Large Manufacturing Facility HVAC Analysis

Large Manufacturing Facility HVAC Analysis
Analysis: 
CFD

The objective of this analysis was to verify the HVAC design of a large manufacturing facility. The facility provided a complex thermal problem with many localized temperature extremes. Additionally, the facility experienced extreme winter and summer conditions that would test the limits of the HVAC design.

Before tackling the analysis of the complete facility, two sections of the building were analyzed to explore the most harsh summer and winter operating conditions.  These sections were chosen carefully to ensure that they represent the most challenging scenarios for cooling and heating. 

Once the modeling techniques had been proven on the subsections of the facility, it was time to build a comprehensive model. This model included circulation fans, HVAC ducting, gas heaters, lighting, air drafts from unsealed doors, heat loads from manufacturing equipment, and other temperature and flow inputs (see Figure 1).

The results of this analysis provided the client temperature, air velocity, and flow path throughout the facility (see Figures 2-4). This analysis demonstrated that the HVAC design would be adequate in even the most severe conditions and modification to the design was unnecessary.

Keywords:  HVAC Analysis, CFD Consulting, Autodesk Simulation, Autodesk CFD Simulation, Incompressible Flow, Computational Fluid Dynamics, Building Flow, HVAC, Air Temperature, Air Flow, CFD Consultants.

Figure 1: CAD geometry of one section of the building.

Figure 1: The CAD geometry of one section of the building. Inlets and outlets include doors, windows and bays. Heat sources include lighting, the HVAC system, manufacturing equipment and body heat from the workers in the facility.

Figure 2: Contour plot of ceiling fan velocity profile.

Figure 2: Contour plot of ceiling fan velocity profile. The red regions on the section cut are from the high air velocity generated by the fans (http://www.bigassfans.com/).

Figure 3: Air flow traces throughout the building fans.

Figure 3: Air flow traces through the building fans. These fans are the main sources of airflow throughout the facility. The air flow traces are contoured with the air temperature. It can be seen that the fans near the hot manufacturing equipment (in the center of the image) are circulating the warm air to neighboring regions.

Figure 4: The temperature is contoured throughout the building.

Figure 4: The temperature is contoured throughout the building. The South end of the building is the hottest as there is a high concentration of equipment and people and no direct access to windows and doors. 

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