REPORT LI-SITI RUBIAH

INDUSTRIAL TRAINING REPORT
N0-1-8 PERSIARAN SEKSYEN 4/1,
BANDAR PUTRA BERTAM,
13200 KEPALA BATAS, PULAU PINANG.
SITI RUBIAH BINTI MOHAMAD ABDUL WAHAB
MA12041
FACULTY OF MECHANICAL ENGINEERING
UNIVERSITI MALAYSIA PAHANG
29TH
JUNE 2015 – 04TH
SEPTEMBER 2015

1
ACKNOWLEDGEMENT
I would like to say thank you to my brother Md. Azlan bin Mohamad Abdul Wahab. It is
because he was the one that sent the application letter to IPPT for my industrial training.
Besides that I am also would like to thanks to my supervisor En. Saiful Bahri Abd Jamil. He is
the one that teach me more in calculation and how to using psychometric chart to calculate the
relative humidity in air conditioning. He was explain to me more in details on work scope in
engineering department. He was also explain about the process occur in decay tank and
firefighting. Encik Husni has been teaching me more about AHU and chiller for the whole time
my industrial training. He showed me how the process works. And teach me about refrigeration
cycle more detail. Other than that he showed me about the chiller system and cooling tower.
He showed me the component that use inside the air conditioning system.
I would like to say thank you to employee in engineering department because they had been
so friendly to me while doing the industrial training.

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ABSTRACT
In this industrial training progress, I will going to learn further about air conditioning
system. Inside of both IPPT buildings, they use Air handling Unit and chiller system. To make
the scope smaller, I will learn about those in Operation Theatre Room (OT). From the plan
given about the OT room, I already get the scale value. So, from the OT room I have get the
dry and wet- bulb temperature. So after I get the temperature I can determine the pressure value
and relative humidity. The relative humidity is the target of what they want. For OT room they
need 50% value of Relative Humidity. By using swing air gauge I can get the temperature for
dry and wet bulb temperature. So, the important parts are the AHU and chiller system. That
controlling the temperature and humidity inside the room. Since that the OT room used 100%
fresh air from outside the building, they need to filter and decreasing the temperature.
Before the fresh air entering the AHU box, it must go through the heat wheel first. The heat
wheel have the host of air flow exhaust from room and from the outside fresh air. Inside the
heat wheel, the air temperature from outside building will exchange heat between the airs that
exhaust from the OT room. After the temperature of fresh air getting lower it will enter the
AHU box, to get lower the temperature. The chiller will supply cold water to make heat
exchange between air and water.
As a conclusion to determine the relative humidity, I will determine the wet and dry bulb
temperature from inside the OT room and environment since it use 100% fresh air. Then, by
using psychometric chart in thermodynamics book, to determine the value of enthalpy. When
the process cooling happen I can calculate the heat loss, 𝑄̇.

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TABLE OF CONTENTS
ACKNOWLEDGEMENT 1
ABSTRACT 2
TABLE OF CONTENTS 3
LIST OF TABLES 4
LIST OF FIGURES 5
CHAPTER 1 COMPANY PROFILE
1.1 INTRODUCTION 6
1.2 COMPANY PROFILE 7-8
1.3 ORGANIZATION STRUCTURE 9
CHAPTER 2 COMPANY ACTIVITY
2.0 INTRODUCTION 10
2.1 WORK SCOPE IN ENGINEERING DEPARTMENT 10
2.2 AIR CONDITIONING MECHANICAL AND EXHAUST SYSTEM 11
2.3 MEDICAL AND PIPELINE SERVICES 11-12
2.4 FIRE PROTECTION SYSTEM 12-13
2.5 CALORIFIER AND HEAT PUMP 13-14
2.6 AUTOCLAVES AND WASHER 14
2.7 DECAY TANK 15
CHAPTER 3 STUDENT SELF ACTIVITY
3.0 INTRODUCTION 16
3.1 REFRIGERATION FOR AIR CONDITIONING 17

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3.2 RATING AIR CONDITIONING EQUIPMENT 18
3.2.1 HUMIDITY CONTROL 18
3.2.2 PRESSURE / TEMPERATURE RELATIONSHIP 19
3.3 REFRIGERATION COMPONENTS 20
3.3.1 EVAPORATORS 20
3.3.2 COMPRESSOR 20-23
3.3.3 CONDENSER 23
3.4 BASIC CHILLED WATER SYSTEM 23-24
3.4.1 EQUIPMENT INSTALLED AND LOCATION 24-26
3.4.2 MAINTENANCE 26
3.4.3 INSTALLATION: MECHANICAL 27-28
3.4.4 RECOMMENDED INSULATION TYPES 28
3.5 CHILLED WATER AIR HANDLING UNIT (AHU) 28
3.5.1 EQUIPMENT INSTALLED AND LOCATION 29
3.5.2 MAINTENANCE CHECK ITEM FOR AHU 29-30
3.6 CALCULATION 30-32
CHAPTER 4 CONCLUSION 33
CHAPTER 5 RECOMMENDATION 34
CHAPTER 6 REFERENCES 35

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LIST OF TABLES
TABLE NO. TITLE PAGE
3.4.4 RECOMMENDED INSULATION TYPES 28

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LIST OF FIGURES
FIGURE NO TITLE PAGE
Figure 1.3 Organizational structure 9
Figure 2.2 Air Handling Unit System 11
Figure 2.3 Medical gas pipeline 12
Figure 2.4(a) Carbon dioxide 13
Figure 2.4(b) Carbon dioxide main nozzle 13
Figure 2.5 Calorfier 14
Figure 3.1 Refrigeration cycle 17
Figure 3.3.2 Pressure/Temperature chart for various refrigerants 19
Figure 3.3.2 (a) The crankshaft converts the circular motion of the motor to
the reciprocating or back and forth motion of the piston.
21
Figure 3.3.2 (b) Rotary Compressor with motion in one direction 22
Figure 3.3.2 (c): The operation of the scroll mechanism of a scroll
compressor
24
Figure 3.4 General CVGF unit component 25
Figure 3.4.1(a) Chiller process 26
Figure 3.4.1(b) Cooling tower 27
Figure 3.5 AHU control and troubleshooting. 29
Figure 3.6 Psychometric chart 33

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CHAPTER 1
COMPANY BACKGROUND
1.1 INTRODUCTION
CORPORATE INFORMATION
Institut Perubatan dan Pergigian Termaju (IPPT) was established on 16 October
2002 with grant of the government of Malaysia including the ministry of Higher
Education. The Malaysia cabinet ministers formally approved the memorandum from
the Ministry of Education (MOE) to set up Institut Perubatan dan Pergigian Termaju
(IPPT). The memorandum also mentioned that the IPPT would be situated in Bertam,
Kepala Batas, Penang. The building and the operating of this institute would be put
under the care of Universiti Sains Malaysia (USM) on that memorable day in history.
IPPT is a post graduate institute specializing in selected medical and dental in areas
including clinical services, collaboration research and post-graduated academic
programme. IPPT also plays a vital role in producing competent medical and dental
specialist who among others are able to conduct clinical trial for patients in the northem
region of Malaysia in our established Clinical Trial Centre.
CLINICAL
Clinical service in IPPT is committed to offer specialised care for the diverse
healthcare needs of our patients. A Clinical Trial Complex has been set up with clinical
expertise and research laboratories to equip the needs of clinical services. It was
officially opened in September 2004 and now operates in a new building in another
branch of USM in Bertam, Kepala Batas. The services offered are Women Wellness
clinic, Specialist Medical clinic, Specialist dental clinic, Clinical Research clinic,
Advanced Clinical Diagnostic Laboratory and Oral Health Clinic. IPPT provide imaging
services such as X-ray, Mammogram, Ultrasound, Echo-cardiogram and Magnetic
Resonance Imaging (MRI).
RESEARCH

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From the perspective of research, all the fields that are selected do exist in some
universities and also the Ministry of Health, the integrative approach proposed is unique
as the integration is both virtual and physical. IPPT has fully equipped a research
environment in the field of medicine and dentistry. The main activity of IPPT is focus
on advanced research elements to train and develop individuals that excel in the fields
of medicine and dentistry. It is hoped these individuals will become the pioneers and
new technologies developers in these two fields and will also contribute meaningfully
to the nation’s economic development.
1.2 COMPANY PROFILE
NAME : Institut Perubatan dan Pergigian Termaju (IPPT)
ADDRESS : No.1-8 Persiaran Seksyen 4/1, Bandar Putra Bertam, 13200 Kepala
Batas, Pulau Pinang.
VISION : “Leading the world in new innovative discoveries towards sustainable
and holistic healthcare deliveries”
MISSION : “ To develop state-of-the-art advanced research, conduct innovatives
postgraduate programmes and delivery tertiary healthcare service
towards sustainable mankind”
OBJECTIVE :
 To provide state-of-the-art research facilities to generate novel
healthcare discoveries of great commercial values.
 To disseminate research findings in the form of presentations and
publications for the advancement of knowledge.
 To achieve and maintain international standards of accreditation in
management, laboratory and research facilities and services.
 To be leading referral centre which provides state-of-the-art healthcare
services, promoting healthy lifestyle.
1.3 ORGANISATION STRUCTURE

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COMPANY ACTIVITY
2.0 INTRODUCTION
Institut Perubatan dan Pergigian Termaju (IPPT) has been used higher technologies for
their clinical services. Such as Linax is a machines that usually used for killing cells cancer.
Most of cancer they use is for breast cancer and bone cancer. Higher technology in this machine
is that it can be setting only to kill the cell cancer without make any harm to the health cell. So
it cost a million ringgit. Besides that, for research building, they have many important samples
to keep in save. So some machine should be in ON mode 24 hours to make sure the sample is
in good condition. Moreover, as in engineering department they should be the one that watch
of those machines and make sure they are not damaged and ON mode for 24 hours. Other than
that, engineering department have to make sure for maintaining the machines regularly.
Since that most of the machines should be in ON mode, they must make sure that there are no
electric tripping on the machines or leakage that can cause damaged and fire.
People on engineering department act as technician when there are problems about
machines and electricity. They will be the one that repair it for users.
2.1 WORK SCOPE IN ENGINEERING DEPARTMENT:
I. Air conditioning, mechanical Ventilation and exhaust system
II. Lift and vertical transportation
III. Medical gases and pipelines services
IV. Fire protection system
V. Building automation system
VI. Cold water/ sanitary Pump
VII. Hot water- Calorifier and heat pump
VIII. Autoclaves and washer
IX. Decay tank
2.2 AIR CONDITIONING MECHANICAL AND EXHAUST SYSTEM
For air conditioning system it depends on the propose temperature of the user. For
hospital building, most of temperature is between 18-20ºC. It is because most of the patient

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there have chemotherapy and nuclear medicine. Since the effect of the medicines are
feeling burn inside the human body or increasing body temperature. Therefore, it need
lower temperature to make the patients comfortable in resting. As exhaust system, both
building use cooling tower. Its function is for releasing the heat from the condenser and get
more loosing heat form that. Then the liquid inside the condenser will move to evaporator
at already low temperature. Then the fan blower will move the air at already low
temperature. Both building used Air Handling Unit system (AHU) for transferring the cold
air into the rooms. The heat transfer occur between the air and water that had been supply
by chiller. The heat exchange is very high in energy loss rapidly, so they can transfer low
temperature of air into the rooms. The relative humidity target is also different depends on
the need of the rooms. For day care the relative humidity is differ from the operation theatre.
Figure 2.2: Air Handling Unit System
2.3 MEDICAL AND PIPELINE SERVICES
In hospital building it have pipeline services for transfer blood samples or small
equipment to another level of building without a person to walk. Moreover, it is the faster
way to move the sample. Other than that, it also can use for result of the sample. To design
the pipeline is one of the engineering departments job to make sure the flow of the delivery
bottle do not stuck in the middle. Other than that, the bottle design also take important part
for transferring it through the pipeline. Moreover, other than transferring sample test etc.
medical pipeline also for medical gases. Gases such as oxygen, nitrogen and etc. example
at the head of patients’ bed have this services. It is for supplying the gases to patient. For
engineering department they must observe if any of the gases leakage. By put the smoke
sensor inside every room to determine the percentage gas release. By doing that they will

12
know that some of the gases have leakage. They also must do the maintenance and change
the parts if there is any leakage.
Figure 2.3: Medical gas pipeline
2.4 FIRE PROTECTION SYSTEM
Fire protection system is really important. It should have in every level on the building.
As for MSB and LV building, is where the electric form TNB came at higher voltage may
cause fire because of leakage. So most of the system use is smoke detector and co2 gas to
get rid of the fire. The control panel had been set when the temperature reach the control
temperature, it will release the carbon dioxide gas for stopping the fire after 30 seconds, for
people inside to get out. Besides that, it also have a close curtain to prevent the carbon
dioxide gas go out from the room. The mechanical system is that the sensor will detect the
smoke then releasing the carbon dioxide after 30 seconds.

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2.5 CALORIFIER AND HEAT PUMP
Engineering department should be monitor the water temperature. It is because some of
the user will make complain whether the water temperature is not hot enough. Domestic
water will enter the heat pump for increasing the water temperature at specific temperature
and store it in calorifier. Which calorifier is the industry form for a storage vessel that has
the capacity to generate heat within a mass of stored water. If user use the water, it will
decreasing the temperature, therefore, the heat pump will provide hot water into the calorie,
for top up the water. It is closed system. Sometimes the heat pump do not function properly,
Figure 2.4(a): Carbon dioxide
tank
Figure 2.4(b): CARBON DIOXIDE NOZZLE

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so technician will look for the problem and repair it or misunderstanding between
mechanical of heat pump and control panel.
Figure 2.5: Calorfier
2.6 AUTOCLAVES AND WASHER
Autoclave is a chamber used to sterilized equipment and supplies (by high pressure
saturated steam). Since the research and hospital need use very clean equipment they need
to use autoclave because it can get to maximum pressure steam. At higher temperature, the
bacteria will die and with clean equipment it prevent infection. Most work research is more
looking cure for cancer. Such as breast cancer. So the cure will get infected and damaged
if the equipment is not clean enough. Therefore, technician will go for the maintenance
weekly to prevent the machine damage or not functioning very well. The technician will
control the pressure of saturated steam from the control panel. It also must have the
maximum value. As the minimum value that had been set, it shows that the machine may
have problem. It is because it does not produce higher pressure and do not clean the
equipment properly.

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2.7 DECAY TANK
Decay tank is the waste product storage of the patients. As the patients have
chemotherapy or nuclear medicines, their waste product must not flow into the normal
sewage. It is because their waste product contain radiation that may be harm to
environment, healthy people, animals or plants. So to prevent that happen, they transfer the
waste into the decay tank for 3-4 days, so that the radiation loss it selves. Besides that the
waste must be treated before transfer it to INDAH WATER. They have process chlorination
to kill the bacteria inside the waste. Then, they must dechlorinating so that the bacteria in
INDAH WATER sewage do not die. The process for holding waste product same as the
animal that had been used for the research before throw it to INDAH WATER sewage.

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CHAPTER 3
STUDENT SELF ACTIVITY
3.0 INTRODUCTION
When I start the industrial training, I had been focused on air conditioning system. Since
all of the building in IPPT using air condition system, so the condition of the systems also
depends on the needs of the building. When doing this industrial training, I will go further on
learning about air conditioning system. Before doing further, I should be strong in
understanding about the cycles and how the process works. Besides that, I do need to know
about all components inside the air conditioning system and their functions. As I said that the
system of air conditioning is depends on the need is such as supplying 100% or 20-40% of
fresh air. These conditions are for different building needs and rooms. For clinical building,
to preventing fungus and bacteria growing they need the place colder than usual environment
temperature. Then, the clean air for the patients inside of the building in day-care room. For
research building also, are the same as clinical building for preventing fungus and some of
the samples should be keep in lower temperature to avoid damage.
IPPT using Air Handling Unit (AHU) and chiller system inside both of buildings. To be
more specific in this industrial training, I will learn about AHU and chiller system in
Operation theatre Room (OT). I have to find the relationship between temperature and
pressure. Other than that, is the effect of relative humidity inside the Operation Theatre Room
(OT). From the second thermodynamics law I can find those relationships and how to get the
value reading.

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3.1 REFRIGERATION FOR AIR CONDITIONING
One of the most common applications of refrigeration is air conditioning (comfort cooling).
Other than that, this type also called as high-temperature refrigeration. High-temperature
refrigeration involves cooling a space to temperature between 45ºF and 75ºF.
 The outside design temperature is 95ºF.
 The inside temperature is 75ºF.
 The cooling coil temperature is 40ºF. This coil transfers heat from the room into the
refrigeration system. Note that with a 75ºF room temperature and a 40ºF cooling
coil temperature, heat will transfer from the room air into the coil. This heat transfer
cools the air leaving the coil to about 55ºF.
Figure 3.1: Refrigeration cycle

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3.2 RATING AIR CONDITIONING EQUIPMENT
Refrigeration equipment must have a rating system so that properly-sized equipment can be
selected and so that equipment from various manufacturers can be compared. The method for
rating this equipment goes back to the days of using ice as the method of removing heat.
Example, it takes 144Btu’s of heat energy to melt a pound of ice at 32 ºF. So, this same figure
is also used in the rating of air-conditioning equipment.
The term used for this rating is the ton. One ton of refrigeration is the amount of heat required
to melt one ton of ice in a 24-hours period. If it takes 144Btu’s of heat to melt a pound of ice,
it would take 2000 times that amount to melt a ton of ice (2000pound= 1 ton).
144
𝐵𝑡𝑢′
𝑠
𝑙𝑏
× 2000𝑙𝑏𝑠 = 288,000 𝐵𝑡𝑢′𝑠
When accomplished in a 24-hours period, it is known as one ton of refrigeration. The
same applies when removing heat from a substance. As example, an air conditioner
having a one-ton capacity will remove 288,000 Btu’s per day or 12,000 Btu’s per hour
or 200 Btu’s per minute.
3.2.1 HUMIDITY CONTROL
All types of comfort cooling are concerned with controlling both temperature and
humidity. For example, a typical air conditioning system operating at an indoor temperature
of 75ºF with a humidity level (moisture content) of 50%. These conditions are to be
maintained inside the house. The air in the house gives up heat to the refrigerant. The
humidity factor must be considered because the indoor coil also responsible for removing
some moisture from the air to keep the humidity at an acceptable level. This is known as
dehumidifying. Moisture removal requires considerable energy.

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3.2.2 PRESSURE / TEMPERATURE RELATIONSHIP
The relationship between pressure and temperature can be determines by boiling and
condensing point of water and other liquids. Pure water boils at 212ºF at sea level when the
air temperature is 70ºF (standard conditions) because this condition exerts pressure on the
water surface of 29.92 in.Hg (14.696 psi). This can be suggest that water has another boiling
temperatures under different pressure (Figure 3.2.2). The boiling point of water can be
changed and controlled the vapour pressure above the water.
The pressure and temperature of a refrigerant will correspond when both liquid and
vapour are present under two conditions:
 When the change of state (boiling and condensing) is occurring.
 When the refrigerant is at equilibrium (no heat is added or removed)
Figure 3.3.2 Pressure/Temperature chart for various refrigerants

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3.3 REFRIGERATION COMPONENTS
Four major components of mechanical refrigeration systems are covered in this book:
1. Evaporators
2. Compressors
3. Condensers
4. Refrigerant metering devices
3.3.1 EVAPORATORS
The evaporators absorbs heat into the air conditioning system. When refrigerant is boiled
at lower temperature than that of the surrounding air, its absorb heat from the air. The
boiling temperature of 40ºF was choose because it is the design temperature normally used
for air conditioning systems. The purpose of the evaporator is to boil all of the liquid into
a vapour just before the end of the coil. This occur approximately 90% of the way through
the coil, when all the liquids are gone, leaving pure vapour. At precise point we have
saturated vapour.
3.3.2 COMPRESSOR
The compressor can be the “heart” for the refrigeration system. It compresses refrigerant
vapour and pump heat-laden refrigerant vapour and refrigerant vapour liquid through the
system. It reduces the pressure in the low-pressure side of the system, which runs from the
metering devices to the compressor inlet and increasing the pressure in the high-pressure
side of the system, which runs from the compressor discharge back to the metering device.
TYPES OF COMPRESSOR
 Reciprocating compressor
 Uses a piston in a cylinder to compress the refrigerant. Valves usually reed or
flapper valves, to ensure that the refrigerant flow in the correct direction. This type

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of compressor is known as a positive displacement compressor. When the cylinder
is filled with vapour it must emptied as the compressor turns or damage will occur.
Figure 3.3.2 (a):
The crankshaft converts the circular motion of the motor to the
reciprocating or back and forth motion of the piston.
 Rotary compressor
 Also positive displacement compressor and it is extremely efficient and have few
moving parts. This type of compressor uses a rotating, drum-like piston that will
squeeze the refrigerant out to the discharge port. Rotary compressor are typically
smaller than Reciprocating compressor with the same capacity.

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Figure 3.3.2 (b): Rotary Compressor with motion in one direction
 Scroll compressor
 The latest design to be developed and has entirely different in working of the
mechanism. It has a stationary scroll and a moving scroll that matches and meshes
with the stationary part. The movable scrolls orbits inside the stationary scroll and
squeezes the vapour between the movable and stationary parts. Several states of
compression are takin in the scrolls at the same time, making it very smooth running
compressor with few moving parts. The scrolls compressor is sealed on the bottom
and top with the rubbing action and at the tip with a tip seal. These sealing surfaces
prevent refrigerant from the high pressure side from pushing back to the low-
pressure side while running.

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Figure 3.3.2 (c): The operation of the scroll mechanism of a scroll
compressor
3.3.3 CONDENSER
The condenser rejects heat from the refrigerant system. It receives the hot gases after it
leaves the compressor through the short pipe between the compressor and condenser
known as the hot gas line or discharged line. The hot gas is being forced into the top of
the condenser coil by the compressor. The gas is pushed along at high speeds and
temperatures.
3.4 BASIC CHILLED WATER SYSTEM
The chilled water system is accomplished by continuously circulating water from
Chiller to the cooling coil of the Air handling Unit and back to the chiller in a closed
piping system. The Chilled Water Pump does the circulating of the chilled water in the
piping system. The heat rejection from the chiller is taken away by continuously
circulating from the cooling tower in an open piping system. The condenser water pump
does the circulating of the condenser water in piping system.

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The main plant room housed the Chillers, Chilled Water Pumps, Condenser Water -
Pumps, and main air-conditioning switchboard. Cooling towers and make-up water tank
located at the rooftop.
Figure 3.4: General CVGF unit component
3.4.1 EQUIPMENT INSTALLED AND LOCATION
A. CENTRIFUGAL WATER-COOLED CHILLER
Three (3) nos. of Trane Centrifugal Water Cooled Chiller model CVGF 500 are
installed in Chiller Plant Room. Two (2) nos. will operating at one time and One (1)
nos. will standby. This Trane CVGF model is completely factory package including
evaporator, condenser, sub-cooled, compressor, motor, lubrication system, control
centre and all interconnecting unit piping and wiring.

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Figure 3.4.1(a): chiller process
B. COOLING TOWER
There are three (3) nos. included draft counter flow Cooling Tower installed at
behind chiller plant room. Two (2) nos. will operating at one time and One (1) nos. will
standby. Truwater series TC750-3B is designed to handle chiller’s condenser heat
rejection by cooling the condenser water from 97ºF to 87ºF with 82ºF wet bulb outside
air temperature.
The Truwater Cooling Tower has 1 fan for each basin and its belt driven. The motor
is furnished with extra protection from moisture on the windings and double sealed
permanently lubricated bearings. Three (3) sets of Cooling Tower were installed on the
up-stand plinth behind the chiller plant room.
The outlet water connections of the Cooling Tower are connected in parallel to a
common condenser water supply pipe and return back to tower through a common
return condenser pipe. The inlet and outlet pipe of the individual Cooling Tower are
fitted with motorized butterfly valve, which operate and correspond to Cooling Tower.

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Figure 3.4.1(b): cooling tower
3.4.2 MAINTENANCE
CHILLERS
a. Inspect chillers general condition. If abnormal, report as necessary
b. Take reading of current, voltage, pressure, temperature etc.
c. Inspect chilled water temperature
d. Inspect condenser water temperature
e. Inspect the operation of safety devices. Clean, adjust, lubricate, repair/replace as
necessary
f. Inspect thee cleanse of chiller
COOLING TOWER
a. Inspect cooling towers general condition
b. Inspect all fan and fan bearing. Lubricate with grease
c. Inspect all belt drives. Adjust and re-tension
d. Inspect and clean all water screens. Drain, clean and flush cooling tower basin
e. Inspect and clean float valve. Adjust water level.
f. Inspect motors and controllers
g. Inspect pipe painting. Ensure pipes coatings of anti-rust and standard colour paint
are clean and in good condition

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3.4.3 INSTALLATION: MECHANICAL
a. STORAGE
If the chiller is to be stored for at least one month prior to installation. Observe the
following precautions:
 Do not remove the protective coverings from the electrical panel
 Store the chiller in a dry, vibration-free, secure area.
 At least every 3 months, attach a gauge to the service valve and manually check the
pressure of dry nitrogen in the refrigerant circuit. If the pressure is below 5 psig
(34kPa) at 70ºF (20ºC) call al qualified service organization and the appropriate
Trane sales office.
b. LOCATION REQUIREMENTS NOISE CONSIDERATIONS
 Locate the unit away from sound-sensitive areas
 Install the isolation pads or isolation springs under the unit
 Use rubber boot-type isolators for all water piping at the unit
 Use flexible electrical conduit for final connection to the UPC
c. FOUNDATION
 Provide rigid, non-warping mounting pads or a concrete foundation of
sufficient strength and mass to support the chiller operating weight (including
completed piping and full operating charges of refrigerant, oil and water)
 After the chiller is in place, level the chiller within ¼’’ (6mm) over its length
and width. Trane is not responsible for equipment problems resulting from an
improperly designed or constructed foundation.
d. VIBRATION ELIMINATORS
 Use rubber boot-type isolators for all water piping at the unit
 Use flexible electrical conduit for final connection to the UPC
 Isolate all the pipe hangers and be sure they are not supported by main structure
beams that could introduce vibration into occupied spaces
 Make sure that the piping does not put additional stress on the unit

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e. CHILLER ISOLATION
 To minimize sound and vibration transmission through the building structure
and to assure proper weight distribution over the mounting surface, install
isolation pads or spring isolators under the chiller feet
3.4.4 RECOMMENDED INSULATION TYPES
LOCATION TYPE SQUARE FEET
(square m)
Evaporator, water boxes and
tube sheets
¾’’ wall (19mm) 160 (15)
Compressor suction elbow
and suction cover
¾’’ wall (19mm) 20 (2)
¾’’ wall (19mm) 10 (1)
3.5 CHILLED WATER AIR HANDLING UNIT (AHU)
The air handling unit (AHU) cooling coil dehumidify the air passing through it which
is then supply to the conditioned space via a series of ductwork and air diffusion
accessories. The air returns back to the unit through return air grille and ceiling slot.
The thermostat controls the conditioned air temperature. The latter shall convey signal
actuate the 2 ways controlled valve in order to modulate flow rate of chilled water through
the cooling coil the desired condition.
Figure 3.5: AHU control and troubleshooting.

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3.5.1 EQUIPMENT INSTALLED AND LOCATION
AIR HANDLING UNIT (AHU)
The AHU are manufactured by Trane and locally made. The Trane AHU’s are factory
assembled which included an internally insulated cabinet, a chilled water cooling coil with
copper tubes and aluminium fins, a centrifugal blower, a blower motor and drive packaged
which include pulley and belts. The unit is equipped with air filter which is installed at the
intake airside of the AHU. These washable filters are easily removable and housed within an
aluminium frame.
The system provides conditioned air for the conditioned area through a network of air duct
and diffuser.
3.5.2 MAINTENANCE CHECK ITEM FOR AHU
After 48 Hours Operation
 Belts have acquired their permanent stretch. Readjust but do not overtighten.
Weekly
 Observe unit weekly for any change in running condition and any unusual noise.
Every month/weekly
 Check air filters. Clean or replace if clogged or dirty. Change bag filters when
pressure drip is 1-inch W.G.
Every three to six months
 Check greasing on fan and motor.
 Align fan motor sheaves (pulley). Tighten sheaves setscrews to the proper torque.
 Check and adjust fan belt tension.
 Tighten electrical connection.
 Inspect coils for dirt build-up or coil freeze up.
Every year
 Inspect the unit casing for corrosion. If damage is found, clean and repaint the
surface with a rust-resistant primer and vinyl chlorinated lacquer.
 Clean the fan wheels and fan shaft. Remove rust with emery cloth and apply a coat
of LPS#3 or an equivalent.

30
 Inspect the condensate drain pan and drain line, remove sludge or foreign materials
that might obstruct proper drainage. Remove obstacles.
a) Filter : The filter should be inspected and clean regularly (monthly) to ensure good
airflow and filtering action
b) Evaporator coil: To minimize dirt to accumulate on the evaporator coil or other
part of the evaporator air circuit. Cleaning is required to assure good system
performance.
c) Lubrication: The bearing blower, shaft and the blower motor should be lubricated
if necessary.
d) Drain pan: The drain pan should be inspected regularly to ensure good drainage
e) Belt: Maintain belt tension to extend belt life. Replace when sign of failure begin
to appear.
3.6 CALCULATION
For this calculation I want to fine the heat loss which is 𝑄̇. The situation has been set
as situation one is the environment and situation 2 is in the operation theatre room. For
operation theatre room the dry-bulb temperature is 18ºC and wet-bulb temperature is
20ºC. For environment, dry-bulb temperature is 28ºCand wet-bulb temperature also 28ºC.
The area of operation theatre is 40.71m² and height of the room is 5.2m. To calculate the
volume flow rate for the room is by using air change per hour formula. Air change per
hour (ACH) is a measure of the air volume added to or removed from space (normally for
room or house) divided by the volume of the space. Number of air changes per hour for
operation theatre room is 12 as my supervisor told me.
ACH equation in Imperial Units:
𝑁 =
60𝑄
𝑉𝑜𝑙
N: number of air changes per hour
Q: volumetric flow rate of air in cubic feet per minute (cfm)
Vol: Space volume 𝐿 × 𝑤 × 𝐻

31
To determine the volume flow rate:
𝑣𝑜𝑙𝑢𝑚𝑒 = 𝑎𝑟𝑒𝑎 × ℎ𝑒𝑖𝑔ℎ𝑡
𝑣𝑜𝑙𝑢𝑚𝑒 = 40.71 𝑚2
× 5.2 𝑚
𝑣𝑜𝑙𝑢𝑚𝑒 = 211.6920𝑚3
𝑁 =
60𝑄
𝑉𝑜𝑙
12 =
60𝑄
211.6920
𝑄 = 42.3384 𝑚3
𝑝𝑒𝑟 𝑚𝑖𝑛
To determine the mass flow rate:
ṁ = 𝜌𝑄 =
𝑄
𝑣
v: specific volume from the psychometric chart 0.855 volume cubic meter per kilogram
dry air.
ṁ =
42.3384
0.855
ṁ = 49.5186 𝑘𝑔 𝑝𝑒𝑟 𝑚𝑖𝑛
ṁ = 0.8253 𝑘𝑔 𝑝𝑒𝑟 𝑠𝑒𝑐𝑜𝑛𝑑
The target of relative humidity for the operation theatre room is 50%. By calculating,
I would like to determine whether the relative humidity get the target or not. By using the
psychometric chart I can determine the relative humidity percentage. The relative
humidity for environment is 95% and in operation theatre room is 86.5%. The enthalpy
also can be determine the psychometric chart. For environment the enthalpy Hı is 87
kilojoule per kg dry air and for the room H₂ is 53.5 kilojoule per kg dry air. By determine
this element I can calculate the heat loss that occur during the process.

32
Figure 3.6: psychometric chart
Formula of heat loss:
𝑄̇ = ṁ (ℎ₂ − ℎ𝚤)
𝑄̇ = 0.8253(87 − 53.5)
𝑄̇ = 27.6479 kJ/s

33
CHAPTER 4
CONCLUSION
The industrial training really give benefits for me. It is because it showed me that this training
can develop my work skill with other people. Other than that, I can apply from what I have
learned in my study into the task given. What I have learned from this training is that the
knowledge that I have can be apply in this work scope. Besides that, it helps me more
understanding in basic knowledge that I have. Moreover, this training teach me how to
communicate with people that older than me and what I can learned from them are very useful.
They really teach me both about work scope and also about life or reality that I will face it later
after I graduate. Most of important is that this training teach me how to respect people more, it
is not because of age, but the knowledge that I can learn from them is huge. The people in the
IPPT is very outstanding because of wide knowledge that they know. My supervisor at IPPT
always asking me about the theory and analysis for some current situation such as relative
humidity and how to obtain it.
Therefore, this industrial training show me what work can mechanical engineering student
can do. By doing the calculation I can determine it by using the formula form thermodynamics
book. This industrial training also teach me to apply formula that I have learned and calculate
it in real life. Other than that, the calculation show the accurate value or target that we want to
obtain.

34
CHAPTER 5
RECOMMENDATION
I would like to suggest that make the industrial more than 2 months. So that make the
student to learned more and apply what they have studied in class and apply it in real
life.

35
REFERENCES
1. https://www.usm.my/index.php/en/about-us/background/usmprofile
2. http://www.amdi.usm.edu.my/aboutippt/corporate-information
3. http://www.amdi.usm.edu.my/aboutippt/vision-mission
4. http://www.slideshare.net/Modyz/hvac-sysems-ahu
5. http://www.slideshare.net/rabeet/upload-29590586

REPORT LI-SITI RUBIAH

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