Industry Directory 2016 | Page 7

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 Ax rem ial fan red ova s ge tw uced l of thenerat wit in imp by usi sw e swirl Cla hin the elle ng irl imp in the rs gu use rov 2.6 sam indep ide van es discha Som e cas end .6. fan the e axi ing ent es, see efficierge airs , kno ly dri Cla ncy tre red forwa al fan wn ven use . Sw am con uction rd ands are and as rev gen figurati wh con in op 2.6.3, irl can the en revers ers era tra posite or by be lly on the in rev e direible, i.e. rot Ax inc atin direct using ial ctio the rea effi ers 2.6. shu fan g see ion sed cie e. In ns, y , see ncy all var oft can op fan t off s can 1. s Pla Cla is low iati en wit era Plat wh s. At pressu ove axi te mo use te er on be ich occlower re, rload for al flow unted em 2.6 and s fromh a perf in the .5 wa fur comes urs pressuthe pe at hig no  bo ou ll, cei impellefans, ise the ormanc th un at the res ak on h pre fan ther Bec lev sta nted ling r runalso info els ndard e the s gene rmstable sta axial the ssu cal pre ause or are pan ning led par sam rall atio and ll dip fans pressure wh Ap ssure of the el mo in a propel fans en to ticular le airfl y rotaten on mechapoint can on plicatio than air re the unt square ler cen attenu y in ow and fas this is nic . At also gocur ve y rea use e open ns an axientry fan ing al thi ter (i.e or rou s, are tha trifug ate the app d in spa includ al flowcon the tha provid failure s po into for axi ch . ins dit int sam n a cen als. than highe y ten n cen larg licatioheat ce to e mo sta al ed tall nd pla basica fan ion can atio pre e spe trif Axial the lowr fre d to trif in Sec occthe fanll Fig e vol ns exchan ano ving of s the n catte sui lly an qu cos ssure. ed, ugal fans to ure 2.1 umes (e.g. con ge ther air thrthe samy de enc gene ugals tion ur, ego table vel ts wh A bu fan delivefrequ ies 5. rat to ori addres 0. Co of air de systemand the ou ry A). op t , e en signifi the cenof the r moencies , whiche mo achievAxial effi fice the s no mp bu nsers). s in y aregh a size less 1 com can par and Pro cie ise lex t on sam re air gene can re no e HV trif mo The imp t nci par fea ug and bla ly ge se AC also tition spe suc jectin de ed &R Per unted es and elle tur al fane size at zer rated be easise, wid tio fro ed. de ne fan to and r pe n sidg on m res forma fan ier oth e of axi wil and o pre by no is mo rform signs rate s can indely pe run e er ct nce s can ise ge unted anc can low pre mo ust typ al fan l devel nin ssure to e. The de hav ne 2 es be g s op the pe ssu ve rial in APPLICATION MANUAL APPLICATION MANUAL Alig of is the mo at the 2.6. pla nds e an rated can de incorp res fan suc ned , see ir low re te. on adjust by gre sign s. tio on In its 2. the atly of orated wh n sid er ere able se Tu a mo sim affe the e the pit fans. ct cat tor plest be ch the fan Pla 3 mo egory moun form axia is moimpelle te Imm Fan l pre ve larg D). ted a sin un r. suc ers s are The wit ssu ted tio ed on • res e vol fan hin gle axi n sid wit Imp made , see um s (als a h al imp e cyl up de eller Fig es of o cal ind ure rica elle air cro signs) – cen of thr 2.11 bu led du l fra r is dir ee ss- , axi trif • t on flow al . ma me ect Ho ug ly gected , (i.e -dr de (fixed al (ba in com and using sig ne prope . ins iven • ns and ckw po bo – vol rat Mo nen are xes e sm ller tallatio by pit ard use che , for ts: are utes, and tor – all fans) n d), d. wa use diff In its ele alte mi rd d. use ctr rna Typ xed and imp mo rs, The on tin ica -flo rad as ica g cur is addeller st fun y are we l con w, lly 1. ll as and ial y 2 ‘fan ed rotatin dam com ren fig Cat : ienc pro ura mu t (AC pro unit’. the Effic g wit ental du (i.e egory tio ct 1 a ‘fanduct Wh combin h or form tated ), direct . no 2. n cas Cat du A ins usa pro the en the atio wit a ‘fan (EC) ing mo curren s ou egory cting). tallatio 3 use ge wit duct’.combin fan n is hout ’ is tor tlet 3. ns B ins s aret (DC and d in hin For atio unit more a cas made . 1 Cat — tall a fan this the sim n is is ins acc ing. up Op use ) ou egory atio app en d. tlet Thi 4. pro licaHVAC plicity, then talled uratelyWhen of an ns inle C ins . &R Cat — mo wit cal a du typ s sec t and Fig tall mo ct. tion com and Op ure ou egory atio ma effe es andtion in re acc hin led tor en op tlet Fan pro Vo 2.1 nu munit line ura a HV a ns inle D ins en sto ct on fan vid lum 0: al, — ou t and a ma s inc . y, the with tely AC&R ry Typ can Typ tall es e flow acc Du sys tlet orp is to 3 com called atio ica cat nn ica cte als tem ess an ove du ora l cha 2 o inc term loo l pe rat d inle ori cte ns mo are egori er tha ted e (q) k at perfo es, rvie — d rac rfo lud ‘fan n like es (e.g t do int t and Du ter ho rm includ w of rm e a ’ as ly to cte es o pro Air w a anc isti an fan op d inle flow cs ce hav . roof-mnot refl ducts fan e. Theing thefan typ en un of e alte ou ect tha wo it a pla t and THE AUS TR ALIAN INS TITUTE OF REFRIGER ATION, AIR CONDITIONING AND HE ATING Fou rks first ir app es, mo te INSTITUTE OF REFRIGERATION, AND red nte AIR t any CONDITIONING . du HEATING par lica tor THE AUSTRALIAN and r ge mo cte pe d exh of are mo A fan t of tio un rfo d or fan neric ted the n and sup is rm aust the sta unted mo pe ins a anc fan plie fan rfo tall fan re rot are e cha s or ndard in of rm atin s the anc ation som three energ g Gu rac AHU se cat ide rot etim ma y to blade ter ins e tests eg isti fans) Van tall ori the ating es ref in com the d ma cs. es atio are es typ are imp it, the err po air or chi Ca n do ne cat ica de ed Fig ne (ie tegory eg lly nts gas wh tha not inceller mo to ure . no ori pe fined pas is as 2.1 (b) pre t aid es. lud con tor the in a fan sin ich con rfo in 1: du A – Op rm ISO ssu s air e cas tain , and Va g Typ cti ed ne the wheel , the throu tinuo re ng en ica Ene to separa ing ed, if for 5801 ax cas ) l con or imp gh usl inl sta s ial on wh rgy et tic tion but one ing rotor, elle it. They e fig is an pre fro ma is use or vol the r wh ura flow ich ma transf d ou ssu m y inc d. tio ute me ich re ge typ y be err re. the n of tle Fan ne bla lude Some , in wh ans is t an at any rat e. In of theed to de a rot fan of axi ed cen the s con atin typ ich al fan on by the trif cen e ins ug ver g diff es trif air by un tin tan mass al fan ugal, rot it g vel use atio ce, Ca Ca teg oci r as of air types axial, n of teg we ty mi ory ory Fan ll as containit is the xed the imp C– B– the ed Du cen -flow elle Op for cte en ce within trifug or cro r d inl inl exe Fan the al for sset et rte an an d by imp ce d du d op the eller cte en 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 rating or contains going commit hy for a develop the design/ ance manage nts accredit particul HVAC&R system Designe building T enants ation and mainten ar requirem ment star rating ment relies mainten rs have need or system. a ance fundingof managers design ance informa ents or credits tool also the system to be instruct on the will be safelegal responsibility ed in the and this and user to maintenance ontion. for operatin respons to be engage to operate to ensure should correct educatio plannin ibility continu g 2.3.5 Syste be in lay operatio that their and maintain n. g, d by 2.3.7 Main either by efficienc terms. Tenants n of the original es through the . This design y/sustain the building manage m comm if further tenance Correct ability features need constru designe The mainten r on the commis design, issioners Contracto Tenant energy underta 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 contrac systems impact on system . 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 is have ance program sioning ance and a respons the ongoing s. Rules ensure data ance The mainten plan, the or procedu redesign as a ibility to . Because entation that any mainten personn will form the result of proposa ance inform negative the res need overall mainten mainten ance basis of el contrac their ls building impacts to ance ance responscommissioning tor needs the mainten owners and of the futureor life cycle costs clients of and system of tenant be in place to should and licensed personnel the and operato ance ibilities. of their respons ensure are appropr to ensure that fit-outs perform Tenant Commis system also have to carry design ibilities on rs with appropr ance is systems iately • Commis that: sioning out the of system regard to iate. Particula mitigate the base building can be connec personn work and trained, skilled sioning mainten d. rly with el are procedu carried ance. the provisio ted part I2 on systems supervis conside The mainten out appropr res for plant ed as rable mainten . They can to or be separate • Commis access for energy efficient ns of the BCA ance iately, be comple and systems develop from ance in regardin sioning ments in contractor should x and require themse Tennant are respons maintenance, installations and g data is properly • System conside lves. there is systems ibility on part J8 red that all areas and advise keep abreast commis now law. Building are also mainten on the recorde modific of econom sioning design covered the ance regime system designe an explicit legislate d and logged, ation can owner when ic advanta data complie data, any tenant/o laws as well by the for adequa r to determi be made for the ge. d • Any s with system wner contracas other laws, BCA and building to the plantit is ne the non-com make the Contrac mainten te access to that system plant tors may pliance ance and to design tual arrange do not recogni to is reported reportin Tenants building owner also of I2, there to be perform plant to allow Specific se ment but g of ongoing have a respons and occupie the respons and address requirem general indicato ible imperat plant with would have beened. Even without required ibility manage rs need ents for for sustaina ed. rs associat ives for for the ment to be informecompliance. ly commis bility or mainten formal facilitate perform a designed requireda responsibility the provisions ed with are required and commis sioning, perform ance ance. d all particul to ensure commis Modern sioning perform to be ar systems ance for mainten reasonable requestand should be of the under a sioning mainten docume ance maintain that . Green Star met if the building ance. and the ance is ntation Specific s for access encouraged HVAC&R a partners mainten s that requirem accredit to constru to HVAC&R system ance contrac knowled manuals hip of ents for ction is star rating ation regime. requirem ge loop, plant operatin and the 2.3.10 tor needs stakeholders The ents for system informa transfer g to ensure manage maintain regarding HVAC&R Occupier commis tool also contains AIRAH tion must of design and maintenance ment. sioning that the ers and under a Occupa related services and commis particular operato building be met if the building HVAC&R nts The mainten rs is facilitate , between a design rating sioning the system need to underst Periodic constru ance contrac and constru or accredit d. recomm ction • Inspecti adminis system on system and the influenc and the correct issioning tors’ role trative mattersction documeation regime. The is is on, testing operatio can include: perform e that their but their perform also required for of a system or nt and BCA is • Repair n of ance. and monitor such as behavio need is parts ance (refer optimum and mainten does not contain Well informe ur can have required implicit ing, to Clause long term of a ance manuals • Complia replacement, to be maintain in order 6.2). to potentia d occupants system nce activitie can alert ed and to know what 2.3.6 Build • Purchas plant is s when. future or l problems and mainten e and installat and records, 2.3.4 HVAC further ance ing/Facilit The building system also identify opportu managers • Purchas improve &R Syste e and installat ion of plant, y mana Occupie manage nities for Regular ments. manage rs form • Control r, facility inspecti gers r ion m has part of knowled contr a manage significa ons should spares and installat of onsite primary of the r or mainten actors ge loop nt mainten ion role of the • Energy stores and be made consum mainten betwee communication represen by HVAC&R system and its ance respons ance ables, manage during spares, manage n system ance. s systems tatives to system ment and • Water contrac ibility. A operatio and are functionr is to ensure ensure: • Adequa tors or their reportin n and manage ing optimal that the building Manage g, ment and te • Supervi rs, as well ly. • Original and safe access reportin sion and as driving • provide g, to plant specific assessm • Cost the mainten is provide ation for the link complie ents, control, Regulators d, ance process betwee d with, materia building • Compla n system ls and equipm occupie Building : • Equipm , also: maintain rs, • need int respons ent & OHS ent is ers and to respond Owners e and trouble • As installed installation requirem Manufactu • ensure to compla shootin 2.3.8 Main ints quickly Designersrers the building g. • Operatin drawings supplied ents are complie • often and Installers d with, occupan g are accurate tenance provide ts are satisfied efficiently, • Commis and maintenance , and contrac a supervis ••• service manuals sioning , ory role tors, Occupiers procedu appropr are personnel It is essentia for mainten • maintain 14 res are carried complete, iately, and l that mainten ance staff docume • The appropr out Tenants Managers operatin ntation installed iately trained, ance service g such 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 system manuals design , meter, need and a should intent. record , • commu Surveyors operate good underst ed for the work the control nicate mainten and report system anding and in system • resolve perform Figure logic being particular fully of how each 2.4 HVAC&R access issues, ance issues, ance, underst Mainten applied system ance to the system.and knowled and licences personnel ge loops require a range on HVAC&R to carry out the required of certifica systems handlin tions particul mainten g, boiler ance work work, water arly in respect and electrica to refrigera treatme l work. 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 Purchase online at www.airah.org.au DA 13