Consult the cornerstone
Consult the DA manual
The Design Application (DA) series of publications produced by
AIRAH are best-practice guidelines to assist HVAC&R practitioners
with their day-to-day tasks in the design, operation and
maintenance of mechanical building services.
THE
ER
AT
G
INST
ITUT
EO
DA01
•
CENTRIFUGAL PUMPS
CENTRIFUGAL PUMPS
Isolate the pump from the structural loads of the
pipework system.
•
Compensate for small deviations in alignment between
the pump and pipework connection.
•
Compensate for expansion and contraction of the
pipework or pump due to temperature changes.
DA02
•
Using a flexible pad (neoprene, silicone or similar)
between the full contact surface of the pump and the
foundation.
•
Using a base isolation system such as rubber pads or
inertia base with spring.
Precision grouting is probably the most critical part of
the installation. The surface beneath the base plate must
be properly prepared for grouting, any concrete laitance
(structurally weak layer) must be removed from the
concrete and the aggregate exposed. All dirt and dust
must be removed from the area prior to grouting. Properly
grouting the base plate to the concrete slab lowers the
natural frequency of the base plate and reduces resonant
vibrations which can damage bearings and seals.
U
MPS
Pipework should be independently supported to ensure
that no forces or moments due to pipe weights or
thermal expansion will be imposed on the pump. Flexible
connectors are never designed to carry loads. Similarly
pump flanges and connections are not designed to carry
the weight of system pipework and liquids. All pipework
and accessories should be supported independently of the
pump.
During the course of physical routing of any piping system,
the installer should ensure the provision of high-point
vent and low-point drain connections for the filling and
draining of the piping system with water (for hydrostatic
testing and operation) and for the purging of air entrapped
within the system.
Pump
60
•
Valves should be installed with the spindles between
the vertically upward and horizontal positions, to
prevent the entrainment of air and debris in the valve.
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
OF
REFRI
GERA
TION,
AIR CO
NDITIO
NING
AN
•
Valves in acid and caustic services should be located
below the plant operator’s eye level or in such a
manner as to not present a safety hazard.
•
The location of valves, with consideration for operating
accessibility, should be accomplished in the natural
routing of the system from point to point.
•
Valves in overhead piping with their spindles in the
near horizontal position should be located so that the
bottom of the hand wheel is no more than 2m above
the floor. Only infrequently operated valves should be
located above this elevation.
•
Space should be provided for the removal of all valve
internals.
A
LI
PP
T
CA
L
UA
flow
N
•••
12
Note: Refer AIRAH DA 27 for further information on the installation of
control wiring.
(a)
Tu
be
ax
ial
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
The provision of adequate access to the pump and its
accessories for maintenance and service is essential and
is a requirement of AS/NZS 3666.1 which is a regulated
requirement in Australia through building and health
regulations. Large centrifugal pumps are often supplied
with access points.
For larger pumps, the provision of lifting eyes and
overhead lifting beams or davits should be considered
to facilitate pump replacement or servicing in a safe
manner.
DA15
MA
IO N
Air
9.4.11. Wiring
All pumps and associated electrical equipment should
be wired in accordance with AS/NZS 3000. Control and
monitoring instrumentation should be wired in accordance
with the manufacturer instructions and all relevant
regulations.
9.4.12. Access
•••
APPL
61
DA16
AIR FILTERS
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
D HE
ATING
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APPLICATION
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APPLICATION MANUAL
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THE AUS TR ALIAN INS TITUTE OF REFRIGER ATION, AIR CONDITIONING
AND HE ATING
Fou
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te
INSTITUTE OF REFRIGERATION,
AND
red nte AIR
t
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DA13
FANS
possible interference such as structural steel. The piping
installer should also recognise that in some applications
insulation may not be required for the prevention
of heat transfer but will be needed for personnel
protection.
Note: Levels of piping insulation, required by regulation
(NCC), have been increased over historical practice
and designers/installers must allow sufficient clearance to
accommodate this.
The piping installer should be familiar with the installation
and engineering of the thermal insulation materials
specified and specifically with the method of fixing
appropriate for the type and thickness of insulation. There
must be spacing and clearanc e between the insulation of
one pipe and any adjacent pipe and insulation, or other
Figure 9.1: Base mounted pumps
FANS
UTE
AIR CONDITIONING LOAD ESTIMATION
APPLICATION MANUAL
Figure 9.2: Supporting pipework independently of pump connections
hammer. The following precautions should be taken
during installation:
9.4.10. Insulation
Pump
isolation
Base
isolation
DA13
INS TIT
DA09
HVAC&R AN INTRODUCTION
APPLICATION MANUAL
9.4.8. Pipework
The piping installer should route the piping with flexibility
designed into it, using the minimum amount of pipe,
fittings, and expansion loops.
9.4.9. Valves
• A minimum 100 mm of knuckle clearance should be
provided around all valve hand wheels.
Improper application and placement of valves in the
piping system can be detrimental to system function
Valves shouldAND
never
be installed with the spindle facing
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR•CONDITIONING
HEATING
and can result in malfunction of the valve and in water
downwards.
Long coupled type pumps will require realignment on site
after installation and after any motor replacement. Install
the motor on the base and, using a straight edge, perform
a preliminary shaft alignment. Shim the motor feet for the
•••
ALIAN
Pressure
TRIF
Very small in-line pumps (such as in-line canned rotor
pumps) can be supported by the system piping but
APPLICATION
MANUALMany
larger pumps need to be
independently supported.
in-line pumps are configured to make it easy to provide the
additional support directly under the pump.
PU
GAL
In all cases the method of isolation should be appropriate
for the environmental conditions in service, including
temperature, humidity and chemical degradation. Install
the pump on the level base and make sure all mounting
bolts are centred. Ensure that the pump is level and if not
level shim the feet to level the shaft.
CEN
DA08
DUCT WORK FOR AIR CONDITIONING
Coordination of condensate trays and drains with pump
mounts and inertia bases is an important aspect to
consider for chilled water pumps.
9.4.7. In-line pumps
Pumps should not be mounted directly on to springs as
this provides no inertia to reduce vibration of the pumps
and will impart all vibration to pipework. If pumps are in
a noise critical area such as on a suspended floor or roof
above or below an inhabited area then inertia bases should
be used.
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
DA03
Modern equipment using laser alignment technology
should be used where possible, especially for larger units.
The advantages of high precision alignment include less
noise and vibration, longer equipment life (bearings and
drive components) and less energy wastage at the drive.
Aligned pumps can be doweled to the base to prevent
future misalignment.
01
A
D
APPLICATION MANUAL
Grouting the pump to a concrete foundation of
suitable mass.
AUSTR
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
DA01
CENTRIFUGAL PUMPS
final alignment and align using a laser based system. This
should normally be carried out by the pump manufacturer
or supplier, and must be completed prior to running the
pump.
NOISE CONTROL
9.4.6. Base mounted pumps
The pump should be correctly levelled before securing to
a stable base. Pumps should be well secured to the base in
accordance with the manufacturers installation instructions
and so that vibration transmission is minimised. Common
installation methods used include:
•
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
DA
13
DA01
LIAN
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
FA
DA11
STEAM AND CONDENSATE
NS
FA
2
2.1
. Se
ctio
NS
Fan
s, a
n
n In
tro
du
ctio
n
ov
erv
iew
ncy
FRIG
TIN
EA
re
F RE
DH
ssu
RA
G AN
pre
ST
R CO
NIN
tic
E AU
, AI
ITIO
IC AT
Effi
cie
TH
ION
ND
Sta
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
2.2
. St
instandar
alla d fa
tio n
n ca
teg
ori
es
IO N
DA17
M AN
Fan
fan
wo
rk
s
DA18
UA L
COOLING TOWERS
AIR CONDITIONING WATER PIPING
2.3
. H
ow
a
d ou
ou
tle
tle
t
t
WATER TREATMENT
Fan
Ca
teg
ory
D
– Du
cte
d inl
et
Fig
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
APPLICATION MANUAL
APPLICATION MANUAL
APPLICATION MANUAL
DA19
HVAC&R
MA
•
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
DA20
HUMID TROPICAL AIR CONDITIONING
APPLICATION MANUAL
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
DA21
AMMONIA REFRIGERATION
APPLICATION MANUAL
APPLICATION MANUAL
d Du
cte
d ou
tle
nd
t
ard
fan
ins
tall
atio
n cat
eg
ori
es
APPLICATION MANUAL
7
NCE
Applicatio
n Manu
al
Applicatio
n Manu
al
HVAC&R
MA
DA19
DA21
DA24
INTENA
NCE
DA19
DA26
HVAC&R MAINTENANCE
APPLICATION MANUAL
an
Fan
2.1
: Sta
•••
INTENA
Maintain
ability of
mainten
the
ance strategy system and
future
• Location
,
of and safe
• Reliable
access to
Contrac
and appropr
the services
tors have
• Monitor
ongoing
a
iate control
,
mainten responsibility
ing, meterin
systems
the future
ance requirem to inform
• Certifica
,
g
owners
tion of commisand recording
ents
with regardresponsibilities
of the
facilities
• Operatin
of system for the plant
to that
sioning
,
and of
g
mainten
owners
and operato
• Detailed and maintenance data and results,
ance.
Specific
• report
requirem
informa
rs
mainten
on the mainten
manuals
ents for
tion for
• Recomm
ance schedul
• are
and the
system,
operatin
ance effective
respons
endatio
es
informa
ns on mainten and instruct
tion are transfer of designg and mainten
ness,
plans and ible for the periodic
Designe
ance
required
constru
ance manage ions,
procedu
rs are best
ction is
to be met related HVAC&R
review
res.
under
mainten
of mainten
regime.
ment.
position
if the building
Success
2.3.9 Tena
ance philosop
The AIRAH a building
ed to
ance
ful mainten
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going commit
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ance manage
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Designe
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star rating
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a
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tool also
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will be safelegal responsibility
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2.3.5 Syste
be in lay
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that their
and maintain
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2.3.7 Main
either by
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. This design
y/sustain the building manage
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if further
tenance
Correct
ability features
need
constru
designe
The mainten
r on the
commis
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issioners
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energy
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or modific rs or by subsequction process
sioning
ance
of the building
optimum
mainten
fit-outs
ken.
of
ation to
can
ance in contractor needs
r
HVAC&R
systems
of a successsystem perform a system is essentia
the originalent designers
accorda
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.
nce with to supply system
t.
Designe
ful mainten ance and
design,
fit-out activitie may
commis
performOF REFRIGERATION, AIR CONDITIONING AND HEATING
the impleml for
THE AUSTRALIAN INSTITUTE OF REFRIGERATION,rsAIR
CONDITIONING AND HEATING
THE AUSTRALIAN
INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
THE AUSTRALIAN
need some INSTITUTE
the mainten
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the mainten
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and system
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the
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of their
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fit-outs
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Tenant
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sioning
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of system
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data is properly
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there is
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part J8
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•••
service
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It is essentia
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14
res are carried complete,
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and
l that mainten
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docume
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Tenants
Managers
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installed
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APPLICATION
APPLICATION
MANUAL
APPLICATION MANUAL
system MANUAL
underta
Operators
Maintainer
skilled and
personn
• monitor and maintenance as the asset
meets the
ken. They
el be
register
Auditors s
supervis
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manuals
design
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need
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record
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logic being particular fully of how each
2.4 HVAC&R
access issues, ance issues,
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underst
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to the system.and
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on HVAC&R to carry out
the required of certifica
systems
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work, water arly in respect
and electrica
to refrigera
treatme
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nt, hydrauli
nt
c services
Inadequ
ate
in unsatisf maintenance
of
unexpe actory operatio mechanical plant
cted breakdo
n, higher
costs and will result
wns.
unnece
ssary
AMMONIA REFRIGERATION
ure
INDOOR AIR QUALITY
WATER SYSTEM BALANCING
THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING
DA27
BUILDING COMMISSIONING
APPLICATION MANUAL
2.4 Imp
licat
of inad ions
maintenequate
ance
•••
15
AIRAH technical publications
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