HDD Test area aircon system improvement design

Hitachi Confidential
f r e e d o m t o i n n o v a t e
© 2004 Hitachi Global Storage Technologies
108/12/17
HDD Test Area Air-conditioningHDD Test Area Air-conditioning
System ImprovementSystem Improvement
Facilities DepartmentFacilities Department
PRESENTED BY: JEDH G. QUEÑANO

208/12/17
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BACKGROUND – TURNING POINT
 The high level of temperature
inside the HDD Test Area
became a big concern
because the 33~35°C room
temperature does not pass
the new requirement for the
Microdrive Test Area
temperature of 26°C and
below.
TURNING POINT:
THE INTRODUCTION OF 1 INCH MICRODRIVES

308/12/17
BACKGROUND – LOCATION
INSIDE FACTORY
Ph-4 Ph-3
Ph-2 Ph-1
PROBLEM: HIGH TEMPERATURE AT
PH-3 HDD TEST AREA
(2004) 33~35°C


408/12/17
AVERAGE TEMPERATURE AT PH-3 TEST AREA LAYOUT (2004)
33-35°C
AHU 24 AHU 23 AHU 22 AHU 21
 33-35°C  32-33°C
 34-36°C  33-34°C

508/12/17
BASIC CONCEPTS FOR AIR-CONDITIONING
 AIR-CONDITIONING
is defined as the
mechanical process of
simultaneously treating air to
control its properties such as:
 1.) temperature,
 2.) humidity,
 3.) air filtration and
 4.) air circulation in a space.
DEFINITION OF AIR-CONDITIONING

608/12/17
BASIC CONCEPTS FOR AIR-CONDITIONING
 AIR HANDLING UNIT
is an equipment which consist
of a set of cooling coils and a
blower. The air is blown
through the cooling coils and
cooled by the chilled water to
decrease and control the air
temperature.
 Chiller (located at the Energy
Center) – provides the chilled
water to the cooling coils of
the Air Handling Units.
DEFINITION OF AIR HANDLING UNIT
Air Handling UnitAir Handling UnitChillerChiller

708/12/17
UNDERSTANDING THE PROBLEM
HEAT FROM THE OVEN
OvenOven
HITACHI PHASE 3 TESTER AREA

808/12/17
PROBLEM IDENTIFICATION
 1st Problem – how to cool down the area temperature
using minimal energy to reduce operational costs
THE PROBLEM
 Reason – HICAP needs to reduce operating costs
TOTAL HICAP AIR-CONDITIONING COST/YEAR:
$ 4,794,855/year

908/12/17
PROBLEM IDENTIFICATION
 2nd Problem – how to remove the hot air and replace with
fresh and cooler air and how to increase air-conditioning
capacity without duct revision inside the area
THE PROBLEM
Not capturing the hot air coming from the test machines
results to its dispersal to the work area causing discomfort
to employees.
The hot working environment inside the HDD Test Area
also became a safety concern and it downgrades the
motivation of the HDD employees working therein.
 Reason

1008/12/17
ORIGINAL DESIGN
 AIR FLOW: Hot air from
testing operations just goes
back to AHUs for cooling.
 EXHAUST SYSTEM: NONE

1108/12/17
ORIGINAL PLAN BASED ON ORIGINAL DESIGN
 AIR FLOW: Hot air from
testing operations just goes
back to AHUs for cooling.
 EXHAUST SYSTEM: NONE
 ADDITIONAL EQUIPMENT: Two (2) units of big-capacity AHUs (AHU 52 & AHU 53) to
add cooling capacity.
 Design Concept is same with existing: To gather the hot air inside the test area,
bring it to AHUs for cooling and supply it back to the test area.

1208/12/17
REVISED PLAN
ADDITIONAL EQUIPMENT:
 One (1) unit Exhaust Fan (UEF)/Ducting
 Two Units of AHU: 1. AHU 52 – Big Capacity 2. AHU 5 – Small Capacity, only for
replacing the hot air removed
Design Concept:
Remove 50 °C hot air
from test machines and
throw it outside the
building and,
 Replace with new and
cooler air.

1308/12/17
OBJECTIVES
SETTING THE OBJECTIVES
Objective No. 1: To be able to
remove hot air coming from the
machines and replace with
fresh and cooler outside air.

1408/12/17
OBJECTIVES
SETTING THE OBJECTIVES
Objective No. 2: To be able to
increase the cooling capacity of the
Air Handling Units (AHU) without
revising the return and supply duct
sizes and arrangement inside the
test area.

1508/12/17
SOLUTION
ATTAINING OBJECTIVES
1.1 Installation of Outside Air AHU No. 5
- This equipment can gather 860 cubic meter per minute
(cmm) of fresh air from outside, cool it down and
distribute it to room AHUs to replace the hot air being
thrown out from inside the HDD test area.

1608/12/17
SOLUTION
1.2 Installation of ducting and exhaust grills designed to
gather hot air from the testers.

1708/12/17
SOLUTION
1.3 Installation of new Utility Exhaust Fan (UEF) enough
to carry 770 cmm of hot air from testers and throw it
out of the Production building.

1808/12/17
SOLUTION
2.1 Installation of the New Air Handling Unit (AHU 52)
at Phase 3 ground floor

1908/12/17
SOLUTION
2.2 AHU Equipment Testing and Temperature
Data Gathering – in distributing the capacity
of the new AHU 52, priority was given to the
Microdrive.

2008/12/17
SOLUTION
 Modification done with minimum
operational cost and capital expenditure

2108/12/17
DESIGN COMPARISON (ORIGINAL PLAN VS. IMPLEMENTED)
ORIGINAL PLAN TOR/day
1. Total Heat Load 950
2. Air-conditioning Capacity
Existing AHU (AHU 21-24) 412
Additional AHU (AHU 52) 308
Additional AHU (AHU 53)
230
IMPLEMENTED TOR/day
1. Total Heat Load 950
2. Air-conditioning Capacity
Existing AHU (AHU 21-24) 412
Additional AHU (AHU 52) 308
Outside air AHU 50
Exhaust Fan (UEF) 180

2208/12/17
COST COMPARISON FOR ONE (1) YEAR – CONSIDER 357 DAYS
ORIGINAL PLAN TOR/year
Additional AHU (AHU 52) 412 x 357
IMPLEMENTED TOR/year
Outside air AHU 50 x 357
Exhaust Fan (UEF) Motor -
INVESTMENT OPERATION COST
190 K$ 882 k$
160 K$
INVESTMENT OPERATION COST
190 K$ 882 K$
50 K$
107 K$
23 K$
TOTAL
TOTAL
492 K$
COST BASIS: $6 / TOR (TONS OF REFRIGERATION)
310 K$
240 K$ 1,012 K$
1,374 K$
CAPITAL COST REDUCTION 110 K$
OPERATION COST BENEFIT (SPENDING) 362 K$

2308/12/17
SUMMARY
1. Energy Conservation/Cost Reduction:
Equivalent Energy Conserved by Removal of Hot Air: 64,260 TOR/year
Operation Cost Reduction/Benefit: 362 K$ Per Year
Capital Cost Reduction: 110 K$
2. Improvement of the Working Condition for HDD Test Area Personnel
Average Temperature for Microdrive Area 25 – 26 °C
Average Temperature around Microdrive Area 28 – 30 °C
(Previously 33 - 35 °C)
Resulting Motivation for HDD Personnel HIGH

2408/12/17
 Back up

2508/12/17
AHU 24 AHU 23 AHU 22 AHU 21
10 9 8 71112
1
3
2
4
6
5
NEW
UEF
(2nd
Fl)AHU 52
AIR HANDLING UNIT SUPPLY AREAS FOR HDD PHASE 3 G/F

2608/12/17
HEAT LOAD CALCULATIONS FRO PHASE 3 1ST
FLOOR AREA
ETF/HR AREA (AHU 24)
1. Future Heat Load
2. Existing AHU 24 Capacity
3. Heat Load Difference
HEAT LOAD
345,854 Kcal/Hr
312,000 Kcal/Hr
33,854 Kcal/Hr
RECOMMENDATION:
NEED UPGRADE AHU 24
VOLUME
For 33,854 Kcal/Hr
DANA AREA (AHU 22)
1. Future Heat Load
HEAT LOAD
471,464 Kcal/Hr
312,000 Kcal/Hr
159,464 Kcal/Hr
RECOMMENDATION:
159,464
0.24 x (45 C-26 C) x 1.2 x 60
Install Heat Exhaust System: 770
VOLUME
(65% OF 770 CMM)
MOBILE AGEING (AHU 23)
1. Future Heat Load
HEAT LOAD
452,266 Kcal/Hr
312,000 Kcal/Hr
140,266 Kcal/Hr
RECOMMENDATION:
NEED UPGRADE AHU 23
(BECAUSE 284 CMM IS NOT
ENOUGH TO COOL DOWN THE
AREA)
VOLUME
140,266
328.32
= 486 CMM
PK ATTACH AREA (AHU
21)
1. Future Heat Load
HEAT LOAD
291,600 Kcal/Hr
312,000 Kcal/Hr
(20,400 Kcal/Hr)
RECOMMENDATION:
291,600 < 312,000
No Need Heat Exhaust System &
No need AHU Upgrade
VOLUME
N/A= 428
BUT 770 – 486 = 284

2708/12/17
Note: 1. Shutdown Works for New AHU already completed (July 3)
2. New AHU is already on-site (To install after removal of old WWT/modifying of foundation)
ACTUAL IMPLEMENTATION SCHEDULEACTUAL IMPLEMENTATION SCHEDULE
July 04

2808/12/17
FACILITIES
THE TEAM
THANK YOU FOR LISTENING…

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