PhEn-602

Pharmaceutical Facility
Design

Notes #7
J. Manfredi

Pharmaceutical Facility Design Spring 1

2009
 HVAC Design
and the
Psychrometric Chart

Pharmaceutical Facility Design Spring 2

2009
 HVAC Considerations
Pharmaceutical Facility Design Process

2. HEATING &
1. SPACE
COOLING
REQUIREMENTS
REQUIREMENTS
Temperature
Air Conditioning loads
Humidity
Process equipment
Air quality
Loads Temperature
Pressurization

4. TESTING/
3. HVAC SYSTEM
EVALUATION
DESIGN
Design stage
Air systems
Consturcion
Power plant (utility)
Post construction testing
Systems
and commissioning
Qualification/Validation

Pharmaceutical Facility Design Spring 3

2009
 Design Process:
Load Calculation

„ Heat loss calculation is used to

determine the heating requirements
• Calculate the heat lost from the building
to the outside during a winter design
condition.
„ The common winter design condition is the
coldest winter night in a particular climate
that is surpassed only 2.5% of the time.

Pharmaceutical Facility Design Spring 4

2009
 Design Process:
Heating Load
„ Types of Heat Loss:
• Conduction: (transmission) Heat transfer thru
solid surfaces such as walls, floors, roofs.
• Convection (ventilation) Warm molecules move
from one place to another typically by air to air
exchange of energy
„ Outside air entering (Doors, fans, etc.)
„ Infiltration leakage through the building envelope is
also a convective heat loss
• Radiation (typically electromagnetic) does not
play a large role in calculating the heating load
as it is generally a very small amount
Pharmaceutical Facility Design Spring 5
2009
 Design Process:
Heating Load

„ Conduction Heat Loss:

• Conduction: Hc= UA (Δ T)
• U= overall heat transfer coefficient, (btu/hr x
area x deg F)
„ U= ∑ (1/R)
„ R= resistance of the building material
• R = R1 + R2 + R3
• A = surface area, in square feet
• Δ T= temperature difference

Pharmaceutical Facility Design Spring 6

2009
 Design Process:
Heating Load

„ Convection Heat Loss:

• Convection: Hv=1.08x cfm x (ΔT)
• 1.08 = Air factor
• CFM = Rate air enters the building
• ΔT= Temperature difference
„ Sources:
„ Infiltration: outside air entering though
cracks in the building envelope.
„ Ventilation

Pharmaceutical Facility Design Spring 7

2009
 Design Process:
Heating Load

„ Total Heat Loss:

„ Ht = Hc + Hv

Pharmaceutical Facility Design Spring 8

2009
 Design Process:
Cooling Load
„ Cooling load is the energy that must be
removed to counteract the heat gain.
• Heat gain components:
„ Conduction heat gain
„ Convection heat gain
„ Solar heat gain
„ Internal heat gain (e.g. lights, motors, equipment)
„ People
• Cooling load is measured in Btu/hr, or in tons
„ 1 Ton = 12,000 Btu/hr
ƒ 1 Btu = amount of energy required to raise the
temperature of one pound of water 1 degree Fahrenheit.

Pharmaceutical Facility Design Spring 9

2009
 Design Process:
Cooling Load
„ Conduction heat gain:
• Hc = UA(CLTD)
• U= overall heat transfer coefficient
• A = surface area, in square feet
• CLTD= cooling load temperature difference
„ Calculated similar to conduction heat loss
„ Recognizes that the exterior temperature of some
building materials may exceed the outside
temperature. (e.g. tar and gravel roof
temperature may exceed 250 deg F during peak
outside air conditions).
Pharmaceutical Facility Design Spring 10
2009
 Design Process:
Cooling Load
Convection Heat Gain: (Two (2) parts)
„ Sensible Heat Gain

• Hsens = 1.08 x cfm x (Δ T)

„ 1.08 is called the “air factor”.
• Air factor units: btu/hr/(cfm) deg F

„ Latent heat gain (Moisture load)

• Hlatent = 4840 cfm (Δ W)
„ W= heat gain from moisture generated in the space
„ Measured in lb of water per lb of dry air

Pharmaceutical Facility Design Spring 11

2009
 Design Process:
Cooling Load

„ Internal Heat Gain:

• From equipment, lights, motors,
computers, copy machines
• Generally adds sensible heat
„ On some occasion, can have equipment
that generates a latent load (e.g. vial
washing machine).

Pharmaceutical Facility Design Spring 12

2009
 Design Process:
Cooling Load
„ Heat Gain from People (Two parts)
• Sensible Heat Gain
• Latent Heat Gain
„ Hp = People Heat Gain (btu/hr)
• Hp= N x Ps (CLF) + N x PL
„ N= Number of occupants
„ Ps=Sensible Heat Gain per person
„ CLF= Cooling load factor; usually 1.0
• Dependent on number of hours in the space
„ PL=Latent Heat Gain per person

Pharmaceutical Facility Design Spring 13

2009
 Design Process:
Cooling Load
„ People Heat Gain:
• Function of activity performed
„ Example; typical male factory worker, performing light
bench work generates about 400 Btu/hr of Sensible Heat
Gain and about 400 Btu/hr Latent Heat Gain
„ For most activities, approximately 1,000 Btu/hr Heat Gain
• Combined 400 Sensible and 600 Latent
„ Typical factory worker performing “light” work, generates
approx. 900 Btu/hr (400 Btu/hr Sensible & 500 Btu/hr
Latent)
„ Dancing results in about 1,400 Btu/hr
„ Gym activity 2,000 Btu/hr
„ Females generate on average; 85% of male Heat Gain
Pharmaceutical Facility Design Spring 14
2009
Common Building Heat
Gains
ROOF

Hc Lights
Hi
Hv Hi He
Hp
Hc
Hc
Hc

Total heat Gain is sum of:

Hp = People Heat Gain
Hc = Conduction Heat gain=UA (CLTD)
Hv = Convective Heat Gain = 1.1 cfm (T)
Hi = Heat Gain from Lights
He = Heat Gain from Equipt.

Pharmaceutical Facility Design Spring 15

2009
 Design Process:
Cooling Load
„ In pharmaceutical facilities:
• Conduction Heat Gain may be significant
• Convection Heat Gain may be significant
depending on process
„ Ventilation load can be significant
• Solar Heat Gain is typically small
„ Locale may have impact
• Internal Heat Gain (i.e.: lights, motors,
equipment) will probably be significant
• Heat Gain from people can vary
„ Generally small, but must be evaluated
Pharmaceutical Facility Design Spring 16
2009
 Design Process:
Cooling Load

„ In pharmaceutical facilities the

infiltration heat gain is typically
negligible for two reasons:
• 1) generally tight construction
• 2) pressurization of rooms

Pharmaceutical Facility Design Spring 17

2009
 Calculating the Cooling Load
Across a Coil

QT= 4.5 x CFM x Δh

„ Where Δh = hm – ho (enthalpy of air
entering the coil minus enthalpy of air
leaving the coil in btu/lb)
• hm Enthalpy of mixed air entering the
cooling coil in btu/lb
• ho Enthalpy of air leaving the cooling coil
in btu/lb
„ QT in btu/hr

Pharmaceutical Facility Design Spring 18

2009
 Total cooling load across coil
Includes sensible and moisture load

QT= 4.5 x CFM x Δh Δh = hm – ho

hm= enthalpy of mixed air
ho= enthalpy of air leaving coil

hm ho
HEPA Filter
Mixed air Leaving air

Outside
air

Cooling 95% Filter

Coil
Return air
from space
Supply air to
the space

Pharmaceutical Facility Design Spring 19

2009
Total cooling load across coil

Total load across the coil is the

sum of the sensible load and
the latent load.

QT = Q s + Q L

Pharmaceutical Facility Design Spring 20

2009
 Sensible cooling load calculation

„ Qs = AF x CFM x ΔT (AF = air factor)

(Equal to 1.08)

Qs= 1.08 (CFM) ΔT

„ ΔT = Temperature difference of air

side in degrees Fahrenheit
„ Qs in Btu/hr

Pharmaceutical Facility Design Spring 21

2009
Latent cooling load calculation

ƒ QL= 4840 x CFM (ΔW)

ƒ ΔW = moisture difference
(moisture level entering coil in lb
of water/lb of dry air, minus
moisture level of air leaving the
coil) in lb of water/lb of dry air
ƒ QL in Btu/hr

Pharmaceutical Facility Design Spring 22

2009
 Latent cooling load calculation
„ If moisture level is given in grains of
water per lb of dry air:
• Latent cooling load calculation
QL= 0.69 CFM ΔW
or
QL= 0.69 CFM ΔGrains
„ ΔW = moisture difference (moisture level entering coil
in grains of water/lb of dry air, minus moisture level of
air leaving the coil) in grains of /lb of dry air
„ QL in Btu/hr
„ Typically use grains of moisture per lb of dry air
• Note: 7,000 grains per lb…(4,840/7,000 = 0.69)

Pharmaceutical Facility Design Spring 23

2009
 Example:
An air handling unit serves a Class 10,000
clean room. Flow through the unit is
5,000 CFM. The enthalpy of the air
leaving the coil is 20 Btu/lb. The
enthalpy of the air entering the coil is a
mixture of return air and outside air, and
has an enthalpy of 27 Btu/lb. What is the
total cooling load across the coil?
Pharmaceutical Facility Design Spring 24
2009
 Answer:

„ QT= 4.5 x CFM x Δh

„ QT = 4.5 x 5,000 x (27 – 20)
„ QT = 157,500 Btu/hr
= 13.1 tons

Pharmaceutical Facility Design Spring 25

2009
 Example (cont’d):
If the dry-bulb temperature exiting the coil was
52 F, and the mixed air temperature entering the
coil was 70 F, what was the sensible load across
the coil?
Qs= 1.08 CFM x ΔT
Qs = 1.08 x 5,000 x (70 - 52)
Qs = 97,200 Btu/hr = 8.1 tons
Based on the above, what was the latent load
across the coil?
QT = sensible load + latent load
13.1 tons = 8.1 tons + latent load
Latent load = 5 tons
Pharmaceutical Facility Design Spring 26
2009
 Sensible Heat Ratio:

SHR: ratio of sensible load divided by

the internal total load.

Pharmaceutical Facility Design Spring 27

2009
 Example:
A clean room has a sensible heat
gain of 90,000 BTU/HR, and a latent
load of 30,000 BTU/HR. What is the
sensible heat ratio?

SHR = 90,000 / (90,000 +30,000)

SHR = 90,000 / 120,000 = 0.75

Pharmaceutical Facility Design Spring 28

2009
 Mixed air entering the coil
„ Mixed-air airflow (CFM) is sum
of outside-air (CFM) and
return-air (CFM)
„ Weighted average of the dry-
bulb temperature of outside-
air and return-air

CFMma x Tma = CFMoa x Toa + CFMra x Tra

Pharmaceutical Facility Design Spring 29

2009
 Example:
Outside air at 500 CFM and 90 F dry-bulb.
Return air at 3,000 CFM and 75 F dry-bulb.
What is the temperature of the mixed air
entering the cooling coil?
CFMma x Tma = CFMoa x Toa + CFMra x Tra

3,500 x Tma = 500 x 90 + 3,000 x 75

3,500 x Tma = 270,000
Tma = 270,000/3,500 = 77.14

Pharmaceutical Facility Design Spring 30

2009
 Psychrometric Chart
Discussion

„ Psychrometric chart
„ Chart that displays the properties
of air and water vapor
„ Essential tool for designing
temperature and humidity control
systems

Pharmaceutical Facility Design Spring 31

2009
 Psychrometric Chart
y Dry bulb temperature on
the x-axis
y Humidity Ratio on vertical
axis
y If we know two properties,
we can obtain all other
properties.

Humidity Ratio also referred to as Specific Humidity. Units are grains of water per lb of dry air.

Pharmaceutical Facility Design Spring 32

2009
Reading the “Psych” Chart

Pharmaceutical Facility Design Spring 33

2009
Wet Bulb Temperature:
Measured with wet wick reading
Measures the temperature of the
air as the moisture evaporates

Pharmaceutical Facility Design Spring 34

2009
 Dew Point Temperature
86
The temperature at which
existing moisture will condense
50°F
from the air (forming dew)
80

70
70°, 50% rh = 50° Dew Point

60

50
40
30
20

50

Pharmaceutical Facility Design Spring 35

2009
Humidity Ratio, Specific Humidity
Absolute measure of moisture
The Ratio of the Weight of Water to the Weight of the Dry Air

Pharmaceutical Facility Design Spring 36

2009
 Relative Humidity:
The moisture content of air expressed as a percent of maximum
moisture at the specified dry bulb temperature

Pharmaceutical Facility Design Spring 37

2009
 Vapor Pressure:
The pressure exerted by the water vapor molecules on the
surrounding environment

0.37" 1.3

1.1

0.9

70°, 50% rh = 0.37" Hg. 0.7

0.5

0.37"
0.3

0.1

Pharmaceutical Facility Design Spring 38

2009
 Enthalpy
„ Total energy in the air
„ The higher the sensible
temperature, the higher the
enthalpy of the air.
„ The higher the moisture content
of the air, the higher the
enthalpy.
„ Measured in Btu/lb
Pharmaceutical Facility Design Spring 39
2009
Enthalpy
Total energy in the air
the higher the sensible temperature,
the higher the enthalpy of the air.
The higher the moisture content of the
air, the higher, the enthalpy.

Pharmaceutical Facility Design Spring 40

2009
Air Conditioning
Processes

Pharmaceutical Facility Design Spring 41

2009
HVAC Systems: Air properties

Understand properties:
„ Dry-bulb and wet-bulb

temperature
„ Humidity ratio

• Moisture content
„ Enthalpy
„ Dew point
Pharmaceutical Facility Design Spring 42
2009
 HVAC Systems:
Psychrometric chart
Identify processes on the chart:
ƒ Sensible heating and cooling
ƒ Cooling and dehumidifying
ƒ Desiccant dehumidifying
ƒ “chemical drying”
ƒ Humidifying
ƒ Mixing

Pharmaceutical Facility Design Spring 43

2009
 Psychrometric Chart
200
Note: Actual
process flow for
cooling

(Humidity Ratio)
Moisture (gr/lb)
0
Temperature
Pharmaceutical Facility Design Spring 44
2009
 Psychrometric Chart
Actual process flow for cooling: 200
1) First sensible cooling occurs
2) Then dehumidification occurs
a) ride along 100% saturation
curve
Cooling Process

(Humidity Ratio)
Moisture (gr/lb)
Dehum idification

Sensible cooling

99% RH

0
Tem perature
Pharmaceutical Facility Design Spring 45
2009
 Psychrometric Chart
„ Cooling-based dehumidification
„ Desiccant dehumidification

Pharmaceutical Facility Design Spring 46

2009
 Sample problem:
Solve using Psychrometric Chart
Background Data:
„ Assume we wish to design an air handling system to serve a
sterile fill room. Room design conditions are 66 deg F DB, 45%
RH. Assume a design outside air condition of 88 DB, 77 WB.
The air handler serving the room supplies 22,000 CFM. Make-up
air for pressurization and ventilation is 4,500 CFM. Assume that
the exfiltration from the space is equal to the pressurization air of
4,500 CFM, with the balance returning to the air handler.
Assume zero duct leakage. Due to the heat gain across the
supply fan and supply ductwork, there is a 6 degree rise in supply
air temperature. Due to the extensive amount of duct pressure
losses, a return fan is installed to boost the pressure in the return
duct, to ensure a consistent flow through the air handler. The
return fan and return ductwork add 3.5 degrees to the air
returning to the air handler. Assume the heat gain in the space
is strictly sensible (negligible moisture gain).
Pharmaceutical Facility Design Spring 47
2009
 Sample problem:
Cooling coil

Hin Hout
M ake-up Air
AIRHANDLING UNIT
4,500 CFM

Return air 22,000 CFM

fan

Class 100
Region
Return Design T= 66 deg F
Airwall RH=45%

Pharmaceutical Facility Design Spring 48

2009
 Sample problem:

Based on the information provided,

answer the following:
a) What is the Dry-bulb temperature
and wet-bulb temperature of the air
entering the cooling coil?
b) What is the cooling load across the
coil?
Pharmaceutical Facility Design Spring 49
2009