LAPORAN PROJEK

DIPLOMA KEMAHIRAN MALAYSIA

DEVELOPMENT OF THE INDOOR AIR

AUTOMATIC CONTROL SYSTEM FOR
MUSHROOM HOUSE

OLEH
MOHAMAD RIZAL BIN HARUN

KEJURUTERAAN PENYELENGGGARAAN
INDUSTRI
ME-010-4:2013
 PENGESAHAN LAPORAN PROJEK

TAJUK PROJEK : DEVELOPMENT OF INDOOR AIR AUTOMATED

SYSTEM FOR MUSHROOM HOUSE
DUTI/ CU BERKAITAN : C01 COMPUTER CONTROLLED MACHINE
MAINTENANCE

Saya membuat akuan bahawa hasil laporan projek dibuat dengan mempraktikkan
pengetahuan dan kemahiran berkaitan dengan bidang berdasarkan kepada pengalaman
serta kemahiran tanpa meniru dari mana-mana sumber.

TANDATANGAN PEMOHON :
NAMA : MOHAMAD RIZAL BIN HARUN
NO KAD PENGENALAN : 790124085165
TARIKH :
NAMA MAJIKAN :

Saya mengaku telah membaca Laporan Projek ini dan pada pandangan saya laporan ini
adalah mencukupi dari skop dan kualiti bagi tujuan penganugerahan Persijilan Kemahiran
Malaysia.

TANDATANGAN PP-PPT :
NAMA :
NO KAD PENGENALAN :
TARIKH :
 ACKNOWLEDGEMENT

I would like to sincerely thank to my project leader, Ir. Dr. Mohd.Rosdzimin bin
Abdul Rahman for their help and providing valuable comments and suggestion to
complete this project.

My sincere thanks go to all the staff of the Mechanical Engineering Department,

UPNM, who assisted me in many ways. Without their helped, this project would have
been never been completed in a timely manner.

I acknowledge my sincere indebtedness and gratitude to my parents for their love,

dream and sacrifice throughout my life. I cannot find the appropriate words that could
properly describe my appreciation for their devotion, support and faith in my ability to
attain my goals.
 ABSTRACT

The aim of this project is to develope The Indoor Air Automatic Control System
in the mushroom room. The temperature and humidity inside the room are significantly
controlled by the outside heat radiated from the sun and airflow inside the room. Higher
temperature inside the mushroom room is a result of the heat tranfer from outside to the
inside due to poor insulation of the room. Bad airflow inside the room result in an increase
or decrease in the humidity. Following the issues, the evaporative cooling technique and
improvement of the room insulation have been analysis in this thesis. Evaporative cooling
is a process that reduces air temperature by evaporation of water into the air surrounding.
As water evaporates, energy is lost from the air surrounding cause its temperature to drop.
A well infiltration and ventilation in evaporative cooling system can reduce incoming air
through the surface. The temperature indoor can be decrease and humidity will increase
to improve the environment surrounding.normally, this heat comes from the solar energy
and the evaporative cooling system is choosen method for cooling system because it can
give low power consumption energy compare to air conditioning energy. This cooling
system give many benefit to people especially in cultivation crop production to make the
farming area building in high relative humidity and low temperature. Based on
experiment, the result of temperature in the mushroom room decrease from 330C to 260C
and the humidity increase in 40% until 84%RH. It show the aim of this thesis to analyze
the evaporative cooling system in other to get expected result which the temperature can
drop in 50C to 70C and humidity increase in 40% until 80%RH for the suitable
temperature of the mushroom crop was achieve.
 CHAPTER 1

INTRODUCTION

1.1 Background

Mushrooms is one of the plants that needs low temperature and high humidity for
their growth. Based on the study, the greenhouse concept is very suitable to plant this crop
because the evaporative cooling system in greenhouse can help the mushroom grow faster
and increase production rate. Most countries in Asia such as Thailand produces mushroom
cultivation in their country by using this system because it can help their farmers to get
high yields and increase the production rate. So, to help farmers especially in Malaysia to
increase their quality of crop cultivation in mushroom. This project is to develop the
system effectiveness and also help the farmer increase their production in modern
technology farming by using evaporative cooling pad system

Mushroom also very popular vegetable in Malaysia people that can be used in
food. Not only has its good tasty but also had many benefits in nutrition. In order to
increase the exporting income, the mushroom growing should be supported. Malaysia is
situated in an equatorial climated and uncertain weather conditions depend on situation.
The normal temperature in the area is 27°C and 40°C and the relative humidity between
60% and 70% Relative Humidity (RH), consequently, not suitable for growing
mushrooms as it requires temperature in the range of 22 ℃ to 28 ℃ with the relative
humidity of 80 ℃ to 90 ℃. However it also can grow in Malaysia in certain month because
of the temperature and humidity is high range in the rainy season between Octobers to
February. So, in order to produce the suitable temperature and humidity inside the
mushroom house for their growth. The design and temperature condition should be
adjusted and investigated. The advantage of this evaporative cooling technique is it can
provide a good environmental surrounding to their growth. By using greenhouse concept
evaporative cooling system, evaporative cooling room for mushroom can be made in other
to produce a suitable temperature and humidity inside the room for the mushroom to
growth every month. Evaporative cooling can be used to provide thermal comfort in
buildings along with better fresh air and sensibly good indoor air quality. Most direct
evaporative coolers draw outdoor air through the wetting media (pads), which trap
significant amount of dust and other particles. Since, it is economical, pollution free and
simple, there is need to review the possibilities of using direct evaporative cooling for
maintaining thermal comfort inside the buildings. There are many types of cooling
systems can be used in greenhouse such as evaporative cooling, fan pad, and ventilation.
Most people use evaporative cooling as a medium cooling system for their cultivation
because easy to process, controlling and creating a good technology cooling method to
monitor temperature and humidity inside the greenhouse. The expected result from this
cooling technique when the cooling system off, hourly mean temperature and relative
moistness from Pad to Fan inside greenhouse changed between 30-33 ℃ and 30-47%
relative humidity (RH ), individually, at outside atmosphere states of 32 ℃ and 25% RH.
After the cooling system was stabile by opening Fan-Pad system, hourly mean
temperature and relative humidity inside greenhouse from pad to fan ran between 20 - 27
℃, and 50 - 68% RH, separately. The air temperature entering to greenhouse with air
speed of 0.8- 0.9 ms-1 through pad was approximately 12- 13 ℃ lower than the outdoor
air temperature. Along these lines, the evaporative cooling system useful for generation
of development with respect to their execution
1.2 PROBLEM STATEMENT

Temperature and humidity are important aspects to be considered in controlling

mushroom house as it is affecting the growth of mold.The temperature during hot or
raining days affected the indoor air properties of mushroom house such as temperature
and humidity.In addition, the selection of design and materials used to make mushroom
houses are also a factor that affecting the temperature and humidity in the mushroom
house. The suitable temperature for mushroom house is at room temperature, between 25-
28 oC. Meanwhile, appropriate humidity is between 70-80 percent humidity. Current
method using sprinkler and mist system to cool the mushroom house manually. Sprinkler
and mist system will increase the humidty. Thus this system should be control
automatically to get the right temperature and humidity inside the mushroom house

1.3 PROJECT OBJECTIVES

The objectives of this study are:

i) To design an automatic control system for temperature, humidity and water
sprinkler system
ii) To develop an automatic control system for temperature, humidity and sprinkler
system
iii) Fabricated of Fan-pad cooling system
1.4 SUMMARY

The main objective of this report is to control two important factors in the process
of growth of mushrooms. Temperature and humidity are important aspects to be
considered in controlling mushroom house as it is affecting the growth of mold. Objectives
of this research are to design and develop automatic control system for temperature,
humidity and to get the right temperature and humidity inside the mushroom house.
Exhaust fan and pump for sprinkler system and cooling pad will control by temperature
sensor inside the mushroom house. Water that sprayed on the rooftop and through cooling
pad will be collected and reuse. Temperature sensor and humidity sensor will be installed
inside the mushroom house.
 CHAPTER 2

RESEARCH METHADOLOGY

2.1 Introduction

This topic discussed the method in conducting this study, since analytical study
was performed, some mathematical formulation were required to restructure the
mushroom room by calculate the temperature and humidity in psychrometric chart

2.2 OVERVIEW DESIGN SYSTEM

Automated control systems will be developed. Pumps, exhaust fans and sprinkler
systems will be controlled by temperature sensors inside the mushroom house. The water
will flow into the cooling pad and sprinkler. Water sprayed on the roof and which goes
into the coolant pad will retreat into the water tank for reuse. Temperature sensor and
humidity sensor will be installed inside the mushroom house. It is important to get the
proper temperature and humidity in the home of mushrooms. The walls and roof of the
mushroom house should use insulation material to reduce temperature and regulate
moisture. Dehumidifier will be installed in mushroom house to control moisture. The
exhaust fan will be installed at the wall opposite the cooling pad to produce a good air
circulation in the mushroom house.
Figure 2.1: Schematic of indoor air automatic control system
2.3 Bill of Materials

Table 2.2: Bill of materials

No Part Quantity
1 Cooling Pad System 2 units
Cooling Pad with Inlet and outlet water system.
Size: 2.5m (H) X 2.5m (W) X 100mm (Thichness)

2 Water Tank 1 unit

Size: 1.2m x 1.2m x 0.5m (H)
3 Water Pump 1 unit
Sinlge phase 240V, flowrate 30 – 50L/m
4 Exhaust Fan 2 units
Diameter 68”, Power 0.37 kW, Single phase 240V,
flowrate 20,000m3/h
5 Polycarbonate sheet 4 rolls
Colour: Transparent,
Thickness: 3.0mm,
Maximum length: 24m/roll
6 Bubble Foil Roofing Insulation 90m2
5 layers laminate double sided, material aluminium,
bonded with bubble pack with special FR material.
7 Humidifier system 1 unit
Single phase 240V, power 120 W, Mist output – 1.6kg/h,
relative humidity:<80%, size: 362 x 206 x 550 (mm)
8 Control box 1 unit
Temperature sensor, Humidity sensor, Timer, Electrical
switch, Contactor 10Amp, Distribution box.
2.4 FLOW CHART

START

Design of the automatic

control system based on
specifications, materials &
analytical calculation

Completion of the
development the automatic
control system

Does the design value and NO

experiment results acceptable?

YES

Submit report

FINISH

Figure 2.3: Project Flow Chart.

2.5 The Principle of Evaporative Cooling in Psychrometric Chart

Evaporative cooling process is a reducing the temperature and relative humidity

through the usage of cooling pad. The hot air is drawn through the pad and as the water
evaporates, energy from the air lost to surrounding which can reduces the temperature. It
can be illustrated in line AB in Figure 2.2 below. The air changes along the lines of
constant wet bulb temperature for the cooling process. Evaporative process use to convert
sensible heat into latent heat, along these lines to decrease the temperature of the air. The
transformation of energy from sensible heat into latent heat does not change overall the
energy contact of the air but rather it can brings lower the temperature of the air and
convert the water vapor content energy to water vapor and increase the relative humidity.

Figure 2.4: Evaporative cooling process in psychrometric chart

2.5.1 COOLING LOAD IN PSYCHOMETRIC CHART

Condition of air entering evaporative cooling (point A on the chart) are dry bulb
temperature is 330 C and wet bulb temperature is 250 C while the relative humidity is 54
%RH. So, by using evaporative cooling system, the maximum reduction that is possible
is the differential between the dry bulb and wet bulb temperature. Since, no system is
perfect because there will be certain losses in the evaporative cooling system. So, these
losses maybe cause by the cooling pad media on the system. If the evaporative cooling
efficiency is 95% RH then the process will take place over 95%RH of the distance from
point A up towards the saturation line (100% relative humidity) along a constant line of
wet bulb temperature. So, the achievable temperature at 95%RH is 280C at point B. Point
B represents the conditions of the air leaving the evaporative cooling where the dry bulb
temperature is 250C, wet bulb temperature 250C and relative humidity is 95%RH. The
condition achieved after evaporative cooling can be stated as low sensible heat energy and
high latent heat energy.
Lastly, the condition of air in area being cooled from B to C. In this condition, the
air in the room being cooled by the evaporative cooling will depend on the heat loading
in the area. If the area is not affected by any other heat conditions then the condition of
the air in the room will be very close to the conditions of the air leaving the evaporative
cooling. But, there are any additional heat loadings in the room cause by the infiltration,
ventilation, crop, material and also the system then the temperature of the air leaving the
evaporative cooling will increase in a few degrees. This would be represented by a
horizontal movement to the right from the condition B to condition C on the psychrometric
chart in Figure 2.5 below.
 Figure 2.5: Cooling load illustrate in psychrometric chart

The design value assumed in psychrometric chart is the temperature may drop in
50C which at 280C and the relative humidity 82%RH as showed in the figure 2.3. In the
psychrometric chart, the additional heat loading from point B to C can be represent the
sensible heat and latent heat through the indoor design condition, lighting, equipment,
infiltration, transpiration of plant and people that tell in chapter 2 in energy balance in the
greenhouse technology. So, to produced suitable temperature and humidity cooling load
in the room very important factor that must be calculate.
2.5.2 Estimation of Evaporative Cooling Pad on the System

In order to remove heat energy in the room from the outside heat, the amount of
water that evaporated from the cooling pad must be find to decrease the temperature and
increase the humidity. So, the sensible and latent loads due to the heat gain from internal
and external sources must be removed. The ventilation very important because it can help
the evaporative process and the removable heat throughout the room. At the first step
needed for cooling greenhouse is ventilation because it is very important process of air
exchange to removes heat and absorbed air from the room and change it for new outside
air. Nadia Christina Sabeh (2007). The function of fan in the Figure 2.6 below to remove
the heat in the room through the outdoor surrounding.

Figure 2.6: Schematic diagram of air movement

2.5.3 ROOM COOLING TECHNOLOGY SYSTEM

Evaporative cooling and ventilation in the room environment are very important
during hot day. The evaporative cooling very useful because the global warming
phenomenon due to greenhouse effect is desirable inside the room to increase the
temperature in other to control the crops from ill effects of overheating. In Malaysia,
greenhouse system required a good benefit to maintaining the desirable temperature and
quality of crop production by moving and mixing for efficient crop production.
Greenhouse cooling required that large volume of air to be brought into the greenhouse.
The calculation of cooling required for standard flow rates of ventilation per square area
of greenhouse are available.
In this study, we used experimental method to obtain data and verify the data with
theoretical approach to get the reliable data of evaporative cooling pad system. Theoretical
approach in greenhouse system with plant grown inside can be apply in room to measure
the temperature and humidity of the system that can growth the crop in suitable condition.
There are many heat that we consider to calculate the cooling load in the room system.

2.5.4 VENTILATION/INFILTRATION

Heat gains from ventilation not consider in this experiment because the experiment
occur in the lab and infiltration needs to be considered in the cooling load calculation
because there are air flow into the room as showed in Equation 3.4 for the sensible heat
equation.

Qs= 1.1 x CFM x TD (3.4)

 Qs = Sensible heat loss from the infiltration kj/s

CFM = Air infiltration flow rate m3/s

TD = temperature difference between inside room and outside room

For the latent heat as showed in equation 3.5

Ql = 0.68 x CFM x TD (3.5)

Ql = Latent heat required for infiltration kj/s

CFM = air infiltration flow rate m3/s

TD = Temperature change between indoor and outdoor

2.5.5 CALCULATION FOR COOLING PAD AND FAN REQUIRED IN THIS
SYSTEM

In this project, the total sensible heat and latent heat must be calculated to
estimate the total cooling pad and ventilation fan for the cooling room to achieve the
objective. The details calculation of cooling load can be showed in the appendix A
section. From the theoretical result calculation, the cooling load produces by the total
sensible heat and latent heat is 1.82kw. So, we can estimate the total cooling pad and
ventilation fan by using the Equation 3.6.

Qc = ṁ(h2-h1) (3.6)

Where,
Qc = total sensible heat + total latent heat

ṁ = mass flow rate kg/s

h1 = the enthalpy in the temperature 280C in psychrometric chart

h2 = the enthalpy in the temperature 330C in psychrometric chart

By using mass flow rate of the air, the volume flow rate for ventilation can be find by
using the Equation 3.7

ṁ = V/v (3.7)
Where,
V= volume flow rate air m3/min
V = velocity of the air m/s

After produce the volume flow rate of the air .we can estimate the total of fan
require to remove the total sensible and latent heat in the room to maintain the temperature
and relative humidity by refer to the Figure 3.7 of the specification of the ventilation fan.

Figure 2.7 Exhaust Fan

The design volume flow rate is 20,000 m3/min by referring to the specification
industrial fan, It show the flow rate theoretical is larger than industrial fan. So, we can
estimate the total of the fan use in the design must have two to achieve the theoretical
result. For the design of the evaporative cooling pad, the two fan required in this cooling
system to remove the heat.

Lastly, we can measure total the cooling pad require by using this Equation 3.8
V=Av (3.8)
Where the A is the total area require for cooling pad must be used in design to reduce the
temperature and increase the humidity. In the design value, the area cooling pad required
is 1.6 m2 by using the Equation 3.9

A= na

Where,
N = number of cooling pad
a = area of cooling pad media in industrial

From the calculation, it show 2 cooling pad required to achieve a good result in this
cooling technique. In conclusion, the design calculation show two ventilation fan required
and two cooling pad media uses in this project to get the accurate data from the
experiment.

Figure 2.8 Evaporative cooling pad with gutter

2.5.6 INSTALLATION AND FABRICATION PROCESS

The fabrication and installation process involves cutting, grinding, drilling, welding,
piping and wiring. Part of the mushroom house such as the wall and the bottom of the roof
will be installed insulation. While on top of the roof will be installed a sprinkler. The
cooling pad system will be installed against the exhaust fan. The pipe will be connected
to the cooling pad system and sprinkler. Electrical wiring will also be carried out involving
equipment such as controller box, exhaust fan and water pump. This process is done
without changing the structure of mushroom house.

Figure 2.9 : Electrical wiring

Figure 3.0 : Installation of insulation
2.6 DEVICE MEASUREMENT

There are some device measurement that being used in this experiment to measure
the data of the temperature, humidity, air flow rate and volume flow rate.

i. Hioki Lr8431-20 Memory Hilogger

Hioki memory hilogger used to measure the temperature. This device

consist ten channel of measurement and can calculate data of the average,
peak value, maximum, minimum, time to maximum and time to minimum.
So, by using this device the data easier to collect and also the graph of the
temperature against time was plot on the device.

ii. Outdoor Dual Temperature Digital Thermometer And

Hygrometer

This device have two function which can measure the temperature and
humidity. It also always on display for 2 temperature indoor and outdoor.it also
can measure the humidity in that place. In this project, the humidity can be measure
manually by using this device and the data was note by 1 minute until 30 minutes
2.7 GANT CHART

Bil Objective WEEK NUMBER (2016 – 2017)

1/9 2/10 5/11 3-12 5/1 1/2 1/3
1 Define research areas, view
issues, topics and objectives
2 Find information and evaluate

3 Designing an insulation system

and an automatic control
system
4 Installation of insulating
material and automatic control
system
5 Complete data collection of
automatic control system for
temperature and humidity
6 Sending final report findings
2.8 SUMMARY

This chapter briefly discusses the methodology from system design to installation
process. All of the decisions were made in accordance with the brainstorming
recommendations, some of which were modified to meet the needs and objectives of the
project. The results and the finished products are discussed and reported in Chapter Three.
 CHAPTER 3

ANALYSIS AND DISCUSSION

3.1 INTRODUCTION

This chapter would discuss the experimental results obtain from the experiments
carried out using the evaporative cooling room. The experiments include to measure the
temperature and humidity in the room. Besides that, the effect of flow rate of water and
flow rate air also been manipulated in this result. All the experiment procedure were
discussed in the previous chapter.

3.2 TEMPERATURE AND HUMIDITY INSIDE THE ROOM

From the result, it is inferred that the evaporative cooling system significant
effect on the temperature and humidity inside the room. The result showed the
temperature and humidity linearly increase with time. The results are compared when
evaporative cooling system was running and while the system was switch off. Insulation
of the house was carried out by insulating the roof and side walls using a bubble foil
insulation and polycarbonate insulation respectively. Air from the outside is pull into the
house using two fan that located at the end of the house (Figure 2). On the other side of
the house, two cooling pad were installed. Air that pull from the ouside will flows
through the cooling pad before entering the house and transfered the heat to the water,
result in low air temperature and increased the humidity inside the house (Figure 2).
Result of the test is shown in Figure 3. It is seen that temperature inside the house
decreases after 10 minutes system running. The humidity inside the house is recorded at
90%. Moreover, the temperature outside of the house is recorded at 32 oC with 65%
humidity.

Figure 3.1: Schematic of the cooling system

Figure 3.2 : Result of temperature

3.3 WHEN SYSTEM SWITCH OFF

Besides that, the result showed in Figure 3.1 and 3.2 when the system was switch off
indicated that no changes in temperature and humidity because the temperature inside
the room and outside is slightly same and no change in temperature and humidity
happened.

Figure 3.3 Temperature when system off

Figure 3.4 Humidity when system off

 Overall the cooling system installed in the mushroom has reduced the temperature
of the mushroom from 32 degrees to an average of 27 degrees. The system has
successfully lowered the temperature to 5 degrees Celsius. Initial humudity of 65% RH
increased to 90%. The electricity used is no more than 1kwh in an hour.
 CHAPTER 4

CONCLUSION AND RECOMMENDATION

4.1 CONCLUSION

In conclusion, this project has successfully reached all the objective stated earlier
in this report. The mushroom room is design and fabricated with the evaporative cooling
pad system. The design value temperature and humidity inside the room also was
validate with the experimental value to provide a good condition for the growth of
mushroom based on their surrounding environment. The suitable temperature for the
mushroom growth based on literature review is 22 ℃ to 28℃ and relative humidity 80%
to 90%RH. In this project, the design value for evaporative cooling system was
calculated by using psychrometric chart to provide the suitable size of cooling pad and
the ventilation fan. The temperature was assume to drop in 5℃ and the humidity
increase. So, in this the experimental the result get from the temperature and humidity
value can be proved by the decreasing of the temperature in an afternoon 12.30 pm until
1.00 pm. The temperature show a positive value where the temperature drop from 33℃
to 26℃ while the humidity also increase from 60%RH to 90%RH. It showed that the
project was successful and the system is suitable for the mushroom to growth inside the
room. The design value and experimental value of the temperature and humidity show
the closer difference and small percentage of error. So, it indicated that the experiment
was accepted and achieve their objective.
4.2 RECOMMENDATION

From this project, we can conclude that the project achieve their objective but
there are another way to improve this project by modifying the system cooling into the
new evaporative cooling technology. To get more accurate result, the selection material
also important because it will decrease the temperature and humidity. All the material
have a different heat produce their thermal conductivity. In order to reduce the heat
produced by the materials, the material that have a lower thermal conductivity can be
used such as by using polycarbonate. The polycarbonate have a lower thermal
conductivity compare to canvas. So, the heat from outside coming through the
polycarbonate is decrease. So, it will make sure the temperature inside the room is
maintain. Overall the project was completed with successful results as per required by
the industry. This approach can be implemented to the other mushroom grower that
facing the heat and humidity issue in Malaysia.
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