Recalculating Cooling Load In Laboratory Room Quality Control

Production Building PT Kimia Farma Sungwun Pharmacopia

Ridwan Septian
Department of Mechanical Engineering,
Faculty of Industrial Technology, Trisakti University,
Jakarta
Email. ridwanseptian01@gmail.com

Abstract -- Laboratory Room is a room that has functions such as Replace sterile
clothes, Preparation, Physical and Chemical Analysis, Chemical storage, Wash tool,
Instrument Analysis, and Sterilization. The cooling load calculation in this building
uses CLTD (Cooling Load Temperature Difference) method. The calculation of cooling
loads based on secondary data is then compared with the installed cooling load
capacity. From the calculation of the above cooling load can be concluded that the
capacity of AHU engine (Air Handling Unit) installed is not sufficient in meeting the
needs of air conditioning system in the laboratory of Quality Control Room of PT Kimia
Farma Sungwun Pharmacopia Production Building.

Keywords: Cooling load calculation, Set Point, Air Handling Unit.

Abstrak -- Ruang Laboratorium Quality Control adalah ruangan yang memiliki fungsi
diantaranya sebagai ruang Analisa fisik dan kimia, Penyimpanan bahan kimia, Cuci
alat, Analisa Instrumen, Ganti pakaian steril, Preparasi, Sterilisasi, serta Area Kerja.
Perhitungan beban pendinginan pada gedung ini menggunakan metode CLTD
(Cooling Load Temperature Difference). Perhitungan beban pendinginan berdasarkan
data sekunder yang kemudian hasilnya dibandingkan dengan kapasitas beban
pendinginan terpasang. Dari hasil perhitungan beban pendingin di atas dapat
disimpulkan bahwa kapasitas mesin AHU (Air Handling Unit) yang terpasang belum
mencukupi dalam memenuhi kebutuhan sistem tata udara pada ruang Laboratorium
Quality Control Gedung Produksi PT Kimia Farma Sungwun Pharmacopia.

Kata Kunci: Beban pendinginan, Set point, Air Handling Unit.

1. INTRODUCTION
Air conditioning is the treatment of air to set the temperature, humidity, cleanliness
and distribution it simultaneously to achieve the comfortable conditions required by
people who are in a room. In addition, air conditioning can be defined as a process of
cooling air to achieve ideal temperature and humidity.
At this time AC (Air Conditioning) has been widely used for everyday purposes and
has become a necessity that must be met, one of which is the office building and
laboratory, because in addition to get comfortable air conditions, also can increase human
productivity. In the installation and application, the system of air conditioning requires a
lot of money. The use of improper air conditioning with its needs will result in waste, both
energy and cost is quite expensive. Any building or room other than having a peak cooling
load condition also has a total cooling load of the room, which usually changes every
hour. Based on that, a building or room that will be conditioned by installing the air
conditioning system it is necessary to know in advance the maximum load and partial
loads that exist and must be addressed appropriately in order to use the right equipment
to be installed. so, there is no wastage of energy and costs, as well as the possible lack of
engine capacity that causes no achievement of the desired conditions. To overcome this
required the calculation of the appropriate load size in the air conditioning system and
determine the load received by the machine.

Laboratory Room Quality Control is a room that has functions such as physical and
chemical analysis, Chemical storage, Wash tool, Instrument Analysis, Replace sterile
clothes, Preparation, Sterilization, and Work Area. Reason for re-calculation of coolant
load at Laboratory Room of Quality Control of Production Building of PT Kimia
Farma Sungwun Pharmacopia. this is because the initial condition of the air
conditioning system in this building operates well where the indoor temperature
setpoint can still be achieved in accordance with the conditions in the field. However,
at this time, the temperature conditions in the laboratory room when used at this time
are not in accordance with the expected set point temperature so that the occupants /
users feel less comfortable. This is reinforced by complaints and complaints from the
users of the laboratory space. The purpose of this paper is to recalculate the cooling
load and compare the number of cooling loads calculated with conditions mounted on
the air conditioning system of the laboratory of Quality Control Laboratory of PT
Kimia Farma Sungwun Pharmacopia Production Building.
 2. BASIC THEORY
Air Conditioning System
The Air Conditioning System is a process of cooling the air so as to achieve the
temperature and humidity corresponding to that required to the air condition of a given room,
regulating the air flow and cleanliness.
Air Conditioning System Principle
Under the first law of thermodynamics, heat Q1 released from the high temperature
cycle is equal to the amount of heat Q2 released at low temperatures and W.
Q1 = Q2 + W..................................... (1)

The energy input required to remove heat Q2 from low temperature to high temperature
requires mechanical work.
The cooling system can not be removed from the heat transfer process where the heat
produced by the room to be conditioned its temperature will be absorbed by the cooling
system and then will be released into the environment.
Cooling Cycle
The cooling cycle consists of four processes, namely :
1) Evaporation
It is a process of exchanging the room's air heat with refrigerant. At this stage there
is a heat exchange in the evaporator, where the heat of the environment or the cooled
medium is absorbed by the liquid refrigerant in the evaporator so that the liquid refrigerant
derived from the pressurized expansion valve and low temperature changes the phase
from the liquid phase to the vapor having high pressure and temperature. So the great heat
that is absorbed by the refrigerant is:
QC = ṁ (h2 – h1) ............................(2)
Where,
QC : The amount of heat absorbed in the time union evaporator (kJ / s)
ṁ : Mass flow rate of
refrigerant (kg / s)
(h2 – h1) : Effect of refrigeration (kJ/kg)

2) Compression
 Compression has two functions, namely : First, to suck the refrigerant from the
evaporator and press it into the condenser. Second, to increase the pressure of refrigerant. At
this stage occurs in the compressor where the vaporized refrigerant with low temperature and
pressure is isotrapically compressed so that the temperature and pressure become high, the
heating capacity can be written by the equation:
QW = ṁ (h3 – h2) ...........................(3)
Where,
Qw : Heating capacity (kJ / s) unity time (kg / s)
ṁ : Mass flow rate of refrigerant (kJ / s)
(h3 – h2) : Compression work (kJ / kg)

3) Condensation (condensation)
Has two functions, namely : First, to remove the heat stored refrigerant on the evaporator.
Second, to change the refrigerant phase from vapor to liquid. At this stage occurs inside the
compressor, where the heat from the vapor refrigerant from the compressor is discharged
into the environment so the refrigerant is condensed. At this stage there is a phase change
from the superheat vapor phase to a saturated aqueous phase, in this saturated liquid phase
the pressure and temperature are still high. The amount of heat released in the condenser is:
qc = h3 – h4 ......................... (4)
where,
qc : Heat released in condenser
(kJ / kg)
h3 : The enthalpy of refrigerant coming out of the compressor (kJ / kg)
h2 : Enthalpi of saturated liquid refrigerant (kJ / kg)
4) Expansion
Changing the hot refrigerant fluid to a cold liquid by lowering the pressure. At this
stage occurs in the expansion valve where the refrigerant is lowered by the pressure
followed by the decrease in the entalphi temperature.
 Hot air from room

Liquid
EKSPANSION EVAPORATION

Cool
Liquid Steam Cool Air

Hot
Steam
COMPRESION CONDENSATION

Figure 1. Cooling Cycle

3. METHODOLOGY
This cooling load calculation uses the method of CLTD (Cooling Load Temperature
Difference) method. The calculation of cooling loads based on secondary data is then compared
with the installed cooling load capacity.

Secondary data used include :

• Floor area, building surface area, building volume, glass surface area, each distinguished
between conditioned and not.

• The surface area of the sheath / fasade, consisting of wall and glass area.

• The width of each building material to its direction.

• Material type, material thickness of building envelope and roof.

• U values for materials used in both walls, glass and roof.

• Value of shade coefficient (SC).

The procedures adopted in this study include :

• Direct observation for data retrieval in conditioned spaces with cooling systems taking into
account internal and external loads on a theoretical basis on existing literature sources.

• Data processing and data calculation.

• Evaluation of the result of calculating the load on the installed machine with the results of
data field.

• Taking conclusions from research

results.
 4. RESULT AND DISCUSSION
Some data are obtained from secondary data. Table 1 shows the data of the room
analyzed.
Table 1. Data Room

DATA ROOM

Floor area 112 m2

High room (High wall) 2.9 m

Room height (Floor to ceiling) 3.0 m

Operation time of laboratory room starts at 08.00 WIB until 16.00 WIB.
Lighting for the room uses different types of lights depending on the function and
location of the lamp placement with an operating time of 8 hours or equal to the office hours
of operation. Lighting data is shown in Table 2.
Table 2. Lighting data lamp

LAMP DATA
NO TYPE OF LIGHTS AMOUNT
1 Center Pin Spot Light 20 Watt 2 Units

2 TL Lamp 2 x 18 Watt 14 Units

Amount of lamp 16 Units

In space analysis, especially space instrument and physical and chemical analysis
certainly can not be separated from the use of laboratory equipment. The use of such
equipment necessarily produces the heat that must be taken into account in the calculation
of the cooling load. Table 3 shows the equipment data used.

Table 3. Equipment Data

EQUIPMENT DATA 2 AA (Microwave) 1 Units

NO NAME OF TOOLS QTY 3 HPLC prominance with 1 Unit

1 Personal Computer 4 Units uv-vis & rf detector

 4 Gas Chromatography 1 Unit 21 Autoclave 1 Unit

5 Mas Air Sampler 1 Unit 22 Hood 1 Unit

6 Airbone particle counter 1 Unit 23 Furnace 1 Unit

7 Spectrophotometer 1 Unit 24 Vacuum Dry Oven + Pump 1 Unit

8 KF Titrator 1 Unit 25 Coductivity meters 1 Unit

9 Stability chamber 2 Units 26 pH meter 1 Unit

10 FT-IR 1 Unit 27 Sonicator 1 Unit

11 Dry Oven 1 Unit 28 Freezer 1 Unit

12 Moisture Analyzer 1 Unit 29 Refrigerator 1 Unit

13 Polarimeter 1 Unit 30 Water Bath 1 Unit

14 Data Logger- 1 Unit 31 Vortex 2 Units

Pressure/Temp 32 Micro centrifuge 1 Unit
15 Ultrapure water production 1 Unit 33 Hot plate/Stirrer 3 Units
unit
34 Hydrometer 1 Unit
16 Balance 2 Units
35 Desiccator 1 Unit
17 Heating Block 1 Unit
36 Glass Thermometers 4 Units
18 Clean Bench 1 Unit
37 TOC Analyzer 1 Unit
19 Incubator (Colon 1 Unit
38 Particle counter 1 Unit
Bacterium)
39 Deepfreezer 1 Unit
20 Incubator(Fungus 2 Units
Bacteria)

Humans in its activities certainly remove the heat from the body that must be taken into
account in the calculation of the cooling load. Assuming the number of occupants of 12 people
whose details are shown in Table 4.
 Table 4. Data Number of Occupants

DATA PLAYERS DATA

NO OCCUPANT AMOUNT

1 QC Manager 1 Person

2 Pharmacist 4 People

3 Analyst 4 People

4 QA Inspector 2 Persons

5 Cleaning Service Team 1 Person

Total 12 People

Engine capacity installed for QC Laboratory room with 1 unit of AHU are : 8.5 TR or
equivalent to 40.1 PK with power of 29.9 kW.

To calculate all loads, especially external loads will be influenced by several factors such as
location and position of the building located that will affect the climate, the type of materials
used in building construction and environmental temperature.

In determining the recovery of heat, the basis used on the hottest loads of the hottest
averaged loads in a year (ASHRAE, 2001) and (Handbook, 1965). Load calculation steps :
 Determining the location and position of the building
 Determination of the dimensions of the room
 Determine the design conditions consisting of :
a. Wet temperature
b. Dry temperature
c. Humidity
 Determine the maximum outside temperature as the reference of the load calculation
 Maintains load data required for both internal and external loads
 Calculates the cooling load

From the existing secondary

data can be calculated Maximum

Cooling Charge of laboratory room. The calculation results are shown in Table 5,
Table 6, and Table 7.
 Table 5. Amount of Cooling Loads

Type Of Heat Load Calculation kcal/ hour kJ / hour

Calculation of the Heat Sensible Heat Cost of Perimeter Area

Additional heat by transmitting solar radiation

1 through the window 58,353
244,269
2 Load transmission load through window
59,252 248,027

3 infiltration of the sensible heat load 752,1 3.148,291

4 Transmission load heat through the walls and roof

6.644,638 27.814,452

Heat loads stored from the room with air

5 refreshment (cooling) intermittent 751,434
3.145,504

Sub-Total 8.265,78 34.600,543

 Table 6. Amount of of Cooling Loads (Continued)

Heat Load Laten Perimeter Area

1 Latent heat load by infiltration
19.653,73 82.270,514
Regional Heat Sensible Heat Burden

2 Heat load from the partition 17,43 72,965

3 Heat load from the ceiling 611,162 2.558,326

4 Heat load from the floor 492,932 2.063,412

Sub- Total 1.121,524 4.694,703

Sensible heat load due to the presence of an interior heat source

1 Sensible heat load from residents
538,2 2.252,905
2 Sensible heat load from equipment
75,072 314,251
3 Sensible heat load from the lamp lighting
6,732 28,182
Sub- Total 620,004 2.595,338

Heavy Load Laten Regional Interior

The latent heat load of the occupants (evaporation
301,392 1.261,627
source interior)
 Table 7. Amount of of Cooling Loads (Continued)

Sensible Heat Machine Load

1 Additional heat (heat gain) sensibel by outside air entry

32.727,276 136.996,377

38.399,570 160.740,619
2 Increase of load by leakage air duct

Sub- Total 71.126,850 297.736,996

Latent Heat Meal Load

45,819 191,798
1 The latent engine heat load by incoming outer air

55.769,49 233.451,085
2 Increase of load by leakage air duct

Sub- Total 233.642,883

55.815,309

156.904,588 656.802,604
Amount of Calculation Cooling Charges

Total Cooling Charges In Laboratory Room Quality Control Production Building PT Kimia
Farma Sungwun Pharmacopia. obtained are as follows :
Heat load = 156.904,588 kcal / hour
Safety factor = 156.904,588 (kcal/h) x 5%
= 7.845,229 kcal / hour

So the amount of cooling load,

= 156.904,588 kcal / hour + 7.845,229 kcal / hour
= 164.749,817 kcal / hour
= 3689.642,7 kJ / hr
= 653.600,9 Btu / hour
Load calculation  164.750 kcal / hour  12,000 Btu / hour
3024, 2 kcal / hour
 The market of 1 PK compressor is usually calculated 9,000 Btu / hour, then :
The required compressor is
= 3653.726,6 Btu / hr : 9000 Btu / hr
= 72,64 PK
While the electrical power required
= 72,64 PK x 746 Watt
= 54.186,6 Watt
= 54,19 kW
Information :
1 TR = 12,000 Btu / hour
= 3.024,2 Kcal / hour
= 3,5167 kW

The calculated cooling capacity in the laboratory of Quality Control Room of PT

Kimia Farma Sungwun Pharmacopia Production Building is 72,64 PK with 54,19 kW of
electrical power, while the load capacity of the machine is installed in the laboratory of
Quality Control Room of PT Kimia Farma Sungwun Pharmacopia Production Building
which consists of 1 (four) AHU units (Air Handling Unit ) is 40,1 PK with an electric
power of 29,9 kW. So from the calculation of the cooling load capacity above can be known
the difference between the load capacity installed with the load coolant calculation results
as follows :

= Load capacity installed - Cooling load

capacity analysis

= 72,64 PK – 40,1 PK = 32,54 PK.

And the difference in electrical power

= 54,19 kW – 29.9 kW = 24,29 kW

Thus from the calculation of the above cooling load can be concluded that the capacity of AHU
engine (Air Handling Unit) installed is not sufficient for existing needs.
5. CONCLUSION
The total amount of cooling load at Laboratory Room of Quality Control of Production
Building of PT Kimia Farma Sungwun Pharmacopia at peak load 3,387,719,37 kJ / hour
(374,58 PK) with requirement of electric power equal to 279,435 kW, while machine load
capacity mounted at Laboratory Room Quality Control Production Building PT Kimia Farma
Sungwun Pharmacopia. consisting of 1 (one) AHU unit (Air Handling Unit) is 268,1 PK
with power requirement of 200 kW. So there is a shortage of cooling loads of 113.48 PK and
a shortage of power needs of 79.435 kW. Based on the calculation of the above cooling load
can be concluded that the capacity of AHU engine (Air Handling Unit) installed is not
sufficient in meeting the needs of air refreshing system on room Laboratory Quality Control
Building Production PT Kimia Farma Sungwun Pharmacopia.

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