HVAC&R Nation August 2017 by AIRAH

Skills WORKSHOP

Electrode vs resistive steam humidifiers

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A wineryâ&#x20AC;&#x2122;s energy-saving chiller upgrade

Harnessing hydrocarbon K

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August 2017 / ISSUE 104 / FREE

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ISSUE 104

HVAC&R Nation is published by the Australian Institute of Refrigeration, Air conditioning and Heating (Inc).

August 2017

AIRAH – National Office James Harrison Centre 3/1 Elizabeth Street, Melbourne VIC 3000, Australia. Tel: 03 8623 3000

Harnessing hydrocarbon

Fax: 03 9614 8949

www.airah.org.au/nation

Magazine team Editor Boon Mark Souphanh boon@airah.org.au Tel: 03 8623 3011 Contributing writer Sean McGowan

Advertising sales Glenn Douglas glenn@airah.org.au Ph: 03 8623 3018 The use of hydrocarbons in refrigeration is becoming more commonplace as operators look to replace synthetic refrigerants with low global-warming potential alternatives. As Sean McGowan reports, a contract winery in Western Australia has realised electrical energy savings of 32 per cent through a hydrocarbon refrigerant conversion of its liquid chiller.

John McGrath john@airah.org.au Ph: 03 8623 3007

ISSN 1834-9522

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The Toolshed see what’s new in the ‘Shed

Skills Workshop 15

A comparison between electrode and resistive steam humidifiers, as well as humidifier installation safety tips.

8 Global Update industry news from around the world

Green Wedge

Exclusive to August

fuel your enviro cred

Disclaimer HVAC&R Nation is an official publication of the Australian Institute of Refrigeration, Air Conditioning and Heating Inc. Statements expressed in HVAC&R Nation do not necessarily reflect the policy or views of AIRAH or its members. No responsibility is accepted by AIRAH, the Editor or HVAC&R Nation’s supply partners for the accuracy of information or for errors or omissions. HVAC&R Nation is distributed without charge to all financial members of AIRAH. The publisher reserves the right to alter or omit any article or advertisement submitted and requires indemnity from advertisers and contributors against damages or liabilities that may arise from material published. No part of this publication may be reproduced, stored in a retrieval system or transmitted in any form or by any means electronic, mechanical, photocopying, recording or otherwise, without permission of the Publisher.

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Humidifiers

Fly Guy accessories to keep you fly

23 AIRAH News what’s happening in the Institute

24 Around the Nation who’s in the news?

26 Safety Corner you can never be too safe

28 Smoko with . . . Q&A with HVAC&R Nation

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Lighter Side the shonkier side of the nation

Image is everything The industry’s profile – or lack thereof – is just one reason why we continue to face a skills shortage. The CEO of the Australian Refrigeration Council, Glenn Evans, says it’s time the industry rebrands itself to better identify with the next generation of our workforce.

Please consider the environment and recycle this magazine if you are not going to keep it.

August 2017 | www.airah.org.au/nation | HVAC&R Nation | 3

Editorial

OLD WAYS WON’T OPEN NEW DOORS When I took over the reins of this magazine a year-and-a-half ago, I inherited somewhat of a rare commodity – a thriving print-based publication. Now into its 10th year, HVAC&R Nation was born of a simple vision – AIRAH’s desire to create a magazine for the man in the van, the guys with the gauges, the “fridgies” that make the industry what it is. It was ambitious, but that vision has now manifested into the largest circulation HVAC&R magazine in the southern hemisphere. And, it doesn’t look like relinquishing that title any time soon. In an era where countless print publications continue to fall by the wayside amid the digital revolution, HVAC&R Nation, along with its sister publication Ecolibrium, remain afloat. Despite this, we’ve been making a big push over the past month to find out more about what you guys want from HVAC&R Nation – it is your “mag” after all. We’ve recently called up close to 100 distributors Australia-wide to gather much-needed feedback. In addition to that, we launched an online readers survey to find out more from the readers want and what they enjoy. At the end of the day, we just want to ensure we’re delivering the best mag we can.

You can always strive for improvement.

of a fridgie. Supermarkets and laboratories won’t function properly without the expert services of a refrigeration and air conditioning tradesperson . . . This is the story that needs to be told.” You can read more about Evans’ vision in the feature on page 20.

You can still respond to the survey throughout August and go into the draw to win a bottle of Jim Beam. Check out the details below.

Personally, I’m of the opinion that the old “if it ain’t broke, don’t fix it” mantra we’ve grown up with can be a bit of a trap. Let’s face it – people are afraid of change.

Also adopting a forward-thinking approach, the CEO of the Australian Refrigeration Council, Glenn Evans, believes it’s time the HVAC&R industry went through its own facelift to better identify with the next generation of our workforce.

Just because something “ain’t broke” doesn’t mean you can’t strive to make it better. And, in an age where the need to adapt is more important than ever, perhaps it’s the approach we need to take.

“The industry deserves to be presented as dynamic, prosperous, and vital, with many exciting and diverse opportunities,” says Evans. “It deserves its own widely recognised profile in the community. Surgery can’t be performed without the work

Boon Mark Souphanh Editor boon@airah.org.au

NEEDS YOUR FEEDBACK! To help improve Australia’s most popular HVAC&R magazine, we are seeking valuable reader feedback. Fill out the HVAC&R Nation readers survey at

www.airah.org.au/HVACR_Nation_survey All responses will go into the draw to win a 700ml bottle of Jim Beam.

4 | HVAC&R Nation | www.airah.org.au/nation | August 2017

Clean Air Home & Office™ HVAC & Duct System Protectant, Cleaner / Freshener Clean Air Home & Office™ is a simple and economical way to clean and freshen HVAC systems and ductwork from large central systems to small wall units. A full treatment takes only minutes, requires no tools and has immediate and long lasting results. Clean Air Home & Office™ cleans away the residue in evaporators and drain pans which is the cause of odours and the growth of bacteria, algae, fungi and moulds. The Clean Air Home & Office™ freshens the entire system leaving behind a durable, invisible, protective coating which is leach-resistant and non-migrating. It protects from broad spectrum biostatic activity on many surfaces and lasts approximately three months in HVAC systems. Heat transfer loss is not compromised due to the microscopic coating. In fact, it can increase efficiency as it breaks down surface tension of condensate water, allowing it to drain out of coils. Clean Air Home & Office™ has little degradation up to 170° C and contains no phenols, tin, heavy metals, lead or formaldehyde. It is non-toxic, water based and provides long term protection. One 250gm can of Clean Air Home & Office™ can treat a five to six tonne unit (approximately 5,000 sq ft of building area), or two to four typical wall units (15,000BTU). For ducted systems, locate the return air grille and remove the filter, with the system ON spray the contents of the can into the duct, the product will then be pulled into your system where it goes to work. You will immediately smell a light fragrance coming from the air vents in every room as the product travels through the entire system. The fragrance should disappear within 24 hours leaving the coating behind to continue its work.

August 2017 | www.airah.org.au/nation | HVAC&R Nation | 5

Toolshed 01

increase the efficiency of air conditioning systems by adjusting the airflow to maintain temperature in rooms that are already naturally warmed up by the sun.

Slick new sensors

Belimo has expanded of its product range with new HVAC sensors. The sensors are designed to complement Belimo actuators and valves, optimising system performance and improving energy efficiency.

“With features such as smart energy and airflow management, intuitive zone control, temperature and run-time monitoring, AirTouch 3 ensures the highest level of efficiency from air conditioning systems to save money on energy bills,” says Polyaire.

For more information, go to www.airtouch.net.au n

The sensor can be integrated into all major building automation systems (BAS), with a universal compact enclosure design, intuitive tool-less snap cover, and detachable mounting plate.

All sensors come with a five-year warranty, conform to NEMA 4X and IP65 requirements, and are UL-compliant.

Heatcraft has responded to the increasing adoption of R448A (N40), by commencing distribution across its New Zealand outlets.

Belimo offers sensors for measuring temperature, humidity, pressure, CO2, and volatile organic compounds (VOC) for pipe, duct, outside, and industrial-room applications. “Belimo sensors not only deliver reliable and accurate readings,” says sensors product manager David Alliband. “But the sensor enclosure design also features a modular-conduit fitting and a spring-loaded removable terminal block that installers and technicians will love.”

Manufacturer Honeywell claims that in supermarket trials conducted in the US and Europe, R448A demonstrated 3 per cent lower energy consumption in low-temperature applications and 5 to 16 per cent lower energy consumption in medium-temperature applications when compared to R404A. This equates to the highest energy performance of any A1 retrofit refrigerant.

An Advanced addition

Advanced Thermal Solutions (ATS) has just released its new line of tube-to-fin, liquid-to-air heat exchangers. An addition to the liquid-cooling line-up, ATS says heat exchangers are made with the industry’s highest density fins to maximise heat transfer from liquid to air, allowing the liquid to be cooled to lower temperatures.

The refrigerant has been approved for use with Dorin H Series, Copeland, and other major commercial compressor brands, as well as control brands including Danfoss, Emerson and Dixell. For other brands, please consult your Heatcraft representative or respective product manufacturer.

The heat exchanger fins and tubes are made of copper and stainless steel, and are suitable for a variety of fluids including water, dielectric fluids, and custom-designed heat-transfer fluids.

For more information, go to www.heatcraft.com.au n

Each of the seven heat-exchanger sizes is available with or without a fan. Tube diameters are available in 0.375 and 0.5 inches.

The MT100 Series combines new electronics technology with application-proven precision-flow sensors.

AirTouch of class

Polyaire has introduced the new AirTouch 3, an integrated allin-one zone-management control for air conditioning systems.

According to the company, the upgraded packaging can withstand the most demanding plant-operating environments.

“They provide temperature-compensated direct-mass flow measurement of air and gases for precise, repeatable measurement with low-maintenance requirements in large diameter pipes, stacks, and rectangular-duct installations,” says AMS.

The unit features a new touch-screen display, and is designed to monitor temperatures in each zone and manage airflow. According to Polyaire, the AirTouch 3 allows the user to control up to 16 zones in the home from one or two AC units, ensuring only those rooms being used are heated or cooled.

The MT100 meter’s sensors can be installed either across a mast or can be inserted at multiple points around the process line in a single plane. In large-stack applications, instrument installation can be done at a single platform location, which can result in cost-savings over other technologies such as ultrasonic meters.

In addition to cost savings from lower energy consumption, the control also has the potential to enhance comfort throughout the lifespan of the ducted reverse-cycle air conditioner. Airflow in each zone in can be controlled in 5 per cent increments and users can adjust set-point temperature for each zone from the touch screen or any smartphone or tablet device. The AirTouch 3 also has an “Individual Temperature Control” feature, which allows each occupant in the home to control the temperature in their specific zone. Additionally, it aims to 6 | HVAC&R Nation | www.airah.org.au/nation | August 2017

Calibration sensation

AMS Instrumentation and Calibration (AMS) has released its next-gen MT100 Series multipoint thermal-mass flow meters, designed to optimise combustion or pre-heated air to large boilers.

For more information, go to www.qats.com n

R448A offers an alternative to R22 and R404A, in both new equipment and retrofit low and medium-temperature applications. R448A is classified A1 by ASHRAE – non-toxic and non-flammable. With a low GWP of 1387, it is around 66 per cent lower than R404A and has the lowest GWP of any A1 retrofit refrigerant.

For more information, go to www.belimo.com n

A Kiwi exclusive

The instrument can measure air/gas processes operating up to 454 °C and flow rates from 0,07 to 305 NMPS with 100:1 turndown and with accuracy of ± 0.75% of reading, ± 0.5% of full scale. For more information, go to www.ams-ic.com.au n

Toolshed 06

Record-breaking efficiency

ABB is claiming a world record in motor efficiency, following tests conducted on a 44MW 6-pole synchronous motor shortly before delivery.

Redback Ladders are the makers of aluminium and fibreglass ladders, which are designed with an industrial rating of 150kg and are manufactured to Australian and New Zealand Standards.

Measuring 5 x 4 x 4m, the motor was ordered by a customer as one of multiple units to drive compressors at an air-separation plant that produces industrial gases. According to ABB, tests carried on the motor showed an efficiency 0.25 per cent greater than the 98.8 per cent stipulated in the contract, resulting in the world record for electric motor efficiency. “This efficiency improvement could save approximately $500,000 in electrical energy costs over the course of a 20-year lifetime for each motor,” says ABB.

“Each model is independently tested by a NATA-approved lab to make sure you get what you want – strength, durability and peace of mind with your investment in our product,” says Redback. “Our range includes single-sided step ladders, double-sided step ladders, and extension ladders.”

The ladders are designed to handle repetitive, everyday use in trade or commercial applications. Standard features for the Redback range include anti-slip treads, triangular double-tread bracing, cross-brace locking system, quad-studded cap plate, spreader arm support, quad-studded spreader plate, reinforced D-ring construction, and double-riveted treads.

The motor’s efficiency was achieved by optimising the electrical and mechanical features. While the average efficiency for this type of synchronous motor is between 98.2 and 98.8 per cent, the 0.25 per cent efficiency improvement equates to 1000MWh energy per year in continuous use. “In addition to extremely high efficiency, synchronous motors are renowned for their proven quality and reliability,” says ABB division president Sami Atiya. “Their robust design ensures reliability through cool operation temperatures and low vibration.” For more information, go to www.abbaustralia.com.au n

Redback steps things up

For more information, go www.redbackladders.com.au n

DO YOU HAVE A NEW PRODUCT TO GO IN THE TOOLSHED?

Email boon@airah.org.au All submissions received will be considered, though publication cannot be guaranteed.

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August 2017 | www.airah.org.au/nation | HVAC&R Nation | 7

Global Update

NIGERIA

BANGLADESH

FIRE CAUSE FOUND

COOL CLAY

COOLING IN A BOTTLE

The UK government has ordered an immediate examination of the fridge freezer confirmed as the source of the Grenfell Tower fire in London in June.

Technology entrepreneur Anaele Iroh says he has created the first-ever air conditioner that works without electricity.

Advertising company Grey Group is heading a social project, which involves recycling old plastic bottles into “Eco-Coolers”.

The underlying theory behind Iroh’s invention relies heavily on the cooling methods of old in the form of clay pots.

To make the Eco-Coolers, plastic bottles are cut in half and then mounted on a board. The boards are placed over a window, with the bottlenecks facing towards the inside of the house.

The announcement was made after the Metropolitan Police revealed that a Hotpoint FF175BP fridge freezer was the initial source of the Grenfell Tower fire, which destroyed 151 homes and left 79 presumed dead. The fridge freezers affected – model numbers FF175BP (white) and FF175BG (graphite) – were manufactured between March 2006 and July 2009. Now discontinued, it is estimated that 64,000 models were manufactured. “We offer our most profound condolences to the victims, those who have lost lovedones, homes, and possessions, and to their friends and families,” says the fridge freezer manufacturer. n

According to Zero Electric Air Conditioner (ZeAC) Indiegogo page, the ZeAC “dehumidifies a room by absorbing vapour from air, cooling additionally through the absorption of heat.” The ZeAC is currently trying to raise funds to set-up manufacturing for its first market-ready version, which involves buying an industrial kiln. "I teamed up with my co-founder Caius, and we started exploring materials and fabrication techniques that could yield optimal evaporative media, and work effectively in hot and humid climates,” says Iroh. n

FRANCE

CHINA

HEATING IN THE PIPELINE

INNOVATIVE INSULATION

Geothermal district heating has helped to reduce carbon emissions from three of Paris’ airports by around 63 per cent since 2009, according to Groupe ADP.

Scientists from a joint US-China study have created a new material made from ceramic nanofibers that could be used in applications ranging from high-temperature insulation to water filtration.

Groupe ADP runs the city's Charles de Gaulle, Orly and Le Bourget airports. The firm says the 135 MWth/12 MWe geothermal district heating system, which came online in 2011, provides 70 per cent of the heat and sanitary water used in Orly’s terminals and new office facilities. It has also saved 50,000 metric tonnes of CO2 over the system’s lifetime. The district heating system features two 1800-metre-deep wells, which produce water at 74˚C. The water is distributed through a 35km pipe network. n

Ceramic is sought after for its ability to withstand hot temperatures, however, it is also susceptible to damage due to its brittle nature. These new ceramic “sponges” retain resilience even when heated to a temperature of 800˚C.

“The change in pressure that occurs when air enters the wider part of the bottle and comes out through the bottleneck cools the air,” says designer Ashis Paul. “It seems uncanny, but the principle is simple. Blow on your hand with your mouth wide open – the air feels hot, doesn’t it? Now, blow on your hand with your lips pursed – it feels like a cool breeze.” The Eco-Coolers run with no electricity and use recyclable materials. “The beauty of it all is how easy these units are to make,” says Paul. “The raw materials are easy to find.” n

THAILAND

A LEAKY BOAT Seventeen people were hospitalised in separate refrigerant leak incidents in Thailand and the US. In Bangkok, 10 fishermen were rushed to hospital, four of them unconscious, following a refrigerant leak onboard a tuna fishing boat. Reports say the leak occurred in the cold storage section of the boat. Twenty crew members were affected in total, but 10 declined hospital treatment after receiving first aid.

The sponges could potentially be used as a heat-resistant flexible insulating material, potentially for firefighters' clothing.

In the US, two firemen and five employees were taken to hospital after a large ammonia leak at a food processing factory.

In lab tests, a flower petal was placed on a 7mm-thick sponge made of the ceramic zirconium dioxide. The bottom of the sponge was heated to 400˚C for 10 minutes, scientists say the petal barely wilted. n

It is reported tha the leak was likely caused when a forklift hit an ammonia refrigeration pipe. n

8 | HVAC&R Nation | www.airah.org.au/nation | August 2017

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August 2017 | www.airah.org.au/nation | HVAC&R Nation | 9

Cover Feature

Naturaliste Vintners in Western Australia is enjoying the fruits of a hydrocarbon conversion.

HARNESSING

HYDROCARBON The use of h ydrocarbons in refrigerati more comm on is becom onplace as o ing perators loo refrigerants k to replace with low glo synthetic bal-warming As Sean Mc potential alte Gowan rep orts, a contra rnatives. has realised ct winery in electrical en Western Aus ergy savings tralia a hydrocarb o f 3 2 per cent thro on refrigeran ugh t conversion of its liquid c hiller. Located at the northern gateway to Western Australia’s famous Margaret River winegrowing region, Naturaliste Vintners is a dedicated, state-of-the-art contract winery serving small and medium growers in the region.

The award-winning winery has long been committed to sustainability, and was one of the first businesses in Australia to be audited and formally certified to meet the standards of Entwine Australia –

10 | HVAC&R Nation | www.airah.org.au/nation | August 2017

Hydrocarbon refrigerants have a lower density than the chemical refrigerants they are designed to replace. This means they have a greater ability to absorb or reject heat

the Australian wine industry’s sustainability program developed by the Winemaker’s Federation of Australia (WFA). As part of its efforts to improve energy efficiency and reduce carbon emissions, the winery applied to the Australian government’s “Clean Technology Food and Foundries Investment Program” in 2012. The program, which is now closed, was established to encourage food and foundry manufacturers to invest in energy-efficient, low-emission equipment, technologies, processes and products. Through the program, Naturaliste Vintners sought funding to upgrade its inefficient 180kW liquid chiller, which operated on R22 (being phased out under Australia’s Montreal Protocol obligations at the time).

Cover Feature Providing cooling to its wine storage vats via a secondary loop of brine, the winery had become increasingly dissatisfied with the plant’s performance since its installation. Indications suggested it had not been commissioned properly, as head pressure fluctuated wildly. Condenser fans would cycle on and off at random (even when one particular circuit was off), which was partly caused by the use of a non-standard controller found to not have been set up correctly. Additionally, the chiller suffered from severe icing on the suction accumulators, as well as on the compressor.

FROM R22 TO HYDROCARBON In August 2012, the winery was successful in securing funding, and engaged hydrocarbon specialists Engas to convert the chiller from R22 to hydrocarbon. According to Engas managing director Selwyn Wallace, M.AIRAH, there are two significant benefits to hydrocarbon refrigerants compared to synthetic refrigerants such as R22. “The first is the environmental qualities of hydrocarbon refrigerants, and the second is the enormous energy savings achievable when using blended-hydrocarbon refrigerants such as M50,” says Wallace. Before the commencement of any works, Engas fitted various, non-evasive sensors to the chiller. These were linked to a 24-channel data logger to record an indication of the current running condition of the plant. This “before” data was saved to provide a baseline comparison once the conversation was completed. Unable to source the commissioning data for the control of the head pressure and fan speed of the chiller, it was decided that the system be bypassed, and a straightforward fan-speed/head-pressure control system also be retrofitted. “Utilising two twin-stage pressure switches switching each circuit – one fan on low speed and rise in pressure, and one fan on high speed, maintained a far better head pressure and increased the performance of the system,” says Wallace.

Further leak tests were also conducted, before the unit was fully labelled and left running.

During the installation of the head-pressure/fan control, the chiller’s existing R22 refrigerant was recovered into suitable recovery cylinders, and the core filters were replaced.

“The most important change (from R22 to hydrocarbon) was to properly seal the electrical panel to ensure that there would never be an ignition source in the event of a refrigerant leak,” says Wallace.

Wallace says one circuit was processed at a time, ensuring continued operation if required. Both circuits were subjected to a deep vacuum to ensure the complete removal of the original refrigerant.

Beyond this, he says there were no major challenges.

The original lubricant was deemed to be in very good condition, with replacement not necessary. Both circuits were also leak and pressure tested, then charged to the correct charge weight with M50 hydrocarbon refrigerant – a direct replacement gas for R22, designed by Engas.

Says Wallace: “A retrofit conversion such as this is not difficult for any engineer, mechanic, or technician who has been properly trained in the safe use and correct application of hydrocarbon refrigerants.”

EFFICIENCY IMPROVEMENTS Returning to the winery some weeks later, “after” data was downloaded from the data logger, verified, and exported before being compared to the “before” data. The brine-return temperature and bring-supply temperature were used to derive the Delta T, which indicated how much cooling the chiller was achieving. The running current was also compared, based on the readings taken from phase 1 of circuit 1.

Comparison of Delta T (Temp in V Temp out) of brine water temperatures based on daily averages

“Hydrocarbon refrigerants have a lower density than the chemical refrigerants they are designed to replace,” Wallace says. “This means they have a greater ability to absorb or reject heat.” M50 has a refrigerating effect of 439.4kJ/kg (kilojoules per kilogram) compared to R22’s 199.3kJ/kg. Once the charge was balanced, adjustments were made to the TX valves as necessary. August 2017 | www.airah.org.au/nation | HVAC&R Nation | 11

Cover Feature FROM COOLING TO AIR CONDITIONING As well as the liquid-chiller conversion, the Naturaliste Vintner’s barrel storage room air conditioning system was also converted to utilise a hydrocarbon refrigerant. Prior to the conversion, the room had been cooled by a compressor connected to two indoor evaporators operating on R134a and controlled by a digital thermometer set at 14°C.

Comparison of running currents – before and after conversion based on daily averages

Similar processes to the chiller conversion were undertaken, including the proper sealing of electrical panels to remove the risk of an ignition source in the event of leak. But because of the indoor location of the air conditioning plant, hydrocarbon sensors were installed to the room. These safety sensors cause the system to pump down in the event of a refrigerant leak. The existing R134a in the system was then reclaimed, with the system charged to the correct charge weight using hydrocarbon refrigerant M30. The energy consumed by this system was measured by manual readings taken from multi-meters and digital thermometers before and after the conversion. Data comparison and actual power savings have shown a 21 per cent improvement in energy consumption.

Off cycle comparisons – Running currents – Amps

SAFETY FIRST The conversion of the Naturaliste Vintners liquidchiller plant and barrel storage room air conditioning system from synthetic refrigerants to hydrocarbons has delivered significant and tangible energy savings to the business. And according to Wallace, this project demonstrates that subject to compliance with certain safety principles, the application of flammable hydrocarbon refrigerants can be done as safely as any other type of refrigerant.

“We did not record the running currents/times of the condenser fans, as we thought that they were set up incorrectly in the first place,” says Wallace. “And, I believe the client was also aware. However, after looking at the performance data, we believe that the system, with better cycling of the condenser fans, will also result in energy savings.”

The data showed that the average current had reduced from 38.31 Amps before conversion, to 21.4 Amps after conversion.

Engas also analysed the off-cycle data, which reflects on the faster cool-down times of the hydrocarbon refrigerant.

“So not only is the hydrocarbon refrigerant pulling the system down to a lower set-point,” says Wallace, “but the system is also pulling down faster.”

This showed that after the conversion the system was “off cycle” far more than when operating on R22. This was further confirmed by Naturaliste Vintners,

“The energy saving, based on the recorded data and taking into account actual power savings, appears to be 32 per cent at the point of conversion.”

who had noted that while the brine was always down to the correct temperature, the system appeared to be off more than before.

Comparison of pull down speeds

“When bearing in mind the conversion of any equipment to hydrocarbon, safety must be the first consideration,” he says. “All refrigerants are dangerous – in fact, all compressed gases are dangerous. Therefore, they should only be handled by engineers, mechanics, or technicians that have been properly trained in their safe use and correct application. This is why training is so important to our industry.” n

NATURALISTE VINTNERS AT A GLANCE THE EQUIPMENT Liquid chiller refrigerant: Engas M50 Barrel room air conditioning refrigerant: Engas M30

THE PERSONNEL Client: Naturaliste Vintners Electrical contractor: Sunwise Electrics Mechanical services contractor: Engas Source: Engas Hydrocarbon Refrigerant Conversion Report – Naturaliste Vintners by Selwyn Wallace, M.AIRAH, and Dr Ladas Taylor

12 | HVAC&R Nation | www.airah.org.au/nation | August 2017

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August 2017 | www.airah.org.au/nation | HVAC&R Nation | 13

Green wedge

BREAKTHROUGH WITH BUTTERFLY WINGS An ANU biomimicry discovery could revolutionise the solar and smart window industries.

Co-researcher Kevin Le from ANU with a blue Morpho butterfly and a solar cell.

Niraj Lal says the nanostructures are able to finely control the direction of light, opening up a huge range of possibilities. “Techniques to finely control the scattering, reflection, and absorption of different colours of light are being used in the next generation of very high-efficiency solar panels,” says Dr Lal. Using tandem cells with a perovskite layer and a silicon layer as an example, he says the aim with the new technology is for the perovskite layer to absorb the blue, green and ultraviolet spectrum of sunlight, while absorbing the red, orange and yellow light in the silicon layer. “Being able to make light go exactly where you want it to go has proven to be tricky up until now,” says Dr Lal. “We were surprised by how well our tiny cone-shaped structures worked to direct different colours of light where we wanted them to go.” Aside from its solar potential, another application could be in the creation of smart windows that can direct the amount of light and heat transmitted. There’s also potential aesthetic applications by being selective within the visible spectrum.

The wings of a butterfly were the inspiration behind a new research from ANU that could lead to more efficient solar cells, smart windows, and even stealth technology.

Tiny nanostructures developed by an ANU team are based upon the wings of the Morpho Didius butterfly, which have cone-shaped structures that scatter light to create a blue iridescence. Lead researcher Dr

Using ANU’s approach, a window could be designed to be transparent to some colours, non-see-through and matte-textured for others. “There are very cool potential applications in architecture,” says Dr Lal. n

GAS

14 | HVAC&R Nation | www.airah.org.au/nation | August 2017

ELECTRODE Skills VS RESISTIVE Workshop STEAM HUMIDIFIERS HVAC&R

MODULE

104

PROUDLY SPONSORED BY

Skills summary n What? A comparison between electrode and resistive steam humidifiers, as well as humidifier installation safety tips.

n Who?

PULLOUT

Contractors, customers, HVAC&R mechanics/technicians

Electrode and resistive are the two main types of electric steam humidifier an HVAC&R contractor will buy and install. Both are versatile and come in a variety of sizes for either in-duct or in-room applications. From a contractor’s perspective, the main considerations when selecting a unit are often purchase cost and ease of installation. For a customer or end-user, the initial cost is also important, but so are on-going operating costs and maintenance requirements.

STEAM CREATION The main differences between electrode and resistive technologies are how they heat the water to create steam, and how they control steam output. Electrode humidifiers boil water by passing electrical current through it, therefore a water conductivity of 120 to 1250 µSiemens/cm is required. The more current passes through the water, the greater the steam production. So, output increases with a higher water level or when higher mineral levels make the water more conductive. To maintain an accurate output, the concentration of minerals in the water is flushed through an automatic drainage cycle and replacement with fresh water. This typically allows for humidity control of around +/-5%RH. Resistive humidifiers create steam through the transfer of heat from the resistance heater elements to the water. Steam output is controlled by applying more or less heat to the water rather than controlling water level or conductivity. This results in more accurate humidity control of around +/-2%RH with mains water. As the mineral content of the water has no impact on steam output, resistive humidifiers can also operate on RO water. As the mineral content of the water is very low, this virtually eliminates scale build-up, significantly reducing maintenance requirements. It also improves humidity control by removing the need for fresh (cold) water to be regularly introduced to reduce mineral levels. A consistent water temperature results in a consistent steam output and enables a resistive humidifier operating on RO water to control humidity to +/-1%RH. August 2017 | www.airah.org.au/nation | HVAC&R Nation | 15

HVAC&R Skills Workshop Overview steam installation for duct humidification

Overview steam installation for duct humidification

Installation costs for both electrode and resistive are comparable, plus both are simple to install as they require connection to power, water mains supply, and drain only. The cost of operating a steam humidifier is largely determined by two things: the energy required to turn water from a liquid to a gas, and the cost of dealing with what’s left behind in the humidifier after this has happened.

DV81 DV61

Pmax 1500 Pa Pmin -1000 Pa

Steam line Steam line – As short as possible (max. length 4 m) • – As short as possible (max min.15 length%4m) Adequate upslope/downslope (8.5°) No restrictions • – Adequate upslope/downslope – min Condensate trap at the lowest point 15% (8.5°) – Hose or fixed pipe (with same inner diameter as • No restrictions steam outlet) • Condensate trap at the lowest point • Hose or fixed pipe (with the same inner diamater as steam outlet)

DV41

KS10

DS80 DS60 DS22

Condsensateline line Condensate – Min. downslope 15 % (8.5°) • Min. downslope 15% (8.5°) – No restrictions – Condensate trap ømin 200 mm • No restrictions • Condensate trap Ømin 200mm

ømin: 200 mm to drain to cylinder

min. 300 mm

With an electrode boiler, as steam is produced, any minerals in the water build up within the plastic cylinder as limescale. When these cylinders are full of limescale, they are replaced, which is straightforward and offers the benefit of very rapid maintenance and minimal downtime for the humidification system. The disadvantage is that cylinders can be expensive and represent an ongoing spares cost.

Supply duct

min. 300 mm

When run on mains water, the energy costs are the same for both humidifiers as they use the same amount of electricity to create the steam. However, if the resistive unit is run on RO water, electrical consumption is less, as very little hot water is sent to drain. Although energy consumption is improved using RO water, water consumption is increased as up to 50 per cent of the water is sent to drain as part of the initial RO filtration system process.

tion

truc

obs . 3 m any min BN to own ce nkn stan is u n di if BN o i t m p 3 or abs .4 ... ated min. 2 l u c or Cal

Electrode humidifiers tend to have the lowest capital cost of the two technologies.

in:

COSTS

As resistive steam humidifiers do not pass current through the water, they can operate with stainless-steel boiling chambers that can be cleaned rather than replaced. This avoids the expense of disposable cylinders reducing spares costs. So much so, that the initial cost of the more expensive resistive unit can be recouped within a short period of time. So, although ongoing operating costs can be less with a resistive humidifier, servicing takes longer as the unit needs to be emptied of scale. However, some advanced systems reduce this service burden through innovative scale management features. These systems use an external scale collector, allowing limescale to be removed quickly and easily without needing to open the main body of the humidifier, greatly reducing service time.

SUMMARY As we’ve seen, both technologies have advantages and disadvantages, and the choice of system largely depends on the end-user’s needs. If very close humidity control is needed, resistive humidifiers with or without RO water could be the best option. If close humidity control isn’t important, but simple maintenance with minimal downtime is, an electrode boiler with its replaceable cylinders could suit. But if a customer wants the lowest whole-life cost across capital, service, and consumables, then a resistive humidifier will provide this. The most important thing to remember is to get good guidance from a competent humidifier supplier. From product selection to servicing there are often opportunities to up-sell to improve your

customers satisfaction and avoid many common errors along the way. A quality humidifier supplier will work alongside you to help you make the most from each project. Things to specifically look for in a supplier include a comprehensive range of approved products, a company which offers support, and advice on installation, commissioning, and servicing.

INSTALLING ELECTRIC HUMIDIFIERS: 10 THINGS A CONTRACTOR SHOULD KNOW Installing electric humidifiers can be tricky as water supply, drainage, single and three-phase power, steam hoses, and controls are all involved. As humidifier projects don’t come along very often for the average HVAC&R contractor, building-up enough experience to overcome the common pitfalls can be difficult.

16 | HVAC&R Nation | www.airah.org.au/nation | August 2017

Here’s a list of ten useful tips that should assist with a smooth and successful humidifier installation.

Tip 1 Check the specification The type of humidifier specified isn’t always the most appropriate for the project. Check with the manufacturer that the model specified will do what the end-user requires. Check the output will meet the project’s requirement given the actual design conditions. Ensure the acceptable humidity control will be met by the model suggested. Ask whether the level of expected maintenance and annual cost of consumable components is acceptable to the end-user.

Tip 2 Humidifier positioning Humidifiers should be located where they can be easily accessed for servicing. Every humidifier needs to be maintained and inconvenient positioning may mean increased labour time or even a two-man job rather than one.

HVAC&R Skills Workshop AS/NZS 3666 AIR-HANDLING AND WATER SYSTEMS OF BUILDINGS – MICROBAL CONTROL

Part 1

Sets forth requirements for the design, installation and commissioning of humidifiers, including ductwork design to avoid the ingress and accumulation of moisture and also drainage of ductwork where moisture is likely to accumulate.

Part 2

Sets out the requirements for regular routine operation and maintenance of various types of humidifiers.

PULLOUT

Tip 3 Steam hose and condensate hose Installing steam hose incorrectly between the humidifier and the steam lance in the duct can cause a drop-in humidifier efficiency and increased humidifier running costs. If the steam hose is too long, the steam will condense prior to being released inside the duct. This results in the humidifier working harder to provide the correct amount of humidity to maintain the required room condition. Generally, steam hoses should not exceed 4m, always avoid sags or dead-legs where condensate can build-up without running to drain. This can cause a restriction in steam flow and a build-up of steam pressure in the system which will need to be relieved by the humidifier. Condensate hose from the distributor pipe should be installed without any sags or dead-legs to ensure free flow of condensate to drain.

Tip 4 Steam distributor pipe The steam distributor pipe’s job is to disperse steam quickly and evenly in the airflow of the duct. It is important to consult the manufacturer’s recommendations for the location of steam distributors. Understanding the conditions of the airflow will determine the positioning and type of the distributor pipe used. If a single pipe is being used, the positioning will typically be central in the duct, with the holes pointing upwards and at a right angle to the airflow. The pipe must always be angled to direct condensate into the drain.

PROUDLY SPONSORED BY

Common problems occur when steam pipes are positioned too close to bends causing steam to condense on the duct prior to absorption. If it is necessary to mount a distributor pipe close to a bend, special “Optisorp” distributor pipes are available with multiple pipes and tiny inner nozzles that take only the hottest, driest steam from the centre of the lance. These quick-absorption manifolds can provide an evaporation distance of just 30cm. Care should be taken to avoid placing lances too close to humidistats, attenuators, and air filters as wetting-out could occur. Locating a steam pipe too high or low in a duct may also cause a problem. Stratification of the air with different humidity levels in the airstream could result in condensation on ductwork and poor humidity control.

Tip 5 Drainage

Tip 7 Control strategy Employ a fully considered control strategy that involves modulating or on/off dependant on the steam capacity of the humidifier. Safety interlock protection is required to ensure that the humidifier cannot operate when the air handling system is switched off. Care needs to be taken with the location of controlling and high-limit sensors.

Tip 8 Power Always consider the full power requirements of the humidifier. Is there enough electrical power available to supply unit selected? Also, is there a requirement for single-phase power? Humidifiers often need single-phase power for the control board and 3-phase power for the heating.

Tip 9

The water being released from a steam humidifier could be between 60–100°C, so consideration should be given to drain piping. Plastic pipes can melt and bend. Some steam humidifiers will temper water temperature prior to release so if this is an issue, select an appropriate model. Don’t position a humidifier above an open drain as steam rising from the drain can enter the unit, resulting in condensation and corrosion or electrical faults in the circuit boards. It’s better to run a long drain and position the humidifier near the duct, so steam hose is an appropriate length, than position the humidifier near the drain and have excessively long steam piping.

Tip 6

Commissioning When commissioning a humidifier, it is important to consider it as part of the whole air-handling system. The humidifier is often accused of under or over-humidifying when air volumes and temperatures have not been checked beforehand. If an external commissioning engineer is being used, check that all services are installed and available prior to him arriving on site. Also, scheduling in the controls company to be on site at the same time often makes for a speedy and accurate testing of the control signal and any remote-indication feedback to the BMS.

Tip 10 Good advice

Water quality Check that the water supply is compatible with the humidifier to be installed. Running a steam humidifier on hard water will inevitably result in an increased maintenance schedule. Limescale left behind after the water evaporates will need removing from the boiling chamber more frequently. Careful consideration ought to be given to appropriate humidifier selection in hard water areas to reduce necessary servicing as much as possible. Installing an electrode boiler humidifier in such an area could cost the end-user dearly in replaceable boiling cylinders. Using a resistive humidifier with an easy-to-service, cleanable cylinder will present better value, even with its higher capital cost. Water treatment, such as reverse osmosis or water softeners, can only be used with resistive element humidifiers and will reduce humidifier maintenance in hard water areas and also improve humidity control as they will be draining less to combat mineral build-up.

Seek good advice from a competent humidifier supplier when tackling a humidifier project. From product selection to servicing, there are many common errors to avoid and often opportunities to up-sell and improve customer satisfaction. A quality humidifier supplier will work alongside the contractor to help them make the most from each project. n

MORE INFORMATION This month’s Skills Workshop has been put together by Aireven – the exclusive distributor in Australia for Condair. For further information contact: Kevin Cronin Aireven Pty Ltd Tel: 02 9987 2006 Email: kcronin@aireven.com.au

Next month: New refrigerants standards August 2017 | www.airah.org.au/nation | HVAC&R Nation | 17

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- Optional EC Plug Fan for improved energy efficiency and precise airflow control

OUTDOOR AIR SERIES

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18 | HVAC&R Nation | www.airah.org.au/nation | August 2017

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Fly Guy

SLIGHTLY LIGHTER, A LOT SMARTER One of Yamahaâ&#x20AC;&#x2122;s motocross favourites gets a tech-filled facelift. One of the most popular offerings in the Yamaha motocross range, the YZ450F motocross racer will have a swag of classleading tech upgrades for 2018.

The bilateral-beam frame has been redesigned to optimise vertical and torsional rigidity. The reverse-tilting single-cylinder engine has been equipped with a new crankshaft, a stronger diamond-like carbon-coated piston, new cam profiles, and a new 44mm Mikuni throttle body. The gearbox and clutch have also been reworked for more durability. Yamaha also claim that the bike is one kilo lighter than the 2017 model at just 111kg, despite having bigger radiators and the addition of an electric starter motor. Rev-heads will have wait till later in the year before figures on the peak power and torque are released, but at 111kg and 450cc, you can rest assure that the new YZ450F will be a certified dirt dancer.â&#x20AC;&#x201A; n

The 2018 model will feature electric start, new suspension, a new frame, and a revised high-traction engine. On top this, the new YZ450F will also include an innovative built-in Wi-Fi hotspot, which gives riders the ability to adjust the fuelling and ignition maps through a smartphone app. Yamaha says the new YZ450F will be the first production motocrosser with a smartphone tuning app, allowing riders to tinker with their machines by the side of the trail at the touch of a fingertip. The Power Tuner mobile app is designed to provide a visual interface for editing, saving, and sharing settings for fuel and ignition mapping changes. It connects to the bike through a built-in Wi-Fi hotspot, and lets riders log and share notes, monitor race settings, and view system diagnostics. Aside from its new connectivity upgrades, purists will rejoice at the new performance features of the bike, which have had a stunning makeover.

August 2017 | www.airah.org.au/nation | HVAC&R Nation | 19

Feature

It’s always been difficult to to gauge where the industry is headed, but according to ARC CEO Glenn Evans, the industry needs to rebrand itself to better identify with the HVAC&R’s next generation.

IMAGE IS EVERYTHING How often h ave you told someone yo and they loo u work in the k at you with HVAC&R ind a b lank stare? Th thereof – is ju ustry, e industry’s pro st one reaso n why we co file – or lack The CEO of th ntinue to fac e Australian e a skills shortag Refrigeration e. says it’s time Council, Glen the industry n Evans, rebrands itse with the nex lf to better id t generation entify of our workfo rce.

SKILLS SHORTAGE The ongoing skills shortage requires the industry to be more targeted with its message at different age groups. This will work towards an industry that provides a unified, positive voice. The collective voice needs to be a positive one – negative commentary within the industry is very damaging, and is a deterrent to new entrants.

Market and economic changes seem to be having an impact in some areas, such as less large businesses who traditionally hosted apprentices. This is where the industry needs to recognise and react to redevelop the apprentice pathway – take a leap of faith in investing in the future of the industry. It is important the industry works collaboratively to promote the benefits of having a career in HVAC&R.

20 | HVAC&R Nation | www.airah.org.au/nation | August 2017

Negative commentary within the industry is very damaging, and is a deterrent to new entrants.

This includes having a mutual understanding of what makes us strong – professionalism driven by skillsbased licensing and training, environmental credentials, passion, and the fact that HVAC&R is vital to modern life. In 2016, the Australian Refrigeration Council (ARC) produced a unique careers video for the HVAC&R industry, presenting it as a dynamic career of choice, and focusing on cutting-edge technologies and diverse career pathways.

Feature Training will always follow the introduction of new technology. However, the trick is to limit the “time to market”. Given Australia is fundamentally a “technology-taker”, we need to be better at looking at developments overseas and being better prepared for their introduction here. The nature of Australia’s training regime is that for a course to be run, there needs to be a demand. One of the key outcomes of the ARC’s new Green Scheme Accreditation program for natural and low global-warming-potential (GWP) refrigerants is to create demand for training and give some confidence to RTOs (registered training organisations) to host training involving these new frontier refrigerants – to help provide a business case. The biggest attribute of the Australian training scheme is its robustness and quality. It is admired by other countries around the world; however, its robustness can also be a weakness as the time taken to get new training to market can be lengthy. This can impede the uptake of new technologies.

Glenn Evans, CEO of the Australian Refrigeration Council.

The video, and an education pack, have been sent to TAFEs and secondary schools Australia-wide and the feedback has been positive. It gets lost just how important HVAC&R is to supporting modern life and lifestyle. And at a grassroots level, it is about image and positioning. New branding would be helpful. My personal preference is the “climate control industry” – something that speaks to the youth of today who are considering many career options. The industry deserves to be presented as dynamic, prosperous, and vital, with many exciting and diverse opportunities. It deserves its own widely recognised profile in the community. Surgery can’t be performed without the work of a fridgie. Supermarkets and laboratories won’t function properly without the expert services of a refrigeration and air conditioning tradesperson. And not only that – our industry leads the world in environmental stewardship, and has access to cutting-edge technologies with a vast array of potential career opportunities. This is the story that needs to be told.

TRAINING The pace of change occurring in the industry at the moment is being driven by regulations such as the HFC phase-down, more so than innovation. Regulation is a lag driver, but it does operate to provide some surety to the market. This issue is exacerbated by the fact that most new technologies are coming into Australia from overseas. But where there are pockets of innovation, they should be better supported. Training isn’t keeping up with the development of new technologies.

The ARC has had some concerns about discrete examples of poor training quality. Especially with unduly short training. We have been active with the Australian Skills Quality Authority (ASQA) in this regard and welcome the recent review of these issues. We are hopeful the quality of training will improve in that respect.

LICENSING Licensing provides a framework for training and lifts the skills of the industry through mandating qualifications and Codes of Practice (standards of work). Prior to the introduction of the ARCTick licence scheme, anybody could deliver RAC services. However, the introduction of the scheme – being skills based – has seen only appropriately qualified technicians now being able to lawfully provide those services. Licensing drives training outcomes and ensures quality in the trade. This in turn encourages consumer confidence and investment. These positive outcomes ultimately ensure the sustainability of the sector as a whole. With over 85,000 ARCTick licensed individuals and businesses Australia-wide – and continuing to grow – licensing contributes to the skills pool available within the industry. It does unapologetically set a standard; however, for those in the industry, so that they are competent to do the work they are permitted by their licence to do. While the policy driver for the ARCTick scheme is environmental protection, as opposed to state occupational licences, which are driven by consumer protection, the Council of Australian Governments (COAG) has independently confirmed there is no difference between the two “on the ground”. Indeed, COAG found that the ARCTick scheme is the most effective and efficient refrigeration and air conditioning licensing scheme in Australia. ARCTick licence holders have contributed significantly to the quality of the environment, preventing approximately 24.37 megatonnes of carbon-equivalent emissions, and returning 5000 tonnes of ozonedepleting substance (ODS). n

GET ACCREDITED! The ARC Green Scheme Accreditation program is a voluntary, qualifications-based accreditation for technicians to work with natural or low-GWP refrigerants. It deals with the area not covered by the ARCTick scheme for ozone-depleting substances (ODP) and synthetic greenhouse gas (SGG) refrigerants. In particular, it deals with hydrocarbons, CO2, ammonia, and R1234yf – which aren’t covered under the current ARCTick national licence for synthetic refrigerants. The accreditation is separate to the ARCTick licence scheme, but builds off it in terms of competencies. Natural and low-GWP refrigerants present unique challenges to technicians due to their flammability, toxicity, and high operating pressures. As a result, the industry was keen to see them licensed. Through the Ozone Act review of last year, the government determined that they couldn’t incorporate all refrigerants into the current ARCTick scheme, as naturals and low-GWP gasses weren’t environmentally damaging and therefore outside their mandate. Given the level of industry demand, the ARC felt compelled to answer the call for training on their use and recognition, for technicians who chose to upskill in this area so they may handle new refrigerants safely. The ARC Green Scheme Accreditation program was launched on July 1, 2017, and the take-up has been surprising. We weren’t expecting to see the full effect to come into place for another 12 months as training aligned with demand. It was launched as an investment in industry, which would reap benefits over time. The benefits to industry are many and include: • Encourage technicians to upskill so they can safely handle natural and low-GWP refrigerants • Help training for these refrigerants to become more mainstream. Where RTOs are not promoting the specific competencies, we encourage technicians to contact training providers to initiate the demand for these competencies to be run. • Help make technicians safer through increased, relevant knowledge of these refrigerants’ properties and uses • Encourage the use and uptake of new technologies • Increase demand for training and therefore the development of courses • Assist in achieving the government’s environmental objectives.

August 2017 | www.airah.org.au/nation | HVAC&R Nation | 21

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 G

THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

DA01 •

CENTRIFUGAL PUMPS

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 NOISE CONTROL

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.

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.

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.

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.

AL P

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.

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.

9.4.9. Valves

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 THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING a preliminary shaft alignment. Shim the motor feet for the

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.

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 location of valves, with consideration for operating accessibility, should be accomplished in the natural routing of the system from point to point.

9.4.11. Wiring

•

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.

•

A minimum 100 mm of knuckle clearance should be provided around all valve hand wheels.

Space should be provided for the removal of all valve internals.

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 clearance between the insulation of one pipe and any adjacent pipe and insulation, or other

Base isolation Figure 9.1: Base mounted pumps

FANS

•

9.4.10. Insulation

DA13

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.

•

PL IC

IO AT

Airfl

•••

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.

Note: Refer AIRAH DA 27 for further information on the installation of control wiring.

(a)

ial

THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

9.4.12. Access

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

N MA

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.

•

•••

A PPLI

DA16

AIR FILTERS

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Th ng th fan ty inlet en -m t re uc wor e it a pl eir pe THE AUS TR ALIAN INS TITUTE OF REFRIGER ATION, AIR CONDITIONING AND HE ATING alter ou flect ts th and Four ate ks. first appl s, m at nt THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND an ed du HEATING ot pa and ge mou cted pe ed ex y of are m A fa rt of icatio or rfo ha th nted or fan neric the n an supp n is rm ust e sta ount mor pe insta ed ance fa fan fan d nd e of rform lla are lies a rota ns char or ard in thes an tion som thre ener ting Gu acte AHU e in ce te cate ide rota etim e main gy to bladed ristic fans sta sts go Va es tin th the llatio are ries ne m e g re co s. ) s Ca n ca typi are do impe it, th ferre mponeair or achine Fig tego cally defin (ie tego nts gas whi that not in ller e mot d to ure . no ry rie perfo ed in 2.1 (b) pres aid cludeis cont or, anas th in a passin ch co s. 1: du A – O e fa rm ISO Va sure s air Typi ctin pe ca ain d th whe n, g th ntin ed ne cal En to sepa sings ed, if e ca el or the im roug uous n in g) for 5801 ax sta ratio bu on sin co ial on let ro pe h it. ly whi ergy nfi tic e is an gu pres n fro t may e is us g or vo tor, th ller w Ther flo ch m trans ratio d ou e hi sure m th inclu ed. lu e ge w type ay be ferre n of tle Fa e bl de Som te, in meansch is . t n an at annerate . 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APPLICATION MANUAL

Figure 9.2: Supporting pipework independently of pump connections

hammer. The following precautions should be taken during installation:

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.

Pump Pump isolation

•••

APPLICATION MANUAL

THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

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HVAC&R AN INTRODUCTION

9.4.7. In-line pumps

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.

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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.

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.

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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.

9.4.6. Base mounted pumps

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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.

Isolate the pump from the structural loads of the pipework system.

• •

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:

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THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

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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

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APPLICATION MANUAL

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•••

MAINT

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The AIRAH r a building 2.3.9 Ten oned enance e philos ng maintenanc rating or contains ophy for to develop the going comm ants accre particular HVAC&R system e mana a buildi design/ Designers Tenants and maint ng or system requiremen star rating ditation maintenanc itment of mana gement relies need have a legal enanc design tool the system to be instru ts or credit on . gers e fundin e inform respo will cted in g and user to maintenanc the onation. s for operaalso responsibili be safe to opera nsibility to ensur the correc to be engagand this shoul e plann education. ting d te and t e that 2.3.5 Sys ing, 2.3.7 Mai either by ty continues efficiency/s ed by the buildibe in lay terms operation of through maintain. This their the origin . 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Rules the ongo have a responsibili program. implementation ce and ing data enance ensure redes The maint plan, the will ing maint that Becau ty form perso any negat or procedures ign as a result enance to inform se the proposals the basis enance overall maintenanc maintenanc nnel comm of need contractor ive impac their building of the ission e respo needs owners and of the futureor life cycle costs clients of ts of tenan to be in place and system should and licens e personnel nsibilities. ing the systemmaintenance and opera to of their t fit-outs responsibili ensure are appro to ensure that performan ed to carry Tenant Commission tors with design also that: appro priate ties systems ce is mitiga on the • Comm out the of system priate. regard to Particularly ing perso have can be base buildi work and ly trained, skilled issioning ted. maintenanc nnel ng system connected to are super procedures carried part I2 on with the provis e. considerable The maint or be separ vised as out appro s. They enanc can • Comm maint priately, for plant and access for energy efficient ions of the BCA ate be comp e contractor developme enance systems regarding issioning lex and from in them Tennant are should responsibilimaintenance, installations and require data is prope • System considered nts in all areas selves. there systems part J8 and advise keep abreast of commission that modi rly record law. 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Even witho required manageme ements for for the ut associated nabili to be inform compliance commission for maint facilitate performan a designed requir a responsibili the provisions . are requir nt and comm with partic ty or performan formal enanc ing, comm ed ty to all ce. issioning ed perfo Modern ce ular system for maint reasonable requee and should be of the issioning under a ed to be met if rmance ensure that maintenanc enance. s. Green Star the buildi documentation maintains and the sts for acces encouraged Specific e is a partn HVAC&R maint ng const requiremen that accreditatio to s to HVAC ership system knowledge enance contr ruction manuals ts for opera n regim &R plant star rating requiremen is and loop, regard actor needsof stakeholders 2.3.10 e. 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The BCA performan but their ve matters suchdocument and includ perfo their • g ed and of e: or Repair and ce. is rmance behaviour does not need is monitoring as maint Well inform (refer to for optimum long parts of a required implic replacemen contain can have enance , Clause 6.2). • Comp to be maint it in order term system manu t, to poten ed occupants liance activi ained and to know what als tial probl can alert 2.3.6 Bui • Purch ties and plant is when. future maintenanc records, ase and or furthe ems and also lding/Fa 2.3.4 HVA e mana installation identi r system The buildi • Purch gers cility man improveme fy opportunit of C&R Sys ase and Occupiers Regular manager ng manager, facilit ies for installation plant, nts. • Contr agers tem con inspe of spare knowledgeform part of the ol of onsite installation ctions shoul primary has a significant y manager or tractors s and consu role of the d be made • Energ stores and maintenanc maintenanc maintenanc loop between communications representa by HVAC&R system mables, and its y mana manager durin spares, e e system systems e. gement tives to is to ensur responsibili • Water contractors g system operation and are funct and repor ensure: • Adeq manageme ioning optim e that the ty. A and or their ting, Managers, uate and building • Super nt and repor ally. safe acces as well • Origin vision and as drivin s to plant • provid al specifi assessment ting, • Cost g the maint is provid cation for e the link complied control, s, Regulators: enance ed, betw materials building with, proce • Comp occupiers, een system Building • Equip and equip laint respo maintainers ss, also: • need ment instal ment is & OHS nse and to respo Owners and lation requir • As instal trouble Manufacturers nd to • ensur ements led drawi shooting. 2.3.8 Mai e the buildi complaints quick Designers are comp • Opera ngs suppl ly and efficie ng occup • often lied with, Installers ting and ied are ntenan ants are accurate, provid maintenanc ntly, • Comm ce satisfied, and contr e a super visory ••• service e manu ission actors, als are comp role for Occupiers appropriate ing procedures person It is essen • maint maintenanc 14 lete, tial are carrie ly, nel and ain docum • The e staff appropriate that maintenanc d out Tenants Manage entati operating installed e servic trained, APPLICATION APPLICATION APPLICATION MANUAL system MANUAL and maint on such as the undertaken lyMANUAL Operatorsrs Maintainers e • moni meets the enance asset regist . They needskilled and super personnel be tor, meter Auditor system manuals, design er and vised a good shoul , record intent. • comm Surveyorss understand for the work and repor the contro d operate and unicate t system ing l system in maintenanc • resolv performan Figure logic being particular fully of how each e issues e acces 2.4 HVAC& understand ce, Maintenanc applied s issues , R system , to the system knowledge and licenc e personnel . require loops a range on HVAC es to carry out of certifi the &R cations handling, systems partic required maint and electr boiler work, waterularly in respect enance work to refrig ical work. treatment, hydraulic erant Inadequate services maintenanc in unsat e of isfacto unexpected ry operation, mechanical plant higher costs will result breakdown and unne s. cessary

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THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

DA27 BUILDING COMMISSIONING

APPLICATION MANUAL

2.4 Im plicat of inade ions mainten quate ance

••• 15

AIRAH technical publications Purchase online at www.airah.org.au/store

22 | HVAC&R Nation | www.airah.org.au/nation | August 2017

DA 13

AIRAH News

Dr Stephen White, F.AIRAH, from the CSIRO, presents at the Innovation Hub Summit in Melbourne.

JOIN THE HUB! used to fund the activities. Eventually, the Innovation Hub aims to build its membership base and IP returns, to a point where it is self-sustaining.

The Innovation Hub for Affordable Heating and Cooling will facilitate the HVAC&R industry’s transition to a low-emissions future, stimulate jobs growth, and showcase HVAC innovations in buildings. In association with the CSIRO and PRIME, AIRAH is proposing to establish the Innovation Hub for Affordable Heating and Cooling, or iHub.

The Innovation Hub will support the broad HVAC industry with knowledge dissemination, skills-development and capacity-building.

OVAT I ON INN HU E H

A board will oversee the strategic operation of the Innovation Hub.

The Innovation Hub for Affordable Heating and Cooling will look to facilitate the HVAC&R industry’s transition to a low-emissions future, stimulate jobs growth, and showcase HVAC innovations in buildings.

STRUCTURE AND GOVERNANCE

Day-to-day administration of the Innovation Hub will be performed jointly by AIRAH and CSIRO, under the governance of the board. Members of the Innovation Hub will be able to access CSIRO’s ON incubator processes and $200 million Innovation Fund.

N LE HE TING A A

It is proposed that industry contributions supplemented with government funding will be

“This will make it easier to incubate ideas and reshape industry practice to the needs of the 21st century. The Innovation Hub will enable Australian small to medium enterprises to accelerate product development, including through access to cutting-edge intellectual property, independent technology validation, and interfaces with venture capital investment.”

I LI V

“The Innovation Hub for Affordable Heating and Cooling will provide virtual and physical spaces where a community of industry innovators, designers and educators can easily access knowledge and research infrastructure,” says AIRAH CEO Tony Gleeson, M.AIRAH.

THE iHUB IN ACTION

R R AT O RIE S P

PRIME A whole-of-industry pathway to a low-emissions future

The Living Laboratories will be established under customised agreements covering agreed protocols for: • Safe and secure access • Commercial and personal privacy • Sharing information and intellectual property • Practical risk issues and their management. The iHub has initially identified five priority building typologies to target with Living Laboratories. These building types were identified as major energy consumers in the commercial building baseline study (2012). For more information, go to www.airah.org.au/ihub n

August 2017 | www.airah.org.au/nation | HVAC&R Nation | 23

Around the nation 1

DAIKIN’S AIRMASTER ACQUISITION MISSION

Airmaster Australia has entered into an agreement to become fully owned by Daikin Australia Pty Ltd, a subsidiary of Daikin Industries Ltd. Daikin will purchase all company shares held by Airmaster's executives at an acquisition price of $100 million. Both Airmaster and Daikin will continue to operate business as usual as independent brands, each with their own specialist product and service offerings. “Forging this agreement with Daikin makes perfect sense for both companies,” says Noel Courtney, M.AIRAH, who will remain as CEO of Airmaster. “In doing so, we are combining two respected industry leaders, both with a strong and loyal customer base. Airmaster’s proven business model in service and maintenance complements Daikin’s strengths in air conditioning products and technologies.” Courtney believes bringing the companies under single ownership will work to combines collective skills, expertise, scale, and resources to realise the growth aspirations of both brands. Daikin says it plans to combine Airmaster's service network and know-how, which extends throughout Australia, with Daikin's expertise on HVAC technologies. “We can be justly proud of our achievements at Airmaster as an Australian-owned company,” says Airmaster managing director Alistair McDonald, M.AIRAH. “And, while there are mixed emotions about the sale to an overseas buyer, we recognise the many benefits of working with Daikin as the world’s premier brand for air conditioning products. Daikin’s desire to ensure a smooth ownership transition will allow for the continuation of the service traditions and culture at Airmaster, whilst offering meaningful career opportunities for staff. Overall, this is a positive move for Airmaster.” Nationally, Airmaster employs approximately 400 service engineers across 12 branch offices. n

RIVERS OF GOLD FOR MELBOURNE'S TRADIES

ServiceSeeking.com.au has collected the latest data on the industries and areas around Melbourne with the lowest level of competition for tradies. According to data submitted in FY17 Q3, competition levels for builders in Albert Park and Collingwood are 43 per cent and 15 per cent below average respectively, representing a real opportunity for builders in those suburbs. Electricians should look towards Middle Park, as skilled “sparkies” are in short supply compared to other areas around Melbourne. For plumbers, Windsor and St Kilda were the suburbs with the shortest supply. “Targeting areas where there’s less competition is the way for Melbourne’s tradies to increase their work flow, increase their prices, and increase their profit,” says ServiceSeeking.com.au CEO Jeremy Levitt. “There are rivers of gold for tradies all over Melbourne. They just need to know the right places to look. Those wanting to raise prices and generate more profit should head to the areas where there’s less competition.” n

SAVE THE DATE FOR ARBS 2018

ARBS 2018, Australia’s only international air conditioning, refrigeration and building services trade exhibition, will be held at the new International Convention Centre (ICC) in Sydney from May 8–10, 2018. The 2018 exhibition will focus on innovative responses to existing and emerging trends in the built environment. Visitors can expect to see the latest products and services, talk to manufacturers and distributors about new innovations, connect with peers at the informative and leading-edge seminar program, and enjoy many of the social activities including the awards presentation dinner. For more information, go to www.arbs.com.au n

24 | HVAC&R Nation | www.airah.org.au/nation | August 2017

NSW U&E ITAB CONFERENCE IN AUGUST

The NSW Utilities and Electrotechnology Industry Training Advisory Body Limited is holding its 20th Annual Conference on August 14–15 at the Gibraltar Hotel Bowral in the Southern Highlands. The NSW U&E ITAB Conference is the key event for those involved in or interested in Utilities & Electrotech nology training in NSW. It brings together rural, regional, and metropolitan players in a focused environment. This year’s conference aims to bring delegates upto-date with the review and update of the NSW Apprenticeship & Traineeship Act and how these changes will impact on employers and RTOs. Delegates will also hear about the new NSW VET Repositioning Strategy, which is designed to integrate a communication and marketing strategy for VET. There will also be an update on the continuing modernisation of TAFE NSW and the development of Industry Skills Points. For more information and to register, contact norm@uensw.com.au n

YOUTH ELIGIBLE FOR 20K BOOST

State treasurer Curtis Pitt recently announced that the Queensland government's Youth Boost payment program is now eligible to all employers in South East Queensland who hire an unemployed young person aged 15–24 until October 31, 2017. A total of $20,000 for a full-time employee is available under the program, with payments done in increments – $6000 after four weeks of continuous employment, another $7,000 after 26 weeks, and a final payment of $7,000 on completion of 52 weeks continuous employment. Payments are available for apprenticeships and traineeships where the employer is not eligible for Queensland’s Apprentice Trainee rebate for payroll tax. For more information, go to backtowork.initiatives. qld.gov.au/youth-boost-payment/ n

Around the nation 6

BREAKING SILENCE ON THE SILENT KILLER: CO

Comedian and TV personality Fiona O'Loughlin has spoken publicly about her near-death experience with carbon monoxide poisoning, which left her in a coma for four weeks. The prolific comic, who has also been upfront about her battles with alcoholism in the past, says she'd suffered carbon monoxide poisoning from her heater, which went undetected because of her “demons”. After being admitted to hospital, O'Loughlin spent nearly one month in a coma. "I was given a 7 per cent chance of life,” says O’Loughlin. “Guess what? I didn't die!" Colourless and odourless, carbon monoxide is frequently referred to as the “silent killer”. It is produced by common household appliances – heaters included – and without proper ventilation, can build up in the home. Prolonged exposure can cause brain damage and even death.

Budarick says he will pursue a career as a refrigeration engineer, rather than installation. With the idea of moving to Adelaide once his apprenticeship with Pilkington Refrigeration is complete, Budarick plans on taking on a prospective role at Seeley International after a gap year.

The new lease will cater for mainly office, warehousing and the wholesaling to trade services.

ACT GOVERNMENT’S APPRENTICE ACTION

Skills Canberra has written to the employers of school-based apprentices to request that Year 9 and 10 students are not involved in "any high-risk activities" after two early-career apprentices were badly injured on ACT construction sites late last year. The ACT government organisation has also brought forward its field officer visits to within the first two months of a school-based apprentice's employment, instead of within the first year, and will prioritise those visits over any other, according to briefing documents released under Freedom of Information laws.

Read more about carbon monoxide poisoning in “The Silent Killer”, which featured in HVAC&R Nation, August 2016. n

The background notes provided to the ACT government outlined the new processes introduced by Skills Canberra.

South Australian Nathan Budarick has been awarded the Playford Trust Seeley International/Playford Trust Scholarship and Most Outstanding Student in Certificate III in air conditioning and refrigeration at TafeSA. The scholarship will enable Budarick to purchase textbooks and complete the course fully funded.

Property major Stockland has secured Daikin Australia as a tenant for part of its 11-hectare industrial business park in Sydney’s Warwick Farm.

Savills Australia’s Darren Curry negotiated the pre-lease and says Daikin plan use the Stockland development to cater for the expansion of its current site.

“I have always been hands on,” he says. “I would definitely encourage people to give [an apprenticeship] a go. Get an apprenticeship with the right person and it’s a breeze.” n

"All I remember is my mother going, 'Oh my god, you're alive?” says O’Loughlin, recalling her memories of awaking from her coma. “’Here, talk to Aunty Genevieve, she's been praying for you.' She threw a phone at me!"

OUTSTANDING APPRENTICE AWARDED IN SA

DAIKIN JOINS THE FARM

Daikin Australia signed a 10-year lease at 200 Governor Macquarie Drive and will shift in early 2018.

Grateful he decided to become an apprentice, Budarick encourages others to do the same.

"From 2017, field officer visits for ASBAs (Australian school-based apprentices) will be brought forward to within the first two months of their training contract approval, and will be prioritised over other visits," says the Notes. "The WorkSafe ACT Guidance Note about the supervision of Australian apprentices in the building and construction industry is now included with the National Code of Good Practice for Australian Apprenticeships, provided with the training contract approval letter sent to employers and Australian apprentices.” n

For more information, go to www.daikin.com.au n

RACE 2 WIN IS BACK

Heatcraft's Race 2 Win promotion is back, giving customers the chance to win a $250,000 major prize, and a VIP three-day experience for two at the Newcastle 500 Supercars Championship in November – accommodation, airfares and a luxury corporate suite all included. The last time Heatcraft ran its Race in 2 Win promotion, the company gave away $100,000 to a lucky customer. This time, Heatcraft has increased the jackpot to $250,000. "We're very excited to be able to offer our customers the chance to win such a significant amount of money that could go towards helping them build their business," says Heatcraft director of marketing Roger Pecnik. "The total prize pool is valued over $300,000, which is our largest promotion in recent years." Heatcraft customers who purchase a minimum $200 during the promotion period receive a scratch gamecard where they can win instant prizes such as wireless headsets and movie tickets. The Heatcraft Race in 2 Win Promotion commences on August 7 and closes on October 28, 2017. For full terms and conditions, visit www.heatcraft.com.au n

August 2017 | www.airah.org.au/nation | HVAC&R Nation | 25

Safety corner

Access safety issues

Designers and owners who do not understand or who choose to disregard their duties in relation to safe access to plant. “Customers see safe access as a cost, not a responsibility”.

AIRAH receive many comments and enquiries from its members and other industry stakeholders regarding safety issues within the HVAC&R industry and decided to run a national survey in collaboration with a range of industry associations. Reaching out to technical service providers on the topic of safety in the HVAC&R industry, the survey focussed on the refrigeration and air conditioning (RAC) sectors. Hundreds of people reviewed the online survey and a total of 79 completed survey responses were received. Here, in an excerpt from AIRAH’s “Safety in the HVAC&R Industry” report, we delve into access – one of key safety issues identified.

WHAT ARE THE ACCESS ISSUES? Safe access to and about HVAC&R equipment is the primary issue in this category, causing ongoing safety issues when servicing and repairing systems. This includes accessing plant on roofs and in roof spaces (e.g. condensing units), in ceiling spaces (e.g. fan-coil units) and in plantrooms and plant cupboards. Plant is often (commonly) installed in inaccessible positions increasing risks for the service person.

Safe access to and about HVAC&R equipment is the primary issue . . . Working at heights presents fall hazards and appropriate safety solutions are often not provided, or the solutions that are provided are inadequate and not used correctly. This is predominately related to rooftop and high-wall installations but also mezzanine plantrooms in warehousing. Access is often compromised because “ladders are cheaper than steps”. Inadequate access panels into ceiling spaces requiring dangerous ladder-based work. Lack of access to roof-mounted or high-wall plant requires scissors lift or scaffolding. Safety risks are imposed on service personnel for the working life of the installation, simply through poor design choices.

Inadequate access panels into ceilings requiring dangerous ladder-based work … Working in confined spaces is a common issue, particularly in difficult-to-access poorly lit and unventilated plantrooms and plant enclosures. Poor lighting in service areas is another access failing that can have serious safety implications for the HVAC&R technician. Safe access is not simply about physical attributes such as steps, harness points newbut takealso on includes the tired old tyre. andArails, environmental parameters such as ambient noise levels, lighting levels, air quality parameters and ventilation levels.

Poor lighting in service areas Working alone and working out of hours, particularly with large industrial refrigeration systems (i.e. large-volume refrigerant systems located in an unoccupied facility). Designers and owners do not fulfil their duties in relation to safe access to plant. Building regulations, through reference to the National Construction Code (NCC), require that access is provided to HVAC&R plant

so that the building and its systems can continue to meet the required minimum performance against which the building was originally approved and certified. It is a requirement of WHS regulations (or OH&S regulations in some states) that the access that is provided for this purpose is “safe” for workers and occupants or is made safe. In plain English, this means that access for HVAC&R maintenance must be provided as part of the NCC building certification process and the access provided must be safe because this access is a workplace-related space. Therefore, there is a legal imperative that HVAC&R plant has to be provided with safe access, which may not be well understood by all stakeholders in the building supply chain.

Designers and owners do not fulfil their duties in relation to safe access to plant. Inadequate access is characterised as a market failure in the construction industry because the market rewards builders and developers that transfer construction costs to owners and operators through increased operating costs.

Inadequate access is characterised as a market failure in the construction industry . . . Retrofitting energy efficiency improvements to existing systems is often not possible due to inadequate space for the additional components needed to improve a system’s energy productivity. This represents an ongoing energy and performance penalty imposed through poor access provisions in the original design.

WHAT IS CAUSING THESE ISSUES? Poor planning and poor integration of HVAC&R plant and equipment into the overall building design process. Rooftop-mounted equipment that is also located too close to the roof edge for example, or multiple rooftop units installed independently and without consideration of each other leading to erratic and hazardous electrical wiring and refrigerant piping distribution networks on the roof Poor planning and poor integration of HVAC&R plant and equipment into the overall building design process.

26 | HVAC&R Nation | www.airah.org.au/nation | August 2017

THE SUGGESTED SOLUTIONS – ACCESS Existing WHS and NCC-regulated requirements for access should be better communicated and enforced. If these rules are consistently not enforced, they will be (and are being) ignored by the market. Industry awareness of the minimum rules need to be increased, provide more monitoring and independent audit, and give agencies a mandate and the required regulatory powers to enforce the existing requirements. Designers and installers need to consider and allow for future access in their designs. This is a requirement of legislation but is not enforced in any way, and so is ultimately ignored by industry and certifiers.

I have had a number of discussions with facilities managers or building owners. And, after explaining that they have safety issues which they are ultimately responsible for, and attempting to work with them to resolve the issues, I find they see it as a money grab. The most common comment is ‘It has been like that for years and if you don’t want to do the work we will find someone who will (and who won’t raise the safety concerns)’. Increase the stringency of rules for access to roof-mounted HVAC&R equipment, ban vertical ladders and require stairs and walkways instead. Provide/require remote monitoring solutions such as automated KPI monitoring and fault detection of plant that reduces the necessity or frequency of physical inspection. Reducing the need for access or reducing the frequency will also reduce the potential for risk. Service personnel should bring Personal Protective equipment (PPE) to every site and every job. That is the harsh safety reality of contemporary RAC work. Pre-construction “Access” reviews for buildings and facilities should be integrated into project management programs, to detect access issues early in the design/construction process. Access provisions in a building or facility could be “Rated” for safety/suitability in the same way as energy (NABERS) and sustainability (Green Star) is currently rated. Create an access rating system and encourage the Property Council of Australia to adopt the system in its building grading matrix. This would help the market to correctly value access provisions in a facility. The market needs better and clearer requirements about access responsibilities and education of owners about their duties. View the full Safety in the HVAC&R Industry report at www.airah.org.au/safety

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AIRAH and Industry classifieds EVENTS Pre-Loved Buildings Forum 2017 The Pre-Loved Buildings Forum advocates that a strong focus on HVAC&R in the existing built environment can achieve dramatic effects when it comes to reducing energy use, conserving water, and improving the occupied space. Date: Thursday, August 3 Venue: Doltone House Hyde Park, Manhattan and Avenue Rooms, 181 Elizabeth Street, Sydney Cost: Members $295, Non-members $395

Cairns Trade Night

AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations. Date: Tuesday, August 8 Time: 4.00pm–7.00pm Venue: Pullman Resort Casino, Cairns Cost: Free

Mackay Trade Night

AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations. Date: Thursday, August 10 Time: 4.00pm–7.00pm Venue: Mackay Grande Suites, Mackay Cost: Free

Wollongong Trade Night AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations. Date: Thursday, August 31 Time: 4.00pm–7.00pm Venue: The Grandstand Premiers Room, Wollongong Cost: Free

Qld – Smoke Control & Fire Dampers

TRAINING Vic – Smoke Control & Fire Dampers

This one day course outlines how AS/NZS 1668.1 applies the principles of smoke control in multi-compartment buildings. Why is smoke control required in buildings? What are the hazards generated by smoke and how does smoke move? Date: Thursday, August 10 Time: 8.30am Venue: Telstra Conference Centre, Level 1, 242 Exhibition Street, Melbourne

NSW – Smoke Control & Fire Dampers

This one day course outlines how AS/NZS 1668.1 applies the principles of smoke control in multi-compartment buildings. Why is smoke control required in buildings? What are the hazards generated by smoke and how does smoke move? Date: Thursday, August 24 Time: 8.30am Venue: Novotel, 169–179 Thomas Street, Sydney

This one-day course outlines how AS/NZS 1668.1 applies the principles of smoke control in multi-compartment buildings. Why is smoke control required in buildings? What are the hazards generated by smoke and how does smoke move? Date: Tuesday, August 29 Time: 8.30am Venue: Novotel, 169–179 Thomas St, Sydney

EMPLOYMENT Sales Manager – High-efficiency Chillers

A European chiller OEM requires a sales and accounts manager to work out of its Melbourne’s office, covering the sales of high efficiency chillers in Australia. A successful candidate will have proven experience with selling oil-free chillers with use of Turbocor compressors, as well as the traditional PD compressors. The position involves intensive interstate travel, as well as infrequent international travel for meetings, training, and equipment testing. Various tasks will occasionally be performed outside of normal working hours or on weekends. For more information, contact Paul Kozlov at p.kozlov@geoclima.com

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August 2017 | www.airah.org.au/nation | HVAC&R Nation | 29

The Lighter Side

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OOPTOP ROMP RWhat’s the collective noun for outdoor units? Spotted by Daniel, he says they were “sticking together to stay warm in the Tasmania winter”. n

JOB EThisXCAVATION unit was mounted under a deck up against a brick wall, with the deck floor hard up against the top of the unit and the pole hard up against the fan. “I had to dig the dirt up to get it out,” say Reece from Victoria. “It ran for seven years!” n

OUT HYes, ANGING the picture is the right way up. Sent in by Adam from NSW. n

HERE’S MY CONDENSER? W Gareth from Queensland spotted this gem on a recent holiday. Or did he? n

HAT THE DUCT? W Terry from Victoria was asked to repair or replace an air conditioning system. On arrival he found that the existing system was actually the cool room with over 40m of ductwork per fan. n

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30 | HVAC&R Nation | www.airah.org.au/nation | August 2017

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