Plasma screen plant for JBF Group, Ras Al Khaimah
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JBF RAK is a company manufacturing PET bottle grade resins and polyester film, etc., it decided to expand its plasma screen manufacturing operations for television and mobile screen applications. The contract for the air-conditioning system of the new facility was awarded to Johnson Controls as part of a design-and-build project. Johnson Controls engaged Consistent to design the air-conditioning system for the facility, with cleanliness class 10,000 and 100,000 for the manufacturing bay and processing area respectively.
The facility had existing water-cooled chillers to feed the facility. Based on the requirements received from JBF and the equipment manufacturer, Team Consistent developed the detailed design.
Challenges
To maintain the positive pressure, the requirement of fresh air induction was very high. The fresh air load also contributed to the additional cooling requirement. Additional chillers were proposed to augment the capacity of the cooling plant and were interfaced with the existing cooling plant to ensure flexibility and redundancy in operation.
The chiller plant was 200 m away from the proposed manufacturing shed of plasma screens.
Design Approach & Solutions
To ensure good quality product, temperature, humidity, and maintaining cleanliness class was of critical importance. The architectural details were studied, and the zones were created considering raw material, final product, and manpower movements. To avoid any infiltration, the pressure of 5 Pa was planned to be maintained in the processing area while the manufacturing bay was planned to maintain positive pressure of 10 Pa.
Additional chilled water flow, increased distances between the load and chiller plant increased the pressure drop in the pipings. The selection of existing pumps was reviewed and additional pump sets were introduced. The entire pumping station needs to be rebalanced due to parallel pump operations where the operating point of the system was established with parallel pump operations.
Separate sets of Air Handling Unit (AHU) were proposed for the processing areas and manufacturing bay. The treated fresh air from Fresh Air Handling Unit (FAHU) was introduced directly into the processing area, while the manufacturing bay was provided with fresh air at lower level with the help of terminal HEPA filters.
Energy Efficiency in Design
In order to optimize the operational costs, the extract taken from high level was routed through the heat recovery section of the FAHU.
Other Design Measures
Thyristor controlled heaters were proposed in the FAHU to ensure relative humidity levels are retained within permissible limits of 50%.
Air distribution system was designed with provision of series of filters i.e. Pre filter, Carbon filter, Hepa filter etc. in accordance with ASHRAE 52.2 - 2013. To ensure dust-free atmosphere, the laminar airflow on the manufacturing bay was planned with discharge hoods, along with terminal HEPA filters having a velocity restricted to half (1/2) meter per second.
The control systems were planned for chilled water and air distribution along with Johnson Controls.
Endnote
The project was successfully completed to the client's satisfaction within one year.
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