
24
24
Psychrometric Chart
Wet
Wet Bulb
Bulb Temperature
Temperature
Relative
Relative
Humidity
Humidity
%RH
%RH
Dew Point
Temperature
Moisture
Moisture
Content
Content
wb dp
F
db F
Dry
Dry Bulb
Bulb Temperature
Temperature
25
25
Psychrometric Chart
Typical Nestle applications

& solutions
26
26
Psychrometric Chart
for Milo Filling Room
Design Room Conditions:
Room Temp = 26C (79F)
Relative Humidity = 45%
Wet Bulb
= 64.5F (18C)
RH=
RH= 45%
45%
Dew Point
= 55F (12.8C)
Moisture
Moisture
Content
Content ==
68
68 gr
gr
wb dp
F
db F
Dry Bulb
= 79F (26C)
27
27
Psychrometric Chart
for Milo Filling Room
Problems: ROOM TOO COLD (esp. at night)
Say, Room Temp = 22C (72F)
Relative Humidity > 55%
Wet Bulb
= 64.5F (18C)
Wet Bulb
= 62F (16.5C)
Design
Design
Conditions
Conditions
26C
26C @
@ 45%RH
45%RH
Dew Point
= 55F (12.8C)
wb dp
F
Moisture
Moisture
Content
Content ==
68
68 gr
gr
RH=55%,
RH=55%,
Too
Too High
High
Dry Bulb
= 72F (22C)
db F
28
28
Psychrometric Chart
Problems: ROOM TOO COLD (esp. at night) for Milo Filling Room
Room Temp = 22C (72F)Relative Humidity > 55%
Solution:
Provide
Provide REHEAT
REHEAT to
to warm
warm the
the
room
room air
air from
from 22C
22C to
to 26C,
26C, thus
thus
lowering
lowering RH
RH from
from 55%
55% to
to 45%
45%
Design
Design
Conditions
Conditions
26C
26C @
@ 45%RH
45%RH
Dew Point
= 55F (12.8C)
wb dp
F
db F
Moisture
Moisture
Content
Content ==
68
68 gr
gr
RH=55%,
RH=55%,
Too
Too High
High
Dry Bulb
= 72F (22C)
Dry Bulb
= 79F (26C)
29
29
Psychrometric Chart
Design Conditions
Conditions
for Milo Filling Room Design
26C
26C @
@ 45%RH
45%RH
Problems: ROOM RH High (esp. More

Outside Air)
Say, Room Temp = 26C (79F)
Relative Humidity > 60%
RH=
RH= 60%
60%
Too
High
Too High
Wet Bulb
= 69F (20.5C)
Moisture
Moisture
Content
Content ==
68
68 gr
gr
Dew Point
= 64F (17.8C)
wb dp
F
db F
Dry Bulb
= 79F (26C)
30
30
Psychrometric Chart
Problems: ROOM RH Hihg (esp. More Outside Air) for Milo Filling Room
Room Temp = 26C (79F) Relative Humidity > 60%
Solutions:
Check
Check cooling
cooling coil
coil conditions;
conditions; eg.
eg.
dirty
dirty coil,
coil, high
high chilled
chilled water
water temp,
temp,
control
control valve
valve not
not working,
working, ensuring
ensuring
that
that coil
coil temp
temp below
below room
room dew
dew point
point
Wet Bulb = 69F (20.5C)
RH=
RH= 60%
60%
Too
High
Too High
Design
Design
Conditions
Conditions
26C
26C @
@ 45%RH
45%RH
Dew Point = 64F (17.8C)

Moisture
Moisture
Content
Content ==
68
68 gr
gr
Dew Point = 55F (12.8C)
wb dp
F
db F
Dry Bulb
= 79F (26C)
31
31
Psychrometric Chart
for Ice Cream Filling Room
Design Room Conditions
Relative Humidity = >60%
Wet Bulb
= 69F (20.5C)
RH
RH ==
60%
60%
Moisture
Moisture
Content
Content
== 90
90 gr
gr
Dew Point
= 64F (17.8C)
wb dp
F
db F
Dry Bulb
= 79F (26C)
32
32
Psychrometric Chart
for General Office
General Office
Relative Humidity = 55%
Wet Bulb
= 64F (17.8C)
Dew Point
= 58F (14.5C)
RH
RH ==
55%
55%
Moisture
Moisture
Content
Content
== 72
72 gr
gr
wb dp
F
db F
Dry Bulb
= 75F (24C)
33
33
Psychrometric Processes in Air Conditioning

1.
2.
3.
4.
5.
6.
7.
8.
Sensible Heating
Sensible Cooling
Humidification
Dehumidification
Cooling and Humidification
(Evaporative Cooling)
Cooling and
Dehumidification
Heating and
Humidification
Heating and
Dehumidification
wb dp
F
db F
34
34
Principles of Heat
35
35
Internal Heat Gain
People
Lights
Motors
Appliances
Computers
Cooking
Process
Machines
36
36
External Heat Gain

Transmission
Hot Outside
Cool Inside
Infiltration
Transmission
37
37
Sensible Heat
Measured on a thermometer
38
38
Sensible Heat
British Thermal Unit (Btu)
Btu is the heat energy necessary to change
one pound of water 1 F
1 F RISE
1 Btu
39
39
Sensible Heat of Water

212
100 Btu needed to raise 32F to 132F 100 F in 1 pound of H20
Temperature F
132
100
42
10 Btu needed to raise 32F to 42F
10 F in 1 pound of H20
32
10
100
Enthalpy (Btu/lb)
180
40
40
Latent Heat
212 F
(100Deg.C)
Total Heat = Sensible Heat + Latent Heat

212 F (100Deg.C)
Not measured on
a thermometer
Change of State
41
41
Total Heat = Sensible Heat + Latent Heat
LATENT HEAT
HEAT
LATENT
AATT
HHEE
L
L
TAA
OT
TTO
SENSIBLE
SENSIBLE HEAT
HEAT
wb dp
F
db F
42
42
Typical Application Absorbing Heat and Humidity
55F (12.5C)
64 gr
Factory, Office etc

78F (26C)
74 gr
43
Executive
in Manufacturing
Manufacturing Management
Executive Diploma
Diploma in
Management
43
Typical AHU Operations

O
A
MIX AIR
COOL
R
A
REHEAT
S
A
Heat
Source
44
44
Typical AHU System Components
Fresh Air Inlet
Air Handling
Unit (AHU)
Supply
Air Duct
Return Air duct

Distribution
duct
textile duct
Return Air Inlet
with Filter
Process Room
45
45
Sensible Cooling
The dry bulb temperature will fall but no change in the moisture content
Sensible Heat, Qs = 1.10 x CFM x t
Airflow 1000 cfm

100 db
70 db
qs = 1.10 1,000 cfm (70 100 ) = 33,000 Btuh
hA
Cooling Coil
hB
wb dp
F
db F
70
100
46
46
Sensible Heating
The dry bulb temperature will rise but no change in the moisture content
Sensible Heat, Qs = 1.10 x CFM x t
Airflow 1000 cfm

100 db
qs = 1.10 1,000 cfm (100 70) = 33,000 Btuh
70 db
hB
Heating Coil
h
A
wb dp
F
db F
70
100
47
47
Dehumidification
The moisture content is reduced at a constant dry bulb temperature
temperature
Latent Heat, Ql = 0.69 x CFM x grains

Airflow 1000 cfm
q l = 0 .69 1,000 cfm (54 94 ) = 27,600 Btuh
70 wb
hB
62 wb
65 dp
50 dp
hA
Dehumidifier
grains
94
gr
54
gr
wb dp
F
db F
48
48
Humidification
The moisture content of air is increase with no change in the dry
dry bulb temperature
Latent Heat, Ql = 0.69 x CFM x grains

Airflow 1000 cfm
80 db
80 db
q l = 0.69 1,000 cfm (94 54 ) = 27,600 Btuh

hA
70 wb
62 wb
65 dp
50 dp
hB
Water
Humidifier
grains
94
gr
54
gr
wb dp
F
db F
49
49
Cooling and Dehumidification

Decrease in both temperature and moisture content
Total Heat, Qt = Qs + Ql
Airflow 1000 cfm

80 db
qs = 1 .10 1,000 cfm (55 80 ) = 27,500 Btuh
55 db
q l = 0 .69 1,000 cfm ( 49 78 ) = 19,720 Btuh

67 wb
51 wb
hA
60 dp
47 dp
Cooling
Coil
grains
hB
55
78 gr
49 gr
wb dp
F
db F
qt = ( 27,500 ) + ( 19,720 ) = 47,220 Btuh
80
50
50
Cooling and Dehumidifying

Coil Surface Temp
= 10C
Cooling Coil
Entering Air
Leaving Air
On Coil Conditions
26C @ 50%RH
Dew Point =14.5C
Off Coil Temp = 12C

Shall be a 2 to 3C below coil
surface temp
Condensation
below the dew point of the entering air
51
51
Psychrometric Plot Of AC System

General
General Office
Office
A
Room
A
Room condition
condition (75F
(75F @
@ 55%RH)
55%RH)
B
Outside
B
Outside condition
condition (92Fdb/82Fwb)
(92Fdb/82Fwb)
C
Mixed
C
Mixed air
air condition
condition (On
(On coil
coil temp)
temp)
D
Room
D
Room dewpoint
dewpoint
E
Effective
E
Effective coil
coil surface
surface temperature
temperature
11
Off
Off coil
coil temperature
temperature
wb dp
F
db F
Dry Bulb Temperature db (F)
52
52
Outside Air Mixing
1000 cfm
= 25 %
3000 cfm + 1000 cfm
Example:
1000 cfm of OA
3000 cfm of RA
Total air = 4000 cfm
%=
25 00%
%
75
%
Mixed Air conditions

are found by ratio
of airflows
O
A
RA
wb dp
F
db F
85F (29C)
53
53
100% Outside Air

Example (Drymix):
100% OA conditions:
92Fdb/82Fwb (33.4Cdb/27.8Cwb)
On Coil
Room conditions:
79Fdb/45%RH, (26Cdb/45%RH)
Dp=55F (12.8C)
Dewpoint
On Coil = 92Fdb/87Fwb
Off Coil =57F/56F
Room Conditions
Coil Surf Temp

wb dp
F
Off Coil
db F
79F (26C)
54
54
30% Outside Air

Example (Cereal):
30% OA conditions:
92Fdb/82Fwb (33.4Cdb/27.8Cwb)
OA
Room conditions:
79Fdb/45%RH, (26Cdb/45%RH)
Dp=55F (12.8C)
Dewpoint
On Coil
On Coil = 79F+30%(9279F+30%(92-79)F=83F
Off Coil =57F/56F
Room Conditions
Coil Surf Temp

wb dp
F
Off Coil
db F
79F (26C)
55
55
Plotting the System
RA
OA
System plots can be

used to understand and
analyze performance
SA
MA
RA
OA
MA
SA
Return Air (A)

Outside Air (B)
Mixed Air/On Coil (C)
Supply Air/Off Coil (1)
56
56
Typical Applications, Nestle

Production Area
Milo Filling Room
Temperature
Deg C
26
Relative Humidity
%
45
Ice Cream Filling
26
60
Maggie Soup/Cube
26
45
Chocolate
20
60
Nescafe
26
45
Cereal
26
45
BMD
26
45
57
57
Module # 2. Air-Conditioning Principles

a. Explain the functions of air-conditioning for personal comfort and process (filling) area.
Typical conditions & ranges for personal comfort and Nestle process areas
Milo/Nescafe/Cereal filling, cold room, ice cream filling.
Impact of air conditions to manufacturing processes, product quality and Food Safety.
b. Identify and describe the different type of AC systems
Their configuration , components, operation, applications and limitations
c. Explain the basic thermodynamics processes, components and installation of the following airconditioning systems.
Direct expansion system (awareness only)
Chilled water system AHU
d. Understand the concept of cooling/heating load by
Identifying the heat load in typical filling rooms and explain how it can affect the performance
of an air-conditioning system.
Explaining the requirement for outside (fresh) air and its effect to the air-conditioning system
performance.
e. Explain the function of room pressuring and the requirements for positive and negative pressure.
Causes and consequences of failing the pressure requirements
58
58
Air-Conditioning Principles
Functions of air-conditioning
59
59
Comfort and Process

Two purposes for air-conditioning:
Comfort air-conditioning
Cools and dehumidifies people
Process air-conditioning
Controls temperature and humidity for
products or processes
The basic cycle is the same

60
60
Comfort / Process
People
Comfort air-conditioning is to maintain an
indoor conditions that are considered
comfortable to the occupants.
Products
Process air-conditioning is to improve an
industrial process so that the quality or
quantity of the products may be
achieved.
61
61
Comfort/Process Parameters
Temperature
Air Purity
Air Quality
Humidity
Air Motion
62
62
Comfort/Process Parameters
1.
Dry Bulb Temperature
2.
Relative Humidity
3.
Air Motion
4.
Air Cleanliness (Purity)
5.
Air Quality (acoustics, noise etc)
63
63
Total Comfort/Process Air Conditioning

It is maintained by:
Heating
Humidifying
Cooling
Dehumidifying
Ventilating
Filtering
Circulating
64
64
Temperature & Comfort
People are highly sensitive to temperature fluctuations.

The comfort zone, ideal comfort temperature for office work 22+/-2 deg C
Work rate and mental performance declined rapidly above 23 deg C for
most people.
The accident rate also rise at high temperatures, due to reduction in
attention, caused by the physiological need to relax.
But, for every 1 deg C increase in room temperature there will be
approximately 3 to 5% reduction in energy consumption.
Caution should be used in adjusting space setpoints to save energy. As
occupant productivity costs may be 100 times the potential energy saving.
The essence of energy savings in therefore in terms of :
- elimination of over-cooling
- temperature set backs at nights or low ambient temperatures
- raising temperature setpoints at non-essential areas
65
65
Relative Humidity & Comfort
Relative humidity greater than 70% are found to contribute to microbial

contaminant growth. Humidity less than 40% may contribute to dermatities.
Lower humidity reduces sensitivity to odors, thus giving a greater feeling of air
freshness.
Lower humidity allows a slightly higher temperature settings for the same
perceived level of comfort.
However, human beings are more sensitive to temperature changes rather than
relative humidity changes.
To lower the relative humidity in the air entails lowering the dew point
temperatures which will consume much more energy than just lowering down
the dry bulb temperature.
To control the relative humidity of the room may require reheating method.
Overcooling the air to extract the moistures and heating it back to comfortable
temperatures again an double expenditure of energy.
66
66
Temperature and Relative Humidity in Different Applications Industry

Industry
Process
Temperature C
Relative Humidity %
Baking
Cake Icing
Cake Mixing
Dough Fermentation
21 23
23 24
28 - 30
50 55
60 65
65 - 70
Cereal
Packaging
23 27
35 50
Confectionery
Chewing Gum Rolling

Chewing Gum Wrapping
Chocolate Covering
Candy Making
Starch Room
21 23
20 22
21 30
20 21
21 - 23
50 55
40 50
40 50
50
50
Food
Butter Making
Daily Chill Room
Storage of Sugar
Storage of meats
16 18
48
20 24
16 - 20
55 65
55 65
35 45
55 - 65
Paper
Binding
Storage of Paper
18 25
18 - 25
35 45
35 - 45
Poultry
Incubators
37 39
55 - 75 67
67
Typical conditions & ranges for

personal comfort & process area
68
68
Temperature and Relative Humidity in Different Applications, Nestle

Chocolate and Biscuits
Product
Hygiene
Level
Temp
Deg.C
RH
%
Filter
Type of Room
Chocolate
med-dry
26
60 H
G4
(manufacturing)
Chocolate
med-dry
20
60 PQ
G4
(moulding)
Chocolate
low-dry
20
60 PQ
G4
(short storage)
Chocolate
low-dry
12
60 PQ
G4
(long storage)
Cocoa Powder
med-dry
17
55 H
G4
(manufacture)
Filled Wafer
med-dry
24
55 PQ
G4
(moulding)
KitKat
med-dry
24
37 PQ
G4
(maturing)
(layering)
med-dry
24
50 PQ
G4
69
69
Typical Applications and Conditions, Nestle

Production Area
Temperature
Deg.C
Relative Humidity
%
Milo Filling Room
26
45
Ice Cream Filling
26
60
Maggie Soup/Cube
26
45
Chocolate
20
60
Beverage Mixer
26
45
Nescafe
26
45
Cereal
26
45
BMD
26
45
70
70
Typical Milo Filling Room
Return air duct.with filter to

prevent contamination
Suitable location of
outside air intake
Locate AHU inside sheltered

space & easily accessible
OA
RA
Air leaks thro conveyor

openings
Textile ducts: short,

easy to clean
SA
Reduce Leaks
Typical Process Room

71
71
Air Handling Systems
Control HUMIDITY
Control TEMPERATURE
Control DUST
Control ROOM PRESSURE
Control AIR QUALITY
72
72
Controlling Growth
Is it possible to control growth in the AHU and in the
PRODUCTION AREA ?
Remove all the air Reduce available water by reducing humidity Remove food from the air Control the temperature to minimise growth rate Stop the clock 73
73
System Standard
What factors which influence the standard of system required ?
Product sensitivity measured by hygiene level and type of cleaning
High, Medium or Basic Hygiene
Wet, Controlled Wet or Dry Cleaning
Contact between Air and Product
Direct Contact Air - Product conveying or cooling, laminar protection
Indirect Contact Air - Production and Filling Rooms
Non Contact Air - Warehouse, Cold Store

74
74
Air and it's Contact with Product

1. Contact air (high hygiene, HEPA filters)
Air in permanent, intensive contact with product
Process Air: blown into product: drying, cooling, conveying,..
Shielding Air: a blanket of clean air spread over sensible product
2. Product rarely contacts air (accidental contact, medium hygiene, coarse and fine
filters)
Covered process equipment limits exposure of product to air
Filling, processing and maturing rooms
3. Product cannot come in contact with air (low hygiene, coarse filters)
Warehouse, cold store, liquid process lines,..
Non-process areas such as laboratory, offices, social, ...
75
75
Direct Contact Air

Process Air Blown onto the Spray Dried Product
Spray
Drier
A
C
A
D
76
76
Contact Air Direct
A filter-fan unit protects a filling line,

inside an airconditioned room
Line
77
77
Accidental Contact
Air-conditioning for Filling & Processing Areas
Outside air
Hygienic Air
handling unit
Short return air

duct with filter
Supply air
duct
Low speed
Air distribution
textile air duct
Close
Openings &
Doors
Pressurised Process Room
78
78
Food Safety and Quality

Can AHU affect SAFETY, FOOD SAFETY, FOOD QUALITY ?
Humidity
Condensation
Sweating
Hydroscopic
products
Temperature
Microbial growth
Sweating
Melting
Dust
Bacteria
Contamination
AIR
QUALITY
Fumes
Smoke
Laws
Room Pressure
Entry of
contamination
Cross
contamination
79
79
Type of AC Systems
80
80
Split type units

Residential/Commercial Systems
81
81
Outdoor Condensing Units

Air-cooled condensing units
Residential
1 to 5 ton
Commercial
6 to 100+ ton
Duct Free
to 5 ton
82
82
Typical Condensing Units
Water-Cooled
Air-Cooled
83
83
AC Component and configuration
Indoor fan
coil Unit
Outdoor Condensing Unit
Filter
Drier
Liquid Line Warm-Temp.

High-Pressure Liquid
Liquid Line
Solenoid Valve
Sight
Glass
Suction Line Low-Temp.

Low-Pressure Vapor
84
84
Four Essential Components
3.
4. Pressure/ flow
control valve
(TX Valve)
Heat rejecting section

(Condenser)
2. Vapor pump
(compressor)
1. Heat absorbing section (Cooling coil)

85
85
Type of common refrigerants

CFC
(R-11 & R-12 ) - Have been eliminated
HCFC (R-22 &R-123a) -Will be eliminated

HFC ( R-134a )
(R-134a)
-Will be primary future refrigerant
HFC (R-410A)
-Best choice for chillers and

mobile air conditioning
-Good choice for packaged unit
HFC (R-404)
-Good choice for refrigeration
Ammonia
-Used in Chembong KitKat,Ice-cream Plant

& cold room Chiller Plant
86
86
Thermodynamic Process
Pressure
1-2
2-3
3-4
4-1
Condensation
Expansion (TXV)
Evaporation (Cooling Coil)
Compression (Compressor)
Condensation (Condenser)
Expansion
Compression
Evaporation
2
Enthalpy
Mollier Chart
87
87
Direct Expansion Component Functions

Liquid Line
Metering Device
- Create a pressure drop and control flow
Evaporator
- Absorb heat
Condenser
- Reject heat
Hi-Pressure Hot
Gas Line
Suction Line Lo
pressure gas line
Compressor
- Create a suction on the evaporator and raise
the pressure to the condensing temperature
88
88
Chilled Water System AHU

Chilled Water (5 to7Deg.C)
Supply line
Return line
Set Point
12 Deg.C
Control
Variable
Outside Air
Process
Variable
Dew
point
temp.
sensor
TC
P
I
P
I
Supply
Air
Return
Air
Chilled water cooling coil
Centrifugal fan
89
89
Reheat Water System AHU

Reheat Water (60Deg.C)
Supply line
Return line
Set Point
26Deg.C
Control
Variable
Outside Air
Return air temp

sensor
Process
Variable
TC
P
I
P
I
Supply
Air
Return
Air
Hot water reheat coil
Centrifugal fan
90
90
PID Control Loop AHU

Supply line
Supply line
Return line
Return line
Control
Variable
Set Point
12 Deg.C
temp.
sensor
TC
Set Point
26Deg.C
Process
Variable
Dew
point
Outside Air
Return air temp

sensor
Control
Variable
Process
Variable
TC
P
I
P
I
Supply
Air
Return
Air
Centrifugal fan
91
91
Chilled water components and

functions
Glycol vs water
92
92
Chilled water components and functions
93
93
Concept of cooling/Heat Load
94
94
Typical Heat Load

Human load depending of activity
95
95
Internal Equipment Load
People
Lights
Motors
Appliances
Cooking
Computers
Process
96
96
External Heat Load
Transmission
Solar
33C Outside
24C
Infiltration
Transmission
97
97
Fresh Air Load

************ use a different slide
Inside
1 cfm
Outside
1 cfm
75 F
1 cfm
1 cfm
Inside
Outside
91 F
q (heat)
qs (heatflow)
qs = 1.10 cfm (tout - tin)
qs = 1.10 cfm (91 - 75)

qs = 17.6 Btuh / cfm
98
98
Psychrometric Plot Of AC System
Chocolate
Chocolate Product
Product Room
Room
A
Room
A
Room condition
condition (79F
(79F @
@ 60%RH)
60%RH)
B
Outside
B
Outside condition
condition (92Fdb/82Fwb)
(92Fdb/82Fwb)
C
Mixed
C
Mixed air
air condition
condition (On
(On coil
coil temp)
temp)
D
Room
D
Room dewpoint
dewpoint
E
Effective
E
Effective coil
coil temperature
temperature
11
Off
Off coil
coil temperature
temperature
wb dp
F
db F
Dry Bulb Temperature db (F)
99
99
Outside Air For Pressurization

Outside Air is brought in
thro the AHU for room
pressurization
1000 cfm
= 25 %
3000 cfm + 1000 cfm
25 00%
%
75
%
Example:
1000 cfm of OA (25%)
3000 cfm of RA
Total air = 4000 cfm
%=
O
A
RA
wb dp
F
db F
85F (29C)
100
100
The reasons for room pressurization:
1. To prevent contamination entering from outside and from other processes.
2. Prevent un-conditioned outside air with higher moisture contents to dilute the
Controlled relative HUMIDITY for HYGROSCOPIC products like Coffee,
Milo, Milk Powders & Cereal base products.
3. The ideal room pressurization value will be :3 mmwg or 10 to 30 Pa.
101
101
To achieve room +ve pressure in Filling Room
Open the outside air damper by 15 to 20%.
Allow fresh air into the Mixing Box.
The supply air pressure will achieve +ve pressure than the atmospheric air pressure
Return air
temp.sensor
Room air pressure

Outside Air
=Atmospheric +10 to 30 Pa
Return air
pressure = xPa
P
D/P
TC
Dew point temp. Sensor
TC
Supply
Air
Return
Air
Mixing box
Centrifugal fan
102
102
Room Pressuzation and Effects

Adjustment of outside air for room
pressurization control
Outside air via AHU
for room
pressurization
Hygienic Air
handling unit
Supply air
duct
Air distribution
textile air duct
Pressurized Process
Room
103
103
Module # 3. Air Handling Unit (AHU)

a. Explain the working principles, design and specification, function & operation of each components.
Reading the process parameters (delta T, delta P, water temperature etc)
How the control loops works in principle, interlocking and control.
b. Explain the correct installation and operation of AHU
Gap reports and case study-identify wrong installation and the problems it can cause.
c. Explain the difference between FCU and AHU
d. Explain the function, classification & specification, installation of air filters
Select the correct type of filters for different applications
Explain the SOP for cleaning & replacement of filters
Explain Nestle guideline for filter use
e. Explain Nestle Star rating for AHU and its application
f. Explain the design and specification of hygienic AHU
g. Explain the routine maintenance for AHU
Condition monitoring (trending)
Coil cleaning, belts change, internal cleaning/hygiene, siphon cleaning, AHU room hygiene,
h. Troubleshoot common AHU problems
Explain the symptoms, possible causes, diagnose true cause, and corrective action
104
104
Functions of Air Handling Unit (AHU)

The air handling unit has four key roles
To control the temperature in the room
Remove heat which is added by people, by process, comes
through the building structure or is brought in with fresh air.
To control moisture in the room
Remove moisture which is added by people, by process, leaks
through the building structure or is brought in by fresh air.
To maintain building pressure and therefore hygiene by replacing
all air which leaks out of the building or is taken out by the process.
To filter the air in the room and air brought in from outside.
105
105
Components of AHU
Outside
Fresh Air
filtration cooling heating ventilation
Mixing Air
Air Return
from Room
Air Supply
to Room
106
106
Typical AHU for Milo Filling Room

Primary filter
EU4
Outside
Air
Return air temp
controller
TC
Water droplet
separator
Secondary filter
EU8
Chilled water
cooling coil
Inside smooth,
gaps sealed
P
I
Return
Air
Filter pressure
differential gauge
Dew point temp.

controller
P
I
TC
TT
I
Supply
Air
T
I
Mixing box
Condensate
syphon
Access & space for

cleaning
Centrifugal fan
107
107
Typical Nestles AHU Filters
Outside
Air
Filter pressure
differential gauge
Primary filter
EU4
Secondary filter
EU8
Water droplet
separator
P
I
P
I
Supply
Air
Return
Air
Mixing box
Condensate
syphon
Centrifugal fan
108
108
Typical Nestles AHU Temp.Control

motorised Air
damper controlled
by PLC/Panel View
Dew point temp.

sensor to control
Chilled water control
valve
Outside
Air
Return air temp
sensor to control
reheat control
Valve
TC
P
I
pressure switch to interlock

Fan Motor
P
I
TC
Supply
Air
Return
Air
Centrifugal fan
speed controlled
by Inverter
109
109
PID Control Loop AHU

Supply line
Supply line
Return line
Return line
Control
Variable
Set Point
12 Deg.C
Control
Variable
Process
Variable
Dew
point
Outside Air
temp.
sensor
Return air temp
sensor
Set Point
26Deg.C
Process
Variable
TC
TC
P
I
P
I
Supply
Air
Return
Air
Centrifugal fan 110
110
Air Handling Unit (AHU)
Measurements of control parameters

Chilled water in/out temp
Reheat water in temp
Return air temp
On Coil & Off coil temp
DP across filters
111
111
Chilled water in/out temp

Chilled water supply temperature = 5 to 7C
Supply line
Return line
Set Point
12 Deg.C
Chilled water return temperature = 10 to 12C

Control
Variable
Outside Air
Process
Variable
Dew
point
temp.
sensor
TC
P
I
P
I
Supply
Air
Return
Air
Centrifugal fan 112
112
Reheat Water In & Out AHU

Reheat water supply temperature = 60 Deg C
Supply line
Return Room temperature = 22 to 26C
Return line
Set Point
26Deg.C
Control
Variable
Outside Air
Return air temp

sensor
Process
Variable
TC
P
I
P
I
Supply
Air
Return
Air
Centrifugal fan 113
113
On Coil & Off Coil Temperature

Coil Surface
Temp= 10C
Cooling Coil
Entering Air
On Coil Conditions
26C @ 50%RH
Dew Point =14.5C
Leaving Air
Off Coil Temp = 12C

Shall be a 2 to 3C below
coil surface temp
Condensation
below the dew point of the entering air
114
114
DP across filters in AHU

Differentiate pressure across prepre-filter
(EU(EU-1 to 5):
Differentiate pressure across Fine

filter (EU(EU-6 to 9):
Initial = 25 - 40Pa
Initial = 35 - 125Pa
Final = 300Pa
Final = 450Pa
Outside Air
P
I
P
I
Supply
Air
Return
Air
Centrifugal fan 115
115
Nestle AHU Installation and Operation Practices

AHU locate inside plant room
Short return air duct protected with EU-4 filter, EU-7 is
used where contamination risk is high
Fresh air intake located well away from sources of
contamination, e.g. vents, exhausts etc
Textile ducts used for air distribution inside room
Maintain building pressure approximately 10 to 30Pa to
prevent contamination ingress
Maintain off coil temperature
Maintain room rH with reheat
116
116
Air Handling Unit & Fan Coil Unit

1. The main difference between AHU & FCU
Is the Cooling Capacity
2. AHU has higher Cooling Capacity
(more than 10 Ton)
3. FCU has a lower Cooling Capacity
( below 10Ton )
117
117
Textile Ducting
Advantages:
Good air distribution (no drafts)
Easy to clean. washable
Lower cost
More flexible, lighter
Easy installation
118
118
Gap and bad practices of

AHU
119
119
Conveyor Opening
Gap and bad practices of
AHU
Minimise conveyor opening size - match

baffles to product size
Fit flexible curtains to reduce flow further
2,400 m3/hr is required to compensate for

an opening 0.5 x 0.5 metre opening in a high
hygiene room (5(5-10 Pa)
120
120
Air Intakes & Exhausts

Intake with designed to minimise water ingress
(downward facing, louvre or droplet separator) in "clean"
location and at least
2m above ground/roof
10m from air exhaust
50m from cooling tower
121
121
Return Air Ducting

No joints - welded SS or polyester
Keep return air duct length to a minimum, preferable less than 2 m
Use a fine filter if longer or difficult to clean
122
122
Defects
Condensate Trap
Poor Filtration
Poor Drain, Condensation
Condensate Trap
123
123
Condensate Syphon: V Poor
124
124
Condensate Syphon: Poor
125
125
Condensate Syphon: Faults
Wrong slope after

trap: Flood
No trap: spray
Trap too deep: Flood
Too shallow: spray

126
126
Good practices of AHU
127
127
Condensate Syphon: Good
128
128
Condensate Syphon: Excellent
129
129
Room Temperature & RH Indicators
130
130
Differential Pressure Indicator

Monitoring Filling Room & Atmospheric Pressure
131
131
Condensate Syphon: The Hygienic Way
Standard trap:
Correct depths, Non-return ball,
Inspection lid
100 mm
Typical value for
negative pressure:
500 Pa = 50mm
50 mm
132
132
Installation Faults
AHU:
Inside the production room, hidden, never visited
Room pressurisation:
Insufficient or none, openable windows, openings, door gaps
Controls:
Poor design, no training or instructions, not calibrated
Outside air intake:

Poor design, wrongly located, contaminated air, rain
Air filters:
Wrong type, poorly installed, leaks, no dP gauge, no monitoring
Syphon:
Not fitted, wrong installation, no water, ball missing, pipework bent
Air ducts:
Design, dust accumulation, no insulation, no access.
Layout:
No enough space for maintenance and cleaning.
Operation:
No training. No instructions. No records. No inspection
133
133
Nestle Guideline For Air Filter
134
134
Filters: Applications & Materials

Group
Filter Class
Efficiency
Filter
Material
Particles
Size
Pre-filter/
Coarse
EU1 to EU4
Final pressure
drop = 250Pa
EU-1, E= 20%
EU-2, E= 20 25%
EU-3, E= 25 35%
EU-4, E= 35 45%
Synthetic
> 5 um
Secondary/
Fine
EU5 to EU9
Final pressure
drop = 450Pa
EU-5, E= 45 - 60%
EU-6, E= 60 80%
EU-7, E= 80 90%
EU-8, E= 90 - 95%
EU-9, E= 95 98%
Glass fiber
paper
> 2 um
HEPA
H10 to H14
Replace
>99.99%
Glass fiber
paper
> 1 um
Efficiency (E) based on average dust spot test (DST), number

of particles, the atmospheric test for fine dust
135
135
Nestles Guideline for Filter Use

MicroMicro-organisms contribute significantly to air borne contamination, generally
generally
larger than 1 micron in particle size
Filter Class
Retention of
particles size less
than 1 micron
Application/hygiene class
EU-4
25%
Pre-filter before cooling coil.

minimum for 1-star hygiene AHU.
Also for return air duct filters.
EU-7
85%
Fine filter installed after fan.

minimum for 2-star hygiene AHU.
EU-9
97% - 99%
HEPA
>99.99
Product sensitive to air-borne contamination.

Minimum for 3-star hygiene AHU
Direct contact with food.
136
136
Filters Class and Applications, Examples

Product
Type of
Room
Hygiene
Level
Filter Class
Food
- Maggi cube
- Maggi soup
- Frozen food
Manufacturing
Filling
Manufacturing
Dry-med
Dry-med
Wet-med
EU-4
EU-4
EU-4
Chocolate & Biscuit

- Chocolate
- Cocoa powder
- Filled wafer
- Kikat
Manufacturing
Manufacturing
Moulding
Maturing
Med-dry
Med-dry
Med-dry
Med-dry
EU-4
EU-4
EU-4
EU-4
Filling
Filling
Filling
Filling
Dry-med
Dry-med
Dry-high
Wet-med
EU-4
EU-4, EU-7
EU-4, EU-9
EU-4, EU-9/H10
Milk & Diary

- ND creamer
- Milk powder
- Infant cereals
- UHT room inside filler
137
137
Washable Filter Media
The filter media shall be of 100% polyester fibres bonded together with synthetic resins that formed a casually arranged non-woven shape. The media has
a varying density that increases in the airflow direction. The thicker and softer front layer is designed to catch the larger dirt particles, and the finer back
layers to trap the smaller dust particles. This guarantees high performance efficiency and high dust holding capacity of the media. Available in rolls of 2m
width and in pre cut pads.
138
138
Pre-Filter Specifications
Frame
Aluminium
Frame thickness (4 types)
12mm, 21mm, 46mm, 98mm
Material
Flame retardant Polyester

GC200/EC250
Material colour
White
Arrestance**
85% / 93%
Initial pressure drop
35 - 41 Pa
Standard dimensions*
300 600, 600 600
Air Flow (face dimension of 610 610mm)
& 1
2,000 m/h
3,400 m/h
6,800 m/h
139
139
Secondary Filter
The ABS plastic framed Pocket Filter is designed

for reliable primary filtration in various applications
from HVAC to Industrial and GT Air Intake
Systems. The Filter area is depending on the
number of Pockets and their length.
Filter Media
Filter Media shall be of 100% polyester fibres for the
EU3 & EU4 Pre-filter classes and 100%
polypropylene fibres for the Fine Filter Classes EU6
to EU9. The nature of the high loft, multi-layered
microfibre media results in low initial air resistance.
The designed mixture of fibres with gradually
different diameters ensures high dust holding
capacity
Frame
The enclosing frame is made of ABS plastic and

0.4mm G.I. Steel as optional. The PK Filter comes
with 6 pockets in the filter classes EU3 & EU4 and
with standard 8 pockets in the fine filter classes.
Optional 10 pockets are available, but results in a
lower DP at the same pocket length.
Efficiencies
PK Filters are available in the common six filter
efficiencies, with the colour-coded media clearly identifying the
Filter Class.
Pre Filter classes with 6 pockets:EU3
30%-35% white
EU4
35%-45% blue/white* or white
Blue/White filter media indicate the Heavy Duty Line while
white media is used in more standard applications such as HVAC.
Fine Filter classes with 8 pockets:EU6
60%-80%
green
EU7
80%-90%
red
EU8
90%-95%
yellow
EU9
> 90%
white
All filter medias are tested and certified by the EN779 and
Ashrae 52.1.94 Standards.
140
140
Filter Choice and Installation
Flat fabric filters bypass (leak) and have

insufficient surface
Use pleated pre-filter
mounted on rigid pleated fine filter
Neoprene gasget on welded SS or
polyester frame to minimise
leakage/bypass
141
141
Filter Efficiency Table
142
142
AHU Selection Criteria

1. Avoid CONDENSATION on cold surfaces (non-sweat)
2. Reduction of airborne and CROSS-CONTAMINATION
by positive pressure to avoid untreated air entering
by directing air from clean to dirty zones
3. Reduce dust, aerosols, gases and vapours

by extraction or dilution
4. Create COMFORTABLE working conditions (sweat)

143
143
Temperature & RH Control Parameters

1.
Room Temperature
Temperature sensor at return air duct (set point room dry bulb C), modulate or
On/Off chilled water control valve to maintain set point.
2.
Relative Humidity
Temperature sensor at upstream cooling coil (set point room dew point C),
modulate or On/Off chilled water control valve to maintain set point (Overrides
room set point when needed).
Humidity sensor at return air duct (set point room %RH), modulate or On/Off hot
water control valve to maintain set point; OR
Temperature control at return air, set point room temp, on-off hot water control
valve to maintain set point.
144
144
Design Parameters
1. Room pressure
at commissioning: manual dampers / fixed flow

continuous: pressure sensor/motorised dampers
2. Air velocity
3. Filtration
in ducts: max 8 m/s to minimise noise

ambient: 0.2 - 0.35 m/s to minimise drafts
under laminar flow hoods: 0.4 - 0.5 m/s
to meet process requirements
145
145
Design Requirements : AHU Filling Room

No return duct inside
room.
Dust filter to protect
return duct
Suitable location of
outside air intake
Reduce size of conveyor

openings.
Seal room to keep
overpressure and to avoid
infiltration
Locate AHU sheltered &

accessible
OA
RA
Ducts: short, easy to

clean tight
SA
Reduce Leaks
Outside fresh air for +ve room

pressurization to prevent foreign
contaminations
146
146
Typical AHU for Filling Room

Primary filter
EU4
Outside
Air
Return air temp
controller
TC
Water droplet
separator
Secondary filter
EU8
Chilled water
cooling coil
Inside smooth,
gaps sealed
P
I
Return
Air
Filter pressure
differential gauge
Dew point temp.

controller
P
I
TC
TT
I
Supply
Air
T
I
Mixing box
Condensate
syphon
Access & space for

cleaning
Centrifugal fan
147
147
Nestle Star Rating For AHU
148
148
Common AHU Type

Group
Low
hygiene or
no contact
Type of AHU
Fan coil units or
AHU, inside or
outside
Quality of AHU
basic hygiene
1 STAR specs
recirculating AHU
outside process
area or fan-filter
with fan-coil units
Food grade AHU

Nestec 2 Star
High
Hygiene
Accident
recirculating AHU
outside room
above critical area

High Hyg
Process
Air
Pretreated room
air into process air
handling unit
sheet metal or
textile ducting
Operation and
maintenance
12 monthly
internal inspection
Monitoring of air
quality
physical as req.
filter pressure drop
Med
Hygiene
Accident
Contact air room high hygiene

Filler
plus filter-fan-unit
Air Distribution
short return ducts

textile distribution
6 monthly
internal inspection
monthly
biosampling
over pressure
according to
Nestec 3 STAR
approved supplier
filtered return duct

permeable textile
access any point
monthly
inspection of AHI
weekly
biosampling
according to
Nestec 3 STAR
approved supplier
permeable textile
or screen
monthly
inspection of FFU
daily biosampling,
particle counter
over pressure
steel duct
access any point
monthly
inspection of AHI
daily
Biosampling.
selected supplier
according to
Nestec 4 STAR
approved supplier
over pressure
149
149
Star Units and Applications

Hollow bodies
Cold bridges
Rating
*
**
***
****
Use
Design
Warehouse
Off Shelf
Coffee
filling
Industry
hygienic
Infant
formulae
filling
CT-Eng
approved
Egron
aftercooler
PTC
approved
Difficult access
* *
**
Fully welded no hollow
bodies
No cold bridges
***
Fully cleanable
150
150
What Star Rating Is This ?

Commercial "Clean Air"
Unit ?
Looks good from the outside

!
BUT
Is the inside hygienic ?
151
151
Only 1 Star Rating AHU

Difficult access
Hollow bodies, Poor insulation
Compact construction
Centrifugal fan with belts inside

fan cabinet !
Cold bridges
Metal and metal contact
Potential condensation
152
152
1-Star AHU at Nestle

Specifications
Standard commercial units, readily
available
Double skin construction, 25mm PU
insulation
Option accessories, e.g. internal lights,
viewing glass windows, stainless steel
inner lining
Standard centrifugal belt driven fans
Not welded joints, potential condensation
at joints
153
153
Standard Centrifugal Fans (1 Star)

Open, belt driven fans.
Need adjustment to belts and mounting
154
154

Specifications
Industry hygienic AHU specifically designed for food industry

Limited joints, closed cell insulation (Polyurethane)
Drain trays and drains in all section to facilitate cleaning, siphons on all drains
No screws or rivets penetrating inner skin or stands
Direct drive plug fan with no scroll for easy cleaning

Internal lights for inspections
Dew point measurement for humidity control
Return air temperature measurement for room temperature control via reheat
155
155
Plenum/Plug Fans (2 Star)

Single width, single inlet airfoil impeller
Direct motor driven, no belts
Direct mounting inside cabinet
156
156
Hygienic Fans and Coils (2 Star)

Open, direct drive fans, no belts
Simple supports with no hollow bodies
Simple, cleanable coils Coated after
assembly
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157

Specifications
In additions to 2-star requirements:
Fully sealed stainless or polyester inner skin with no joints except at doors and ducts
All internal components supported separately on simple stands
All construction materials food grade
No internal sharp corners, corner radii>25mm
All penetrations welded to inner skin and sealed with glands
Spacious and easy access to all sections for cleaning and maintenance
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Typical Hygienic AHU, SS (3 Star)

Easy inspection and cleaning
Closed cell foam insulation
Washable - double slope bottom, drains all sections
No internal joints
No cold bridges
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Typical Hygienic AHU, Polyester (3 Star)
Monolithic - no joints
Closed cell foam insulation
Easy inspection and cleaning
No space for residues to collect

No hollow bodies
No cold bridges
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160
Star Rating
500
420%
Cost Ratio (%)
400
260%
300
210%
200
100%
100
1 Star
2 Star
3 Star
4 Star
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161
A Hygienic AHU (3 and 4 Star)
Dampers
for room
pressure
control & to
keep out
pirate air
Loop 3
Cooling coil and dew

point sensor for humidity
control Loop 1
Filters
before
coils with
dP gauge
PI
Low airspeed (2.5m/s) to

separate water
droplets w/o separator
TC
PI
TC
TI
Prefilter
G4
TI
Inside smooth,
rounded corners, no
joints
Hot water reheat

(sensor in return
air) for temp
control Loop 2
TI
Fine
filter
F7
350mm
Access and space
for cleaning
Sloped pans, space, syphons and air gap
Open direct drive

fan, no fan belts
inside casing
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Routine Maintenance
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163
Routine Maintenance Schedules
Operating parameters recorded and analysed daily.

Maintenance checklist established, trended and reviewed regularly.
Training, monitoring, inspection, cleaning.
Maintenance (filters, condensate trap, coils, air ducts).
Monitor the chilled water, reheat water.flow rate and temperatures.
Supply, return and fresh air flow rate.
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Routine Maintenance Tasks

Coil Section
Clean coil with city water, chemical clean if required

Wash clean pre-filter, replace when necessary
Replace secondary fine filters
Remove strainer for wash clean and reinstall
Check operational function of chilled water control valve, modulating/onoff
Check operational function of hot water control valve, modulating/on-off
Inspect valve leakages and integrity of insulation
Record supply/return chilled water temperatures
Record supply/return hot water temperatures
Clean drain pan
Inspect syphon conditions
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165

Fan Section
Wash clean fan blades and scrolls

Check and correct abnormal noise and vibration
Adjust fan belts for proper tension and alignment for standard centrifugal
fans
Check fan motor and pulley assemblies
Inspect direct coupling for plug fans
Check and tighten fan mounting
Measure and record fan motor running current
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Other AHU Section
Check operational functions of all motorized dampers and actuators

Check inside lighting and switches
Check pipe connections and insulation integrities at unit
Check duct connections and insulation integrities at unit
Inspect AHU panels, name plates, access and latches for corrosion
Check electrical cables and connections
Check duct, pipe and electrical supports and brackets
Vacuum clean starter/control panel
Wipe clean temperature remote sensing elements and bulbs
Inspect and note control parameters and set points
Make appraisal of general conditions, e.g. floor,
drain outlets etc
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167
Condition Monitoring
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Condition Monitoring
Temperatures
Humidity
Filters
Overpressure
Air distribution
Noise
Integrity
Room and AHU operating temperatures

Room with Hygrograph
Initial and final pressure differential across filters
Room air flow to outside at conveyor outlets
Air velocity, balanced, no hot/cold spots
Unusual vibration
Duct and pipe connections, unit appraisal
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Filter Pressure Differentiate Gauge

Differentiate pressure across preprefilter (EU(EU-1 to 5):
Differentiate pressure across Fine

filter (EU(EU-6 to 9):
Initial = 25 - 40Pa
Initial = 35 - 125Pa
Final = 300Pa
Final = 450Pa
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Dial Thermometer
Off coil temperature = 10 to 14C
Chilled water supply temperature = 5 to 7C
Chilled water return temperature = 10 to 12C
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Troubleshooting
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Room Temperature Too High

Symptoms
People feel and complaint of uncomfortable
Possible Causes
Coil surface temperature is high

Chilled water supply temperature is high
Loose fan belts
Temperature set point out
Increase in internal cooling load
Diagnose True Cause
Corrective Actions
Operator actions
Measure and record room temp and rH
Report to Maintenance
Maintenance actions
Check chilled water supply/return temp

Check off coil temp
Check pressure drop across air filters
Use flow chart
Dirty air filters

Dirty coil
Defective control valves
Defective chillers
Defective temperature controllers
Broken fan belts/fan motor
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Room RH Too High

Symptoms
Hydroscopic products may be sticky
Floor and machine sticky with products
Product net weight out of control
Possible Causes
Hot water supply temperature is low

Temperature set point out
Increase in outside air quantity
Decrease in internal load
Diagnose True Cause
Corrective Actions
Front line actions by production:
Measure and record room dry and wet bulb temp
Identify the room dew point at the psy-chart
Measure and record the coil surface temperature
Actions by Engineering:
Clean filters and coil
Repair or replace control valves
Repair or replace temperature controllers
Adjust fan belts
Verify correct reheat function
Verify correct outside air volume
Dirty air filters and coil

Defective control valves for chilled or hot water
Defective temperature controllers for chilled or hot water
Defective outside air damper control
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That Concludes My Presentation
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175

EF303 - Climate Systems - AHU System

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EDMM 210 - Process and equipment

Routine Maintenance and Troubleshooting of AHU Systems

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Routine Maintenance and Troubleshooting of AHU Systems

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Module # 1. Basic air principles

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Routine Maintenance and Troubleshooting of AHU Systems

Basic air principles

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Composition of Dry Air

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Water Vapor in Air

Executive Diploma in Manufacturing Management

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

In A Unit Volume of Air

Executive Diploma in Manufacturing Management

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Cool Air Sample

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Warm Air Holds More Moisture

The warmer air able to hold more moisture

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Basic Air Principles

The temperature of air as registered by an ordinary thermometer.

Wet Bulb Temperature

Dew Point Temperature

Moisture Content (Specific Humidity)

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Basic air principles

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Understand the properties of air and water vapor mixtures

Build the psychrometric chart

Use the psychrometric chart to determine the properties of an air/water

Use the psychrometric chart to understand the basic air conditioning

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Psychrometric Chart, Normal Temperature, Sea Level

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Avoid adverse conditions that

can affect reading

Moisten wick before procedure

Rotate device at least 2 minutes

Read device immediately after rotation

Warning: Mercury instrument/equipment is absolutely prohibited in Nestle

Routine Maintenance and Troubleshooting of AHU system

EDMM 210 - Process and equipment

Dry & Wet Bulb Temperatures

Wet bulb temperature

Dry Bulb Line F

75 Deg. F db ( 24Deg.C Dry bulb)

Executive Diploma in Manufacturing Management