Detailed Project Report on super efficient air conditioner (only inverter)

SUPER EFFICIENT AIR CONDITIONER (ONLY INVERTER)

 [CODE NO.3834]  

An air conditioner is a machine which keeps the air in a building cool and dry.

The purpose of an air conditioner is to maintain a comfortable indoor environment. The comfort we are used is to determined by a combination of 3 factors.

• Temperature

• Humidity

• Air Distribution

For this reason, the main purposes of air conditioners are to:

• Control room temperatures (cooling/heating).

• Control room humidity levels (drying, humidifying).

• Optimize air flow (circulation, distribution).

• Clean the air (filtration)

Working principle

An air conditioner collects hot air from a given space, processes it within itself with the help of a refrigerant and a bunch of coils and then releases cool air into the same space where the hot air had originally been collected. This is essentially how all air conditioners work.

Many folks believe that an air conditioner produces chilled air with the help of machines installed inside it, allowing it to cool a room so quickly. That might also explain why it consumes so much electricity. In reality, however, that’s a misconception. An air conditioner is not a magical device; it just uses some physical and chemical phenomena very effectively to cool a given space.

When you switch an AC on and set your desired temperature (say, 20 degrees Celsius), the thermostat installed in it senses that there is a difference in the temperature of the room’s air and the temperature that you’ve chosen.

A thermostat constantly monitors the temperature of the system so that it’s maintained near a user’s desired point. 

This warm air is drawn in through a grille at the base of the indoor unit, which then flows over some pipes through which the refrigerant (i.e., a coolant fluid) is flowing. The refrigerant liquid absorbs the heat and becomes a hot gas itself. This is how heat is removed from the air that falls on the evaporator coils. Note that the evaporator coil not only absorbs heat, but also wrings out moisture from the incoming air, which helps to dehumidify the room.

This hot refrigerant gas is then passed on to the compressor (located on the outside unit). Being true to its name, the compressor compresses the gas so that it becomes hot, since compressing a gas increases its temperature.

This hot, high-pressure gas then travels to the third component – the condenser. Again, the condenser remains true to its name, and condenses the hot gas so that it becomes a liquid.

The refrigerant reaches the condenser as a hot gas, but quickly becomes a cooler liquid because the heat of the ‘hot gas’ is dissipated to the surroundings through metal fins. So, as the refrigerant leaves the condenser, it loses its heat and becomes a cooler liquid. This flows through an expansion valve – a tiny hole in the system’s copper tubing – which controls the flow of cool liquid refrigerant into the evaporator, so the refrigerant arrives at the point where its journey started.

Here’s a simplified diagram of the air-conditioning process:

(Photo Credit : Ilmari Karonen/Wikipedia)

Although all the components involved in the air-conditioning process in window ACs are located inside the same metal box, the underlying process of cooling remains exactly the same.

Parts of a window air conditioner. (Photo Credit : Wikipedia)

The entire process is repeated over and over again until the desired temperature is attained. In a nutshell, an AC unit keeps drawing in warm air and expelling it back into the room until there’s no more warm air left to cool.

SPLIT AIR CONDITIONER

A split air conditioning imply means that the condenser (or sometimes referred to as the “outdoor unit”) is separated from the   “indoor unit”, thus the term “split”. 

The split air conditioning has at least one unit that sits inside your room. The compressor sits outside of the room, sometimes on the ground or on brackets hung to the wall. Some models come with multiple indoor units that will use one single compressor, this is known as the multisplit air conditioning system.

A split air conditioner consists of two main parts: the outdoor unit and the indoor unit. The outdoor unit is installed on or near the wall outside of the room or space that you wish to cool. The unit houses the compressor, condenser coil and the expansion coil or capillary tubing. The sleek-looking indoor unit contains the cooling coil, a long blower and an air filter.

A split air conditioner is a suitable alternative to wall, window, or centralized air conditioner systems. Often called mini-split, ductless split, or duct-free air conditioning, this system can adequately cool a standard-sized house without requiring extensive installation costs and efforts.

Split air conditioners are home appliances that do not require ductwork, which reduces energy expenditures. Still, many homeowners shy away from a split air conditioner system because they do not know how it works or why it is a viable option for cooling down.

The following information will fill you in on the function and installation of split air conditioner systems. They are uncommon, but not through any fault or flaw. 

CONSTRUCTION

The split air conditioner comprises of two parts: the outdoor unit and the indoor unit. The outdoor unit, fitted outside the room, houses components like the compressor, condenser and the expansion valve. The indoor unit comprises the evaporator or cooling coil and the cooling fan. For this unit, you don’t have to make any slot in the wall of the room. Further, present day split units have aesthetic appeal and do not take up as much space as the window unit. A split air conditioner can be used to cool one or two rooms.

COST ESTIMATION

Plant Capacity                                        333,3333 Nos

Land & Building (4000 sq.mt.)           Rs. 5.65 Cr    

Plant & Machinery                                Rs. 3.63 Cr 

Working Capital for 2 Months            Rs. 33.68 Cr 

Total Capital Investment                    Rs. 43.56 Cr 

Rate of Return                                     48%

Break Even Point                                30%

• INTRODUCTION
  
• WORKING PRINCIPLE
• HERE’S A SIMPLIFIED DIAGRAM OF THE AIR-CONDITIONING PROCESS:
• SPLIT AIR CONDITIONER
• CONSTRUCTION
• PARTS OF SPLIT AIR-CONDITIONER:
• WALL MOUNTED INDOOR UNIT:
• 1) EVAPORATOR COIL OR THE COOLING COIL:
• 2) AIR FILTER:
• 3) COOLING FAN OR BLOWER:
• 4) DRAIN PIPE:
• 5) LOUVERS OR FINS:
• OUTDOOR UNIT
• REFRIGERANT PIPING OR TUBING
• ADVANTAGES
• USES AND APPLICATION
• B.I.S. SPECIFICATION
• ENERGY EFFICIENT AIR CONDITIONER
• OVERVIEW OF SUPER EFFICIENT AIR CONDITIONER
• GOING STRONG
• GROWTH STRATEGY
• NEW LAUNCHES
• MAKING A MARK
• INVERTER AIR CONDITIONER AND ITS COMPONENTS
• AC INDUCTION MOTOR
• DC BRUSHLESS MOTOR
• DC INVERTER CONTROL CIRCUITRY
• THE FIRST SECTION CONSISTS OF A DC CONVERTER
• THE SECOND SECTION BEING PFC OR POWER FACTOR CORRECTION
• THE THIRD SECTION IS THE INVERTER CONSISTING OF IGBT TRANSISTORS
• RAW MATERIALS
• DESIGN OF AIR CONDITIONER
• MARKET OVERVIEW OF AIR CONDITIONER IN INDIA
• ENERGY EFFICIENCY
• REFRIGERANTS
• STRATEGIES TO EXPAND CLIMATEFRIENDLY ROOM AC MARKET SHARE
• STRATEGY 1: OPPORTUNITIES THROUGH THE MONTREAL PROTOCOL
• HCFC PHASE OUT MANAGEMENT PLANS (HPMPS)
• THE HFC PHASE DOWN
• FLAMMABILITY & SAFETY STANDARDS
• THE ENERGY EFFICIENCY OPPORTUNITY
• SUMMARY
• STRATEGY 2: ENERGY EFFICIENCY AND LOW-GWP STANDARDS & LABELS
• UPDATING THE STAR RATING SCALE
• VARIABLE SPEED TECHNOLOGY
• TEST PROCEDURE
• THE BIG PICTURE
• SUMMARY
• STRATEGY 3: BULK PROCUREMENT PROGRAMS
• PROGRAMS IN INDIA
• SUMMARY
• STRATEGY 4: RAISING CONSUMER AWARENESS
• THE IMPORTANCE OF ENERGY LABELS
• REFRIGERANT AWARENESS
• REDUCING DEMAND
• SUMMARY
• STRATEGY 5: LOCALIZING SUPPLY CHAINS & RESEARCH & DEVELOPMENT
• INCREASING DOMESTIC COMPONENT MANUFACTURING
• RESEARCH & DEVELOPMENT
• SUMMARY
• STRATEGY 6: BRINGING IT ALL TOGETHER: NATIONAL COOLING 
•    ACTION PLANS
• SUMMARY
• CONCLUSION
• ROOM AIRCON INDUSTRY (INVERTER)
• INVERTER ACS TO ACCOUNT FOR 30% OF INDUSTRY VOLUMES 
•    IN FY18E AND 50% IN FY20E
• VOLTAS MAY NOT SEE MEANINGFUL GAINS EVEN WITH LG’S 
•     COMPLETE EXIT FROM FIXED-SPEED ACS
• HIGH COMPETITIVE INTENSITY
• BRAND, DISTRIBUTION, SERVICE CENTER NETWORK AND DEALER 
•    MARGINS ARE KEY
• SUMMER STRATEGIES OF AC MANUFACTURERS
• BLUE STAR – IMPRESSIVE LINE-UP OF AC MODELS; MARKET 
•    SHARE TARGET AT 13%
• VOLTAS – TARGETING 15-20% GROWTH THIS SUMMER SEASON
• LG INDIA – LOOKING FOR 30% GROWTH IN CY17
• DAIKIN INDIA – TARGET TO EXPAND REACH AND MARKET SHARE;DOUBLING CAPACITY AT NEEMRANA TO 1.2M UNITS
• PANASONIC – ‘A BETTER LIFE, A BETTER WORLD’ – AIMS FOR 30-35%
•    GROWTH IN FY18
• GODREJ APPLIANCES – EYEING 20% SHARE IN INVERTER/5-STAR 
•    AC SEGMENT
• SAMSUNG – INVERTER RANGE LAUNCHED IN AFFORDABLE LUXURY
•    SEGMENT
• VIDEOCON – TARGETS 13% SHARE AND TO INCREASE PRESENCE 
•    IN TIER 2/3 CITIES
• SWOT ANALYSIS
• DETAILED EXPORT DATA OF SPLIT AC
• DETAILED IMPORT DATA OF SPLIT AC
• MANUFACTURERS/SUPPLIERS OF SPLIT AC
• MANUFACTURING PROCESS OF AIR CONDITIONER
• CREATING ENCASEMENT PARTS FROM GALVANIZED SHEET METAL 
•    AND STRUCTURAL STEEL
• PUNCH PRESSING THE SHEET METAL FORMS
• CLEANING THE PARTS
• POWDER COATING
• BENDING THE TUBING FOR THE CONDENSER AND EVAPORATOR
• JOINING THE COPPER TUBING WITH THE ALUMINUM PLATES
• INSTALLING THE PUMP
• QUALITY CONTROL
• PROCESS FLOW CHART
• PRODUCTION PROCESS
• (1) PROCUREMENT OF RAW MATERIALS
• THE MANUFACTURING PROCESS
• (1) MAKING THE PARTS
• (A) CONSTRUCTING THE CASING, BRACKETS, AND OTHER SUPPORTS
• (B) PUNCH PRESSING THE SHEET METAL FORMS
• (C) CREATING ENCASEMENT PARTS FROM GALVANIZED SHEET METAL 
•    AND STRUCTURAL STEEL
• (D) CLEANING THE PARTS
• (E) POWDER COATING
• (F) FABRICATION OF COIL
• (G) FINISHING THE EVAPORATOR AND CONDENSER COILS
• (2) ASSEMBLY
• (3) CHARGING AND FINISHING
• (4) QUALITY CONTROL
• (A) PRODUCTION ROUTINE TESTS
• (I) GENERAL RUNNING TEST —
• (II) PRESSURE TEST OR LEAKAGE TEST —
• (III) INSULATION RESISTANCE TEST —
• (IV) HIGH VOLTAGE TEST —
• (V) PERFORMANCE TEST —
• (VI) LEAKAGE CURRENT TEST —
• (VII) EARTHING RESISTANCE TEST —
• (B) TYPE TESTS
• (6) MARKING
• PLANT LAYOUT
• SUPPLIERS OF RAW MATERIALS
• ALUMINIUM FIN STOCK FOIL
• COPPER TUBE
• M.S SHEETS
• ABS GRANULE
• BRAZZING WIRE
• MIG WELDING WIRE ELECTRODE
• REFRIGERANT GASES
• PICKLING CHEMICALS
• SUPPLIERS OF AC COMPRESSOR
• AIR CONDITIONER PARTS
• SUPPLIERS OF PLANT AND EQUIPMENTS
• SUPPLIERS OF FIN PRESS
• SUPPLIERS OF FIN DIE
• SUPPLIERS OF VERTICAL EXPANDER
• SUPPLIERS OF HAIRPIN BENDER
• CNC PRESS
• POWDER COATING MACHINE
• INJECTION MOLDING MACHINE
• SUPPLIERS OF IDU ASSEMBLING LINE
• SUPPLIERS OF BRAZING MACHINES
• SUPPLIERS OF REFRIGERANT CHARGING UNIT
• SUPPLIERS OF REFRIGERANT (HALIDE) LEAK DETECTOR
• ELECTRICAL MEASURING INSTRUMENTS
• SUPPLIERS OF POWER TRANSFORMER
• SUPPLIERS OF ELECTRICAL PANEL
• AIR POLLUTION CONTROL EQUIPMENTS
• AIR COMPRESSORS
• MATERIAL HANDLING EQUIPMENTS
• FIRE FIGHTING EQUIPMENTS
• SHOT BLASTING MACHINE

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)