HVAC&R Nation March 2017 by AIRAH

Skills WORKSHOP

An overview of water-cooled condensers

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March 2017

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A major mechanical services plant retrofit at the University of South Australia has improved thermal conditions and staff productivity, as well as delivered a significant decrease in energy consumption. Sean McGowan reports on this 2016 AIRAH Awards “Best HVAC&R Retrofit or Upgrade” finalist.

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HVAC&R Nation regulars 6

The Toolshed see what’s new in the ‘Shed

Skills Workshop 15

Water-cooled condensers

8 Global Update industry news from around the world

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.

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Coming soon: HFC phase-down Concerns about the increasing rate of HFC emissions and their impact on climate change has brought about a phase-down that will begin from January next year. HVAC&R Nation finds out how it will impact you and the wider industry.

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

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

➲ Editorial

HOT IN THE CITY

Unsurprisingly, peak energy loads across the country also hit record highs as the masses sought refuge in the form of ACs and fans. The sad reality is – consumers don’t really think too much about the environmental impact associated with HVAC&R use. And I’m sure a good chunk of the trade space doesn’t either. Recent research has found that 69 per cent of homeowners put more importance on the cost of running an AC, rather than its environmental impact. Furthermore, 63 per cent admit they do not feel guilty about energy usage while running their air conditioners. At AIRAH, we are about safe, sustainable, healthy, and effective environments, and HVAC&R obviously plays an integral role in that. So, we think it’s vital to ensure everyone involved is doing their part to spruik the importance of efficiency and emissions reduction. You can start by familiarising yourself with the imminent HFC phase-down, which will begin January next year. It will impact you and the wider industry, so get a low-down on the phase-down in our exclusive feature on page 10.

And just like that, we close the book on another record-breaking summer. Without a doubt the busiest time of year for the HVAC&R trade sector, I’m sure you’re all looking forward to the milder temperatures, perhaps a bit of time off, and of course – footy season. You’re not alone either, the summer of 2016/2017 was bloody hot. In Sydney, the warmest pair of nights ever recorded took place, with the minimum temperature dropping to a sticky 25.8˚C one night, followed by 26.2˚C the next. The city also matched its record tally of nine days over 35˚C, while the New South Wales town of Richmond smashed its record of days over 40˚C with eight – the previous record was six.

There’s also a wealth of AIRAH resources at your disposal – most notably, the HVAC Optimisation Guide (available free at www.airah.org.au/resources), our DA manuals, and Fairair.com.au. Energy efficiency is often passed off as something the guys in suits and lab coats need to worry about. It’s time for that perception to change, because the guys on the tools also have an important role to play. Look, no one’s asking you to become a tree hugger here, just a little more aware. A little goes a long way. Boon Mark Souphanh Editor

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

➲ Toolshed 01

A pipe-stopping dream

Ebm-papst has developed a patented membrane that is designed to protect electronic components in fans against corrosion that causes malfunctions, even in environments subject to frequent fluctuations in temperature and humidity.

Manufacturing a wide range of plugs and stoppers of up to two metres in diameter, Huntingdon Fusion Techniques HFT’s Pipestoppers Division has released an updated range. Pipe plugs and stoppers are in use for a large variety of applications. This includes leak testing, weld purging, debris stopping and pipe freezing for repair or maintenance work for thousands of different industries.

“Moisture can accumulate when temperature fluctuations occur frequently, for example in on/off operation, leading first to corrosion and then to failure of the electronics,” says the company. “ebm-papst has developed a housing with a special patented membrane to provide optimum moisture proofing for electronic components.”

The current range of products includes nylon plugs, aluminium plugs, steel plugs, and inflatable stoppers. Lighter in weight, the inflatable stoppers come in all shapes and sizes, including low-profile, cylindrical and spherical. They are designed for several applications, which include blocking pipes, tanks or other orifices, weld purging, routine maintenance, or to prevent the entry of foreign bodies.

This membrane aims to compensate for pressure fluctuations such as those resulting from rapid temperature changes. The housing is hermetically sealed, allowing it to withstand higher dynamic temperature changes from -40 °C to +70 °C. The electronics have a dustproof casing and are resistant to highpressure cleaners, complying with the requirements for IP69K.

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

Alfresco air

The company says the new membrane allows fans to keep the electronics at a steady low temperature and ensure reliable heat dissipation, minimising the risk of component failure and extending system service life.

Honeywell Evaporative Air Coolers has launched a new range of evaporative air coolers for alfresco cooling in large open areas, covered patios, and backyards.

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

Designed to be low cost and energy efficient, the units expel powerful airflow and are built with durable wheels.

The company says measurements can be done to a thermal sensitivity of 0.06°C, and users can make use of the free Testo Thermography App to wirelessly transmit readings from the Testo 770-3 clamp meter and the Testo 605i humidity measuring instrument (both available separately).

The units can also be used indoors, and the heavy-duty wheels allow for movement between settings. 03

“The Testo 872 thermal imager is ideally suited for professional industrial and building thermography – at the same time it ensures your work is both quick and easy,” says the company. “It is versatile to use, for example in industrial and mechanical maintenance, or for detecting structural defects. You can generate error-free and objectively comparable infrared images using its handy functions.”

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

Innovative imager

The 872 is the latest thermal imager from Testo, featuring an IR resolution of 320 x 240 pixels via integrated Testo SuperResolution Technology 640 x 480 pixels.

There are two different sizes and models – CL40PM and CL60PM – both of which can cool surrounding temperatures by 7–10˚C, according to Honeywell.

The models will be available across Australia and MSRP is $549 for the CL40PM and $699 for the CL60PM.

Membrane marvel

Carrier carries on

Part of the updated 2017 range, Carrier’s High Static Ducted (SDHV) and the Slimline Ducted (SHDS) series are designed to give consumers control of their indoor environment without the need to install individual indoor units on the wall. Allowing for minimal interference in architectural and room design, the Slimline Ducted (SHDS) system is designed for apartment, hotel, and office applications.

The Testo 872 thermal imager can be connected to mobile terminal devices via WLAN, while the Testo Thermography App for iOS and Android offers the possibility of writing and sending reports on site, as well as saving them online. Users can also use a smartphone or tablet as a second display or for remote control. For more information, go to www.testoaus.com.au n

On the other hand, the High Static Ducted units cover areas where flexibility is a priority by presenting extended duct connection. This lowers installation costs making it more suited to residential use.

Airefrig embraces App tech

Both the SHDS and SDHV series utilise a DC Inverter System technology, designed with sustainability in mind to achieve efficient use of energy.

The new CPS VG200W wireless vacuum gauge is now available at all Airefrig branches across Australia.

In addition, the new units come with a 5-year warranty and include other features like sleep mode, lock function for temperature stability, and set temperature range to cover suited to Australia’s weather.

The CPS Blackmax VG200W wireless is designed a provide precision digital readings with the added flexibility and features of the wireless app and inbuilt technology, which is free to download to any Apple or Android device.

“The engineers behind Carrier’s new Inverter Ducted Air Conditioners have once again proven their expertise by bringing to our market up-to-date products without the premium cost,” says Carrier’s business unit manager John Caione. For more information, go to www.carrierair.com.au n 6 | HVAC&R Nation | www.airah.org.au/nation | March 2017

The unit can be used as a standalone device, with live readings displayed on its LCD screen. It can also be linked to a handheld device such as a smart phone or tablet using the CPS VG Link app. Users can then set a target micron level and let the device alarm a phone or tablet when the vacuum level is reached.

Toolshed Airefrig general manager Stephen Cross says the wholesaler is dedicated to offering customers the latest in technology.

The AJ2 series is compatible with the pipe positions being either the same or within millimetres of the existing CAJ/TAJ series. The pipe diameters are identical and the overall compressor height has been reduced on most models. The electrical components are the same and included with the TE-Connect.

“We have had over a decade of success with the VG200 vacrometer and the additional wireless feature and app will take it to the next level,” says Cross. “It is a welcome addition to the CPS wireless app-based tool range.”

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

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

Get connected with AJ2

A split fit for all occasions

Haier says it has seen huge demand Hi-Wall Split systems over the summer period in Australia.

Tecumseh has announced the arrival of its new AJ2 compressor, which incorporates a patented electrical connection called TE-Connect.

The company’s Premier and Elite systems are designed to be super quiet, with increased airflow for and multi-layer filters. The filters are designed to remove impurities from the air for improved indoor air quality (IAQ).

The TE-Connect is pre-wired at the factory and incorporates a moulded plug that slides onto the electrical pins of the compressor. It includes a circlip on the earth connection, which is designed to ensure a good quality earth every time.

The Hi-Wall Split System has a special program designed to ensure temperatures don’t become too hot or cold at night.

“Field wiring errors will be virtually eliminated and the TE-Connect is suitable for use with flammable refrigerants allowing Tecumseh to offer flammable refrigerant ready models within the AJ2 range,” says the company. “Tecumseh redesigned the suction and discharge mufflers, and the compressor housing to lower the overall sound level. The valve plate design has been upgraded to further improve gas flow, increasing the compressor efficiency.”

There is also an auto-cleaning function, which the company says reduces bacteria and odours, as well the need to clean as often. Both Elite and Premier Hi Wall split systems are Wi-Fi compatible by purchasing a USB accessory Wi-Fi module. 08

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

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

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

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

➲ Global Update QATAR

SWITZERLAND

NEW-AGE HELMET BEATS HEAT

THERMAL STORAGE SOLUTION

The Doha News has reported that researchers at Qatar University are developing solar-powered hard hats that will cool the heads of construction workers working on 2022 soccer World Cup projects.

Swiss researchers say they’ve managed to developed a method of storing heat captured during summer for simple and effective use in winter.

The helmets will use solar-powered fans to blow air over cooling material. The cool air comes down over the front of the user’s face and provides a cooler micro-climate for the worker, according to engineering professor Dr. Saud Abdul-Aziz Abdul-Ghani. Abdul-Ghani suggested employers will recoup the extra costs of the helmets from "less lost time on site due to heat-related complaints”. Human rights groups and labour unions have put pressure on FIFA to get Qatar to improve the quality of working and living conditions, as well as worker rights. n

An added bonus, the captured energy can be physically transported anywhere it’s needed. The new system uses concentrated sodium hydroxide (NaOH) as the thermal storage medium, and a collection of largely off-the-shelf components to capture, convert, and release heat energy on demand. The system is the prototype stage and the research team are looking for commercial partners to assist in creating a compact version of the system for residential use. n

GERMANY

BAVARIAN LOW-GWP BOON Starting this year, the updated version of Germany’s refrigeration and air conditioning directive will subsidise the installation of refrigeration systems based on “non-halogenated and low-GWP refrigerants”. The subsidy scheme seeks to reduce the energy consumption of refrigeration and air conditioning systems and runs from January 2017 until January 2019. The amended directive extends funding to partial retrofits in addition to new system installations and full retrofits or replacements. Applicants can hope to be awarded a maximum of 150,000 EUR per installation (AU$213,000). n

CUSTOMS CAUTION The UK’s HM Customs & Revenue has warned that no HFC pre-charged air conditioners or refrigeration units can now be placed on the market unless accounted for within the F-gas quota system. From the start of this year, HVAC&R equipment charged with HFCs have become part of the HFC phase-down system implemented under the European F-gas regulations implemented in 2015. This means importers of equipment into Europe pre-charged with HFCs must ensure that the HFCs charged into the equipment are accounted for within the quota system when placing pre-charged equipment on the EU market. Companies are classified as importers if they import equipment from countries outside the EU. n

JAMAICA

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The Caribbean Development Bank (CDB) has hosted a study tour of Canada, with the intention of researching seawater air conditioning (SWAC) technology and how can help reduce electricity costs. In the Caribbean, air conditioning accounts for approximately 50 per cent of the total energy consumption in commercial buildings, including hotels, offices and commercial shopping enterprises. SWAC is estimated to reduce electricity consumption for air conditioning by up to 90 per cent. A SWAC system in the Caribbean could potentially draw cold seawater from a depth lower than 800m to a cooling station. This chilled water is then used to absorb heat from buildings and then returned to the ocean, usually at a shallower depth. Several buildings can be connected to the chilled freshwater loop, a process that replaces conventional air conditioning. n

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

NASA has conceptualised a building that could potentially house astronauts on Mars. Dubbed the “Mars Ice Home,” the structure relies on a protective coating of ice drawn from the surface of the planet. According to NASA, the low-tech building would both protect astronauts from Mars’ harmful cosmic radiation and be almost infinitely scalable. The dome has some major drawbacks, namely that it’d take more than a year to fill with ice. That being said, the principal investigator Kevin Kempton isn’t worried. “After months of travel in space, when you first arrive at Mars and your new home is ready for you to move in, it will be a great day,” says Kempton. n

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

➲ Feature

COMING SOON: HFC PHASE-DOWN

Bulk imports of HFC gas only The HFC phase-down applies to bulk imports of gas such as in cylinders, but does not apply to gas imported in pre-charged equipment such as air conditioners or refrigerators. Under the Montreal Protocol, gas contained in equipment is counted against the limit of the country where the equipment is manufactured. Equipment bans may be considered in the future to support the phase-down. In the past, Australia has banned the manufacture and import of equipment containing CFC and HCFC refrigerant after most manufacturers had moved to alternatives. Similar HFC equipment bans will be considered where alternative equipment is available but not being provided to the Australian market.

No one will be forced to replace their equipment The overall pace of the phase-down is designed to match demand and end-of-life equipment replacement. What is the HFC phase-down? And, what does it mean for Australia?

If adopted, any future equipment bans would only apply to new equipment being imported or manufactured, and not to equipment already installed in Australia.

The phase-down will take place over 18 years HFC refrigera nts have bec ome a main However, co stay of the H ncerns abou VAC&R indus t th e try. increasing ra their impact te of HFC emis on climate c sions and hange has b that will beg rought abou in from Janu t a phase-do ary next yea wn r. H V A how it will im C&R Nation finds out pact you an d the wider industry. In May last year, the Australian government decided on a range of measures to improve the efficiency and effectiveness of the Ozone Protection and Synthetic Greenhouse Gas Management (OPSGGM) program. One of the key measures is an 85 per cent phase-down of HFC (hydrofluorocarbon) imports, commencing on January 1, 2018, which will see this target reached by 2036.

“The phase-down recognises that there are some HFC uses where it will be difficult to develop alternatives,” says Edwards. “These include uses of HFCs such as in metered dose inhalers for asthma management.” So, what does the looming HFC phase-down mean for the HVAC&R industry and its members? Here’s what you need to know.

According to Bruce Edwards, the Assistant Secretary Assessments and Air Branch at the Department of the Environment and Energy, the phase-down is an effective way of reducing HFC emissions before they become a major emissions source.

HFCS AND HFC REFRIGERANT BLENDS ARE AFFECTED

“A phase-down is achievable, and can be done at a low cost to business and consumers,” he says.

The phase-down applies to the following commonly used HFCs and includes refrigerant blends containing these HFCs:

The phase-down will cap and gradually reduce HFC imports to 15 per cent by 2036. This is different to a phase-out, where the gradual reduction would end in a total ban on imports.

HFC23, HFC32, HFC41, HFC125, HFC134, HFC134a, HFC143, HFC143a, HFC152, HFC152a, HFC161, HFC227ea, HFC236cb, HFC236ea, HFC236fa, HFC245ca, HFC245fa, HFC365mfc and HFC43-10mee.

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

Australia’s HFC phase-down will begin in January 2018 and reach 85 per cent by December 2036. “It is happening over a long period to allow business and consumers time to adopt alternatives, avoid premature retirement of equipment, and so that there is a continued supply of HFCs to service equipment,” says Edwards. “This approach provides industry and consumers with investment certainty, and a long period to plan the required changes. The same approach has been used to phase out HCFCs.”

Australia’s phase-down of HFCs is consistent with action being taken internationally Australia’s phase-down, which was developed in consultation with Australian industry, is largely consistent with the Montreal Protocol agreement. “Australia’s phase-down starts one year earlier than the Montreal Protocol and has a lower starting point, which reflects current HFC use,” says Edwards. “It also has smaller and more frequent reductions, reflecting industry’s preference.”

Refrigerant prices should not be affected Edwards is confident refrigerant prices will not be affected when the phase-down begins next January.

Feature “The phase-down has been designed to match the reduction in demand as businesses and consumers convert to different technologies,” he says. “The availability of alternative refrigerants for existing HFC equipment will also help put a cap on prices.”

There are a number of potential replacements for HFCs Several refrigerants with no or very low GWP (global warming potential) are now available in Australia, which may be appropriate for use in the same applications as HFCs. These gases are not regulated under the OSGG Program and comprise of naturally occurring substances known as “natural” refrigerants, including ammonia, carbon dioxide and hydrocarbons, as well as manufactured substances (e.g., hydrofluoro-olefins or HFOs).

The HFC phase-down and other measures from the review of the OPSGGM program, including promotion of equipment maintenance, will reduce emissions by up to 80Mt CO2-e in the period to 2030.

“The phase-down does not mean instant change,” says Edwards.

“As well as significant environmental benefits, the phase-down will also bring long-term investment certainty for businesses throughout the supply chain and pave the way for the introduction of state-of-theart refrigeration and air conditioning equipment,” says Edwards. n

“Contractors and licensed technicians should become familiar with the phase-down and what it will mean for their customers, including learning about the alternative technologies coming online for various sectors.”

The phase-down will start on January 1, 2018 with an annual import limit of 8 megatonnes (Mt) CO2-e per year. Australian industry has agreed that this starting point is consistent with current use.

Phase-down steps The phase-down will have reductions at the start of each two-yearly quota period, aligned with licensing periods under the OPSGGM Act. These steps can be seen in the blue line in Figure 2 below. (Note: The schedule will be adjusted slightly as Australia’s limit is slightly above the Montreal Protocol limit in 2029–2031 and 2034–2035.

4.00

2040

2039

2038

2037

2036

2035

2034

2033

2032

2031

2030

2029

2028

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0.00

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The starting point

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2021

Key features of the phase-down are:

8.00

2020

The Department of the Environment and Energy will administer the HFC phase-down through the existing licensing scheme under the Ozone Protection and Synthetic Greenhouse Gas Management Act 1989 (OPSGGM Act).

Phase-down trajectory Imports without the phase-down

10.00

2019

KEY FEATURES OF THE PHASE-DOWN

Australia’s domestic HFC phase-down

12.00

2018

There will be no regulatory changes for technicians because HFC systems will continue to be installed, serviced and decommissioned for many years to come.

Become familiar with what the phasedown means for you and your customers

2017

There will be no regulatory changes for licensed technicians

The HFC phasedown will contribute significantly to Australia’s emissions reduction target

However, technicians will need to learn and be trained to work on alternative technologies so they can install and service this equipment into the future, and advise their customers of the options available.

2016

Some alternative gases can be flammable and some, such as ammonia, can be toxic. For some sectors with “hard to transition” technologies, it may be that use of HFCs continues – because it is an HFC phase-down, not an HFC phase-out.

In October 2016, 197 Parties to the Montreal Protocol agreed to gradually limit their production and use of HFCs at a meeting in Kigali, Rwanda.

MtCO2e

Natural refrigerants and HFOs may offer improved performance and energy efficiency in fit-for-purpose systems. In considering an alternative refrigerant, it is important that it be used in equipment that is fit for purpose and not used in equipment designed for a specific HFC; this could prove hazardous.

Year Figure 2: Australia’s domestic HFC phase-down compared to business-as-usual (BAU) projections.

The end point The end point of 1.607 Mt CO2-e will be reached on December 31, 2035, and will remain at 1.607 Mt CO2-e for each quota period from then on. This figure is based on the 15% of average HFC imports and 75% of HCFC imports for the period 2011–2013. This is the basis for calculations of a HFC phase-down under the Montreal Protocol. Source: With the assistance of the Department of the Environment and Energy

Need further information? More information on the HFC phase-down is available at www.environment.gov.au/protection/ozone March 2017 | www.airah.org.au/nation | HVAC&R Nation | 11

➲ Green wedge

THE SEARCH FOR GREEN Google’s data centres and the offices are now powered entirely by 100 per cent renewable energy, but it’s not done searching just yet.

The company’s biggest demand for energy is its data centres and it admits the overall thirst for power is growing, despite experiments to improve efficiency through AI. Having used 5.7 terawatt-hours of electricity in total last year, Google claims the figure equates to almost half of what San Francisco consumed over the same period. And now, it plans to ramp up its efforts and draw on renewables for every last unit of electricity needed for its global operations.

Google’s senior vice president for technical infrastructure Urs Hölzle says the company will broaden purchases to a variety of energy sources that can enable renewable power, every hour of every day. He says the ultimate goal is to create a world where everyone – not just Google – has access to clean energy. “The science tells us that tackling climate change is an urgent global priority,” says Hölzle. “We believe the private sector, in partnership with policy leaders, must take bold steps and that we can do so in a way that leads to growth and opportunity. And we have a responsibility to do so – to our users and the environment.” n

Google is “feeling lucky” when it comes to its renewable energy ambitions.

With a reputation for championing a greener approach, Google established itself as the world’s biggest corporate buyer of renewable electricity in 2016, buying 44 per cent of its power from wind and solar farms. Off the back of that landmark year, the internet giant claims it is now running on 100 per cent renewables – and isn’t ruling out investing in nuclear as part of its future. “We are convinced this is good for business, this is not about greenwashing,” says Google’s EU energy lead Marc Oman. “This is about locking in prices for us in the long term. Increasingly, renewable energy is the lowest cost option. Our founders are convinced climate change is a real, immediate threat, so we have to do our part.”

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12 | HVAC&R Nation | www.airah.org.au/nation | March 2017 HVAC HP Be Impressed 220X150 NoBleed v1.indd 1

19/10/2015 12:23 pm

AIRAH TRADE NIGHTS AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry’s latest innovations. Whether you’re looking for the latest technology to improve your business, or extending your networks, there will be plenty on offer. AIRAH Trade Nights are free to attend and open to everyone, but you must be registered to attend.

March 2

Port Macquarie

March 9

Hobart

March 16

Wagga Wagga

March 30

NSW

July 27

Central Sydney

August 8

Cairns

Qld

NSW

August 10

Mackay

Qld

Rockhampton

Qld

August 31

Wollongong

May 11

Melbourne

Vic

September 14

Ballarat

May 25

Perth

September 28

Canberra

June 1

Western Sydney

NSW

October 12

Shepparton

Vic

June 8

Darwin

October 19

Adelaide

July 20

Brisbane

Tas

NSW

NSW Vic ACT

Qld

Free entry –Doors open at 4pm Exhibitors with the latest HVAC&R products and innovations. Drinks, food and more.

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

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

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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

ING

Ax rem ial fans redu oval ge tw ced of th nerate within im by us e sw swirl Clau in th pelle ing irl im in th se e sa rs inde guid prov e di 2.6 es Som .6. me ca pende vane fan scharg the e ax effi sin s, g, knently see cie e airstr redu forw ial fan ow drive Clau ncy. eam confi ction ard an s are n as n in se 2.6 Sw irl an ge gura wh d re reve cont op .3, ca d th nera tio en ve rsi ra ro posit or by n be e in rse ble, n lly Ax inc the reve direc i.e. tatin e dire usin reas effi rse 2.6 tio th shutial fans g se ctio g ed cienc . In all ns, ey ca ns e .1. , se fans off can n of Pla e Cl y is low varia ten oper whi . 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Co of air ndensyste and th roug me velop ry A) e whe. A sig t th n, of liver quen s, w rate to ac 5. Ax . effi e th s no mpl bu sers) ms in ey ar h a size less n co nific e ce the mor cies hich mor hiev ial 1 Proj mpa ant ntrif sam e air gene can e no e moucienc e im ise an ex bl t only . Th HVAC e als parti and sp suct ectin ies pelle d ade ge ese o w tion red featur ugal e siz at ze rate be ise, ee nt &R Pe pe ne fa ea ion g on fro d. e id fa rfo ed an d to m resp rm fans d no r is m rformdesig rate ns ca and ely othee of ax n will and ro pr by sier sid e ect ance ca ise ount an ns ca low n m indu r ty ial fa de runn essure ve to in de n ha gene ed ce. Th n be pres ove strial pe 2 thMANUAL s of ns is lop g at APPLICATION APPLICATION MANUAL Alig e pl pend ve an rate in ca e de inco sure 2.6 fans their mor the ate. s on ad d by n gr sig rp s, se suct ned low e . In its .2. ion on whe justa thes eatly n of orat e er ed bl Tu th sid a m sim e aff re e the e pitc fans ect e be cate otor ples fan h im . Pla the 3 mov gory mou t form axia is m pe te Im nt Fans mer lle ou l pres e lar D). ed a sin suct se nted r. are sure ge The with gle ion d on • mad with s, se volu fans in a axial sid Im e e Fig mes (also cylin im de peller e up ure of air calle drica pelle cros signs – ce of thre 2.11. bu d du l fra r is di • s-fl ), axial ntrif em t on me, rect Ho ct ug ow ain ed ly ge (i.e -d de (fixe al (b co and using sig d an ac ne prop . instariven • ns kw mpo bo – vo rate ell by Mot ne are d pi ard, xes lu sm er fa llatio nt us tche fo ar tes, an or all ns) n d), rwar s: In its d ele – alt e used diffu ed. mixe d er sers, Ty im mos ctro natin . Th pica d-floand ra nica g as ey is adpeller t fu well l co w, dial are: lly curre 1. and 2 ‘fan ded rota ndam nfig co as ncy nt Ca prod urat prod unit’. the ting w enta mmut (AC) Efficie (i.e tegory uc ion 1 a ‘fa uct Whe combi ith or l form ated , dire . no 2. t ca Ca sin du A insta usag n pr the n th natio with a ‘fa (EC) ct cu gs mot rre ou tegory cting) llatio 3 used e w oduc combi e fan n is out n’ is tle 3. ors nt (D . m t’. ith m a ns un B in na t. and in ca ad or 1 in Fo are C) Ca tio it — sta a fa this the r sim n is is in e accu sing. e up Op us llatio ou tegory en n pr appl HVAC plici then stalle ra Whe of an ed. tle Th 4. ns inlet tely C in t. is ica ty od n d &R Ca — m se , type ct uc tion Fig sta or with ca a m and co an Op t. llatio ure ou tego man mm d in e ac in a lled otor eff s an ion en op Fans tlet. ry D pr Vo 2.1 ns inlet en ual, unity line w curate HVACa sto ect on d fan ovid lum 0: insta — ou a in ry Typi ca and ith Ty ly , es e m ac co Du tle is to syste ce n als the flo 3 llatio pica an co ca &R t cate anne rpor cted cal du 2 o in term mm lled look m pe ssor over l pe w rate cted ns ch are gorie r that ated inlet arac — clu ‘fa on rfor (q) at ho rfo ies, in view likely s (e. do into Du de n’ as teris and rm clu m cted Airfl a fa w a an an di of to g. ro es no prod tic op ce n un ow have of s of fan ce. 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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AIR CONDITIONING LOAD ESTIMATION

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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DA09

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.

CEN

DA08

DUCT WORK FOR AIR CONDITIONING

Coordination of condensate trays and drains with pump mounts and inertia bases is an important aspect to consider for chilled water pumps.

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.

UG TRIF

AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING E OTHE F RE FRIG ER AT ION, AIR CO NDIT IONI NG AN D

Pressure

1 0 DA Grouting the pump to a concrete foundation of suitable mass.

•

DA03

Modern equipment using laser alignment technology should be used where possible, especially for larger units. The advantages of high precision alignment include less noise and vibration, longer equipment life (bearings and drive components) and less energy wastage at the drive. Aligned pumps can be doweled to the base to prevent future misalignment.

9.4.6. Base mounted pumps

•

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:

APPLICATION MANUAL

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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

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THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

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AIR CONDITIONING WATER PIPING

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THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

APPLICATION MANUAL

DA19

HVAC&R

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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

DA21 AMMONIA REFRIGERATION

APPLICATION MANUAL

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APPLICATION MANUAL

ENANCE

Applica tion Man ual

HVAC&R

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DA19 DA21 DA24

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DA19

DA26

HVAC&R MAINTENANCE

APPLICATION MANUAL

d Du

•••

MAINT

Maintainab maintenancility of the system e strate and future • Locat gy, ion of and safe • Reliab Contractors le and appro access to the have a respo • Monit priate contro services, ongoing oring, meter nsibili maintenanc l system the future • Certifi ing and s, e requir ty to inform owne recording cation of ements rs of the with regardresponsibilities commission facilities, • Opera of system for the plant to that ting and and ing data maintenanc owners and result maintenanc and opera of • Detai Specific e. • repor s, led maint e inform requiremen tors t on the manuals ation for enance • Recom ts for opera maintenanc • are sched and system mendations ules and responsible ting e effect information the transfer instructions , iveness, of desig and maintenanc on maint for the plans and Designers constructio are required n , enance procedures periodic review to be met related HVAC&R e manageme n is unde maintenancare best positi . of maint regim if the buildi Successful nt. e. 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 . Tenants tem com ng mana ustainability ntenan design the const if furthe Correct al desig need The maint ger on r desig mission ruction features commission ce Con Tenant enance proce undertaken n, or modi ners or by subse of the buildithe energy optimum tractor ers maintenanc fit-outs contractor fication quent desig ss system ing of a system . ng system can HVAC&R to the origin e needs of in accor perfo is a succe contract. s. systems impact on system dance with to supply ssful maint rmance and essential for al desig ners Designers fit-out activi may commission performan n, is the THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING THE AUSTRALIAN OF REFRIGERATION, AIR CONDITIONING AND HEATING need some INSTITUTE the maint system enance THE AUSTRALIAN ties. 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. Buildi are also maintenancty on the system is now an explic on econo desig cover the ed ficatio ng mic ing data and logge owne designer laws as n data, it ed by the advantage. n can be any tenan for adequ e regime for complies well as to deter legislated BCA and made to r when it is • Any the ate acces with system d, non-compl building make the t/owner contractuaother laws, do the plant Contractors maintenanc s to that system plant and mine the not recog to building iance is may also l arrang to desig repor Tenan of I2, there e to be perfo plant to allow repor nise owne ement but Specific n have ting ts and ted and r respo rmed the requir generally addressed. indicators of ongoing sustaia responsibility imperatives occupiers need nsible for plant with would have been . 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. The AIRAH ting system information the transfer tool also to ensur manageme ts for comm ing HVAC maintainers Occupi of desig and maintenanc contains must issioning n relate under a nt. er Occupants e and opera &R services, e that the and comm particular d HVAC building be met if the buildi between The maint tors is facilit &R a design issioning rating or the system need to unde Periodic enance ated. and accreditationg constructio rstand the recommissio contr • Inspe administrati constructio n is system on system and the influe n regim ction, testin actors’ role can n is also requir ning of a system nce that correct operation e. 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

AMMONIA REFRIGERATION

ure

INDOOR AIR QUALITY

WATER SYSTEM BALANCING

THE AUSTRALIAN INSTITUTE OF REFRIGERATION, AIR CONDITIONING AND HEATING

DA27 BUILDING COMMISSIONING

APPLICATION MANUAL

2.4 Im plicat of inade ions mainten quate ance

••• 15

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

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

DA 13

AN OVERVIEW Skills OF WATER-COOLED Workshop (TYPE 2) CONDENSERS HVAC&R

MODULE

PULLOUT

PROUDLY SPONSORED BY

AIRAH has taken over responsibility for the Australian Refrigeration and Air-Conditioning (ARAC) Manuals Volumes 1 and 2, lauded since its original release in 1988 as the country’s primary resource for training the refrigeration and air conditioning industry. Authored by Graham Boyle, M.AIRAH, the ARAC Manual covers everything from the basic principles of refrigeration through to equipment, tools, principles, systems, testing, load estimating, installation, maintenance and commissioning. In this month’s Skills Workshop, we showcase an sample extract from the Manual – an overview of water-cooled condensers and their typical issues.

WATER‑COOLED (TYPE 2) CONDENSERS Water‑cooled condensers offer considerable advantages, particularly for large machines. These include more compact condensers and lower head pressures, with subsequent increase in unit capacity with lower power requirement. However, because of widespread shortages of fresh water around the world, few countries can afford to run water to waste, particularly at the rate demanded by large air‑conditioners. For example, one air‑conditioner of the size required by a large office building could use 160 000 litres of water per hour in summer. For this reason, all water‑cooled refrigeration and air‑conditioning systems must recirculate the water using cooling towers to cool the water by evaporation. Evaporative condensers also recirculate water and will be considered later.

Shell‑and‑coil condensers The shell condenser, or shell‑and‑coil condenser as it is commonly called, is a tank made of steel with copper tubes inserted in the shell. Water circulates through the tubing and condenses hot gases into a liquid. The bottom of the shell serves as the liquid receiver. The advantages of this style of construction are compactness of design, the elimination of fans and a separate condenser. A

A – refrigerant out B – refrigerant in

There are many varieties and sizes of water‑cooled condensers.

C – water in

Water‑cooled condensers owe their efficiency to the fact that:

D – water out

• water is usually cooler than summer air and this reduces the condensing unit’s head pressure for higher volumetric efficiency

• heat transfer from a metal to a liquid is up to 50 times faster than from a metal to air, so the same condenser surface area could conduct up to 30 000 kilojoules of heat per hour to moving water, compared with only 600 kilojoules per hour to moving air.

tailpipe

Water‑cooled condensers mainly use copper tubing to prevent corrosion and for maximum heat transfer and, on large units, integrally finned tubing is also used to advantage. Commercial water‑cooled condensers are of three basic types: • shell‑and‑coil

D B

• tube‑within‑a-tube, or double-tube • shell‑and‑tube multi‑pass.

Fig 3.18: A water‑cooled condenser which also serves as the liquid receiver.

March 2017 | www.airah.org.au/nation | HVAC&R Nation | 15

➲ HVAC&R Skills Worskhop refrigerant vapour in refrigerant

water out

water water in

condensed refrigerant out Fig 3.19: Double‑tube water‑cooled condenser.

NOTE

The increasing need to conserve fresh water means that it is now unusual to find a system that runs ‘fresh’ water to waste.

Also, it allows a very flexible type of assembly. Some companies produced this type of condenser with the difference that, instead of a coil of copper tubing being used for the water passages, the liquid receiver was given a double wall within which the cooling water circulated. This type may be used on small units with water running to waste, in which case it is operated in conjunction with a water valve that operates either from head pressure or water temperature, to regulate the flow of water to the requirements of the load and day temperatures. These valves are described later in this chapter (see Figure 3.27). However, most of these systems use remote cooling towers and have recirculated water pumped through them. Many such condensers can be connected to a single cooling tower, so such systems can still be economically viable.

This condenser may be constructed either in the cylindrical spiral style or in the rectangular style. Small condensers of this type may run water to waste and use water valves to regulate flow. However, these condensers are usually used in conjunction with a cooling tower and water is recirculated. The water enters the condenser at the point where the refrigerant leaves the condenser to go into the liquid receiver, and the water leaves the condenser at the point where the compressor is connected to it. This is called contra‑flow (or counter‑flow) construction. The warmest water is adjacent to the warmest refrigerant and the coolest water adjacent to the coolest refrigerant (see Figure 3.19).

Tube‑within‑a‑tube (double‑tube) condensers

As with air‑cooled condensers and evaporators, the flow of cooling water in water-cooled condensers should be in the opposite direction, or counter, to the refrigerant flow, to ensure that the coldest water comes in contact with the coldest refrigerant. This provides the greatest mean temperature differential and the highest rate of heat transfer.

The second type of water‑cooled condenser, which is very popular because it can easily be made to fit the size of the unit to be cooled, is the double‑tube type. One tube is put within another in such a way that water passing through the inside tube cools the refrigerant in the outside tubing. The outside tubing is also cooled by the air in the room, allowing very efficient operation.

Water‑cooled compressors are sometimes used with water‑cooled condensers. The water flow, with few exceptions, is through the condenser first, then through the cylinder head and finally out into the drain. The water flow through these condensers is regulated by means of an automatic water valve, similar to that used on the previous type.

These condensers are not normally used on plants exceeding 35kW of refrigeration capacity.

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Shell‑and‑tube condensers Shell‑and‑tube condensers are available in capacities ranging from 7kW of refrigeration up to 3500kW or more. Shell diameters range from approximately 100 mm up to two metres; tube length varies from approximately one to six metres. The number and the diameter of the tubes depend on the diameter of the shell. Tube diameters of 15mm to 50mm are common, while the number of tubes in the condenser varies from as few as six or eight to as many as one thousand or more. The end‑plates of the condenser are removable to permit mechanical cleaning of the water tubes.

Service problems with water‑cooled condensers Water corrosion Properly designed and sized condensers present very few problems from the refrigerant side. However, the cooling water and its accessories require regular maintenance and frequent replacement due to the corrosive nature of the supply waters with their dissolved salts and the effects of electrolytic corrosion between dissimilar metals. Water corrosion is a serious problem in Australia for two main reasons: • Water cannot be run to waste, but must mostly be recirculated, requiring the use of cooling towers which cool the condenser water by evaporation of some of the water. This leads to a concentration of the corrosive salts and scale‑producing carbonates.

HVAC&R Skills Worskhop water into tubes

refrigerant into shell

tube bundle inlet plenum

baffles water out

refrigerant out Fig 3.20 : Shell‑and‑tube condenser.

EDITION

ATION FRIGER NG LIAN RE DITIONI AUSTRAD AIR-CONNATIONAL RESOURCE AN

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MORE INFORMATION

Only shell‑and‑tube condensers can be physically cleaned and inspected, because the tubes can be scraped using rods with nylon brushes attached when the end shields are removed. Shell‑and‑coil and tube‑in‑tube condensers are cleaned by

It is claimed that the ‘scaling factor’ will be reduced from 0.001 to 0.0005, effectively increasing the condenser capacity by over 25 per cent. If successful, condenser capacity should remain constant and not suffer a slow decline between overhauls, as scale build‑up is eliminated.

Usually the evaporative condenser is mounted out of doors; however, it is possible to locate an evaporative condenser indoors by providing air ducts linking the condenser to the outside. n

HT UG O

TO YOU

GIVIN

Cleaning condensers

The latest shell‑and‑tube condensers have self‑cleaning brushes fitted into the tubes. Small nylon brushes in brass casings are fitted into each tube. When the plant is in normal operation, the brushes are at one end of the condenser tubes. At the end of each day’s operation, the direction of water flow through the condenser is reversed by a set of valves and the brushes move through the tubes to the other end, scraping off the day’s accumulation of scale. The flow is then reversed to normal and a second cleaning ‘pass’ results.

As with all parts of a refrigeration system, excessive heat is a major enemy. High condensing temperatures resulting from insufficient water flow, high water temperatures, air in the system and overloading all increase the rate at which scale forms on the surfaces of the condenser. Scale acts as an insulating blanket, reducing heat transfer and further raising temperatures. It sets rock hard and sometimes cannot be removed, even with physical scraping or raw acid dosing.

Self‑cleaning condensers

NCE 1920

Heat

Very often, shell‑and‑coil condensers are considered to be ‘throw away’ components, replaceable at less than the cost of repairs.

The water treatments recommended by chemical suppliers are usually potent corrosives themselves and designed to neutralise the water’s salts, to hold scale‑forming carbonates in suspension and prevent fungal and bacterial growth in the water. Unless checked daily or weekly, the balance can be lost and the water can become highly corrosive.

water is sprayed over the condenser to promote cooling of the refrigerant and air flows over the condenser to promote evaporation of the water and removal of heat energy. The water cycle is all in the condenser cabinet in this system. Longer refrigerant runs are usually needed to carry refrigerant to the evaporative condensers.

circulating an approved chemical through the water tubes.

• In some areas, an increasing use of underground water with higher concentrations of solids has made chemical treatment of the water much more costly and difficult to control as concentrations can vary from day to day.

PULLOUT

outlet plenum

D THE IN

This month’s Skills Workshop has been adapted from the Australian Refrigeration and Air-Conditioning (ARAC) Manual, Volume 1.

VOLUME

Evaporative (Type 3) condensers Evaporative condensers utilise both air and water to achieve heat rejection. The refrigerant flows into a condenser located in an enclosure;

For more information, go to www.airah.org.au/arac

Next month: Refrigerants Standards March 2017 | www.airah.org.au/nation | HVAC&R Nation | 17

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Visit commercial.daikin.com.au or call us on 1300 368 300

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

*Applies only to Standard Series models

Fly Guy

NOT YOUR CLASSIC KOMBI As part of its electric evolution, Volkswagen breathes new life into a famed oldie.

Paying homage to the famed Kombi 2, the I.D. Buzz minibus concept consists of a modular, convertible cabin, augmented reality HUD, removable dash and speakers, and laser-guided self-driving. The I.D. Buzz concept puts a modern twist on a familiar shape, with a more aerodynamic front profile and a cutting-edge converting interior that reflects VW's ambition to make this a unique multi-function vehicle. “In the year 2020, the Volkswagen brand will launch a major new electric vehicle initiative with a completely new vehicle architecture,” says Volkswagen CEO Dr Herbert Diess in regards to the I.D sub-brand. “Then we will bring a whole new generation of fully networked, fully electric vehicles onto the market. By 2025, we want to sell one million electric cars per year. We want to make electromobility the new trademark of Volkswagen.”

German carmaker Volkswagen has announced its plans to go “all in” on its production of electric vehicles (EVs) by 2020. And, perhaps fittingly, the company has chosen to give us a sneak peak of its electric future by resurrecting one of its icons.

Volkswagen says the back and middle seats of the I.D Buzz will be able to be folded down to take cargo, or to take up to six passengers. The gamechanger? The driver can choose to take the wheel, or let the car self-drive. When this function is initiated, the minivan’s front seats spin around to create a moving loungeroom experience. The main dash is a large, detachable touchscreen unit that sits on the front console. Passengers can

pass it around the car or take it out with them. The same can be done with the centre console, which also consists of the vehicles built-in speakers. This means the speakers are fully removable and can be used outside of the car – perfect for a day at the beach. Still very much in its concept stage, the I.D Buzz is yet to get a price tag. However, with the no-frills design of its predecessor a thing of the past, potential buyers can also expect a hefty hit to the back pocket. Interestingly, once heralded for its simplicity and low cost, the classic Kombi is arguably more sought-after than ever, with one 1960s model auctioned off for over $200,000 in 2015. n

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

➲ Cover feature Built in the 1930s, the physical and spatial constraints of UniSA’s Playford building provided numerous plant retrofit challenges. Credit: State Library of SA.

RETRO RETROFIT A major mec hanical servic es plant retro of South Au fit at the Univ stralia has im ersity p ro ved thermal productivity c onditions an , as well as d d staff elivered a sig consumptio n ifi c a n t decrease in n. Sean McG energy owan report s on this 201 “Best HVAC& 6 AIRAH Award R Retrofit or s Upgrade” fin alist. Named after the former premier of South Australia, the seven-level Playford building at the University of South Australia’s City East Campus in Adelaide was built in the 1930s. It adjoins the Bonython Jubilee building to its north via an elevated walkway over an access road. As well as student study spaces, the Playford and Bonython Jubilee buildings contain a number of research spaces, many of which are temperature critical. Both buildings operate around the clock, year round. In early 2012, the university’s engineering team recognised the need for the Playford building’s aging mechanical services plant to be replaced

in order to reduce energy consumption and maintain good internal conditions for staff and students. The Level 7 and Level 8 rooftop plant consisted of a 17-year-old air-cooled chiller, and a water-cooled reciprocating chiller that had originally been installed in 1976 and was at the end of its useful life. The system operated on a basic primary/secondary chilled-water (CHW) closed loop, with heating hot water (HHW) provided by two atmospheric boilers feeding a primary-only HHW closed loop. Designed by consulting engineers Aurecon with assistance from Air Con Serve – who provided BMS services to the University for over 30 years

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

– the new mechanical services design introduced some significant changes to both the building and campus. The major change was the creation of a new central thermal plant to serve both the Playford and Bonython Jubilee buildings, with the ability for future expansion. Facing spatial constraints on Level 7, a decision was made to utilise the former gymnasium space on Level 2 (a 16m x 7.5m room with 4.5m ceiling heights) to accommodate the new thermal plant. By relocating the plant to Level 2, it freed up space on Level 7 for the inclusion of two new draw-through cooling towers, with the option for a third in the future. According to Paul Jeffery, senior project manager for mechanical services contractor Westside Mechanical Contracting, very little of the original Level 7 plant was retained, aside from some distribution pipework. This included three HHW and four CHW supplyand-return risers feeding the various spaces within the Playford and Bonython Jubilee buildings. Of the existing Level 8 rooftop plant, an existing air-cooled chiller piped into a new common-coupled header was retained to provide redundancy until a third chiller is installed in the new Level 2 plantroom in the future.

Cover feature OVERCOMING CHALLENGES

External pipe installation.

The project presented a number of challenges not normally encountered in a typical mechanical services plant retrofit. This required quality design, collaborative management, and careful planning and execution to overcome. The primary challenge was the transformation of the Level 2 gymnasium space (with standard power and lighting) into a fully functioning thermal plant room with 800A capacity, and room for future expansion.

Due to both the physical and spatial constraints of the 80-year old building, CW and CHW pipework could not be installed internally from Level 2 to the cooling towers and secondary CHW headers on Level 7 and 8. Rather, pipework had to be run external to the building.

As well as needing to address concerns about complementing the retro design and age of the building, its besser block construction meant the flooded pipework – estimated to weigh between 7000kg and 8000kg – needed to be carefully attached. “This was overcome by prefabricating pipework as a rigid 4x pipe system made up of two condenser pipes and two chilled water pipes, transferring the bulk of the mechanical pipe weight to the ground via a purpose-built foundation, and fixing the structure to the wall with chemical anchoring,” says Jeffery. The entire prefabricated structure was lifted into place in 6m sections in one day, reducing installation time, scaffolding and the closure of the access road.

To maintain conditions in the buildings during the retrofit, the project was delivered in two stages. The first stage saw the CHW plant completed in November 2014, ahead of the warmer summer period in Adelaide. The HHW plant was delivered in a second stage in February 2015. Plant changeover was carefully planned and took place over the course of two weekends. Westside’s mechanical plumbing, BMS controls and electrical teams worked in rotating shifts beginning on Friday afternoon and ran non-stop to Sunday night to ensure all systems were operational on Monday morning. “We also chose this timeframe to modify the main electrical switchboard in view of future works,” says Jeffery.

CW and CHW pipework could not be installed internally, thus external pipework lines the building.

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

➲ Cover feature CENTRAL PLANT The new central chilled-water plant consists of two 620kW centrifugal chillers – one two-pass unit and one three-pass unit with turn-down capabilities of 10 per cent. The inclusion of the lower percentage of turn-down on this chiller was initiated by Westside and Air Con Serve. It was based on the facility’s historical low-load conditions and the separation distance between the primary chilled-water plant and the secondary distribution. The two new draw-through cooling towers have been coupled with an oversized balance line and only motorised isolation valves on the tower inlets. This allows optimisation of the installed heat rejection capacity and matching of the minimum tower nozzle flows to condenser water flow rate.

The gymnasium, pre-fitout.

The new heating water plant consists of two condensing boilers of 539kW each. Variable speed drives (VSDs) were also installed on all primary, secondary and condensing pumps for variable flow control to suit demand and improve motor efficiency. Each pump has also been fitted with motorised isolation valves. “No check valves have been installed, as they would impose additional system pressure losses and can be prone to failure in variable pumping applications,” says Jeffery. As the existing plant suffered from poor water distribution (causing flow issues to air handling equipment), the pumping configuration was changed to provide a more effective distribution network. The four main distribution networks were isolated into their own dedicated secondary pumps to maintain the appropriate differential pressures to each system. Both CHW and HHW systems were installed with low-loss common-coupled headers to provide

low system-pressure drop and reliable hydraulic operation through the range of system demands. All CHW headers were fabricated with additional inlets and outlets to cater for future plant expansion. The external condenser and CHW pipework was also engineered to accommodate the greater capacity required once the additional chiller and cooling tower are installed. Magnetic flow measurement devices were installed for each primary and secondary pump circuit, and in the decoupling line in each header to ensure optimal efficiency in the balance between the secondary field demand and primary flows. The variable primary/variable secondary configuration has allowed the plant to respond rapidly to the changes in the system load, common in university settings.

“The primary/secondary arrangement allowed for rapid implementation of the system and the flexibility to provide effective tuning of the systems during full building occupancy,” says Jeffery. “Robust system stability allows for maintenance operations to be undertaken of system components without adversely affecting the delivery of thermal capacity to the load.”

CAREFUL CONTROL Working closely with the university, Aurecon, and Westside, Air Con Serve’s engineer and project manager Mark Wood played a key role in ensuring the new system met the design goals and achieved the best possible outcomes for the university. He says a major challenge was maintaining all existing controls systems while the new plant and equipment was integrated.

Thermal plant equipment was installed in three separated plant locations.

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Cover feature This was complicated by the existence of three generations of BMS control systems servicing the building.

REAL-LIFE PERFORMANCE

“The new thermal plant equipment was installed in three geographically separated plant locations throughout the building over four mechanical switchboards,” Wood says. “This meant that different sections of the BMS network needed to be operational to suit the staging of the installation works.”

Since reaching practical completion in early 2015, the performance of the new central thermal plant has exceeded all expectations.

A new BMS network dedicated to the new thermal plant on the most current BMS technology was designed, allowing Air Con Serve to preconfigure the new network without compromising any existing equipment controls. As new equipment was brought online, it was commissioned on the new BMS thermal network and redundant equipment was progressively decommissioned. “The main changeover of the chilled-water system occurred without any issues,” says Wood. “It was well organised. The control systems were preconfigured and tested, and probably most importantly, the hydraulic design of the primary/secondary distribution system was well thought-out, simple, and executed perfectly.” “The water went where it was supposed to, which meant the system was not reliant on the controls to make it hydraulically work. This also allowed the controls to be used to optimise the performance of the system.”

A significant decrease in energy consumption has delivered savings in excess of $10,000 per month during the summer months, and the new plant has provided a reliable and stable supply of chilled and heating water to the facility. Wood says the primary/secondary configuration has been simple to operate and service. It allows technicians to easily isolate chillers and boilers for service and maintenance without compromising conditions.

Increased productivity of staff and improved learning conditions for students have also resulted, with the University of South Australia undertaking their own internal study into staff productivity. n

PROJECT AT A GLANCE THE EQUIPMENT BMS: Air Con Serve Chillers: Powerpax Cooling towers: BAC Condensing boilers: Rendamax Controls: Niagara AX

“Isolating the four main distribution networks into their own dedicated secondary pumps to maintain appropriate differential pressures to each system, has resulted in significantly improved water-flow delivery and a reduction in noise-related complaints from previously over-pressurised valve trains,” he says.

Fans: Fantech

“The system can run in stable operation down to as low as 5 per cent of one chiller with very minimal pumping and cooling tower fan power, which is perfect for a university application.”

Client: University of South Australia (UniSA)

Improvements in thermal conditions within the occupied spaces of the buildings have also been realised, while a reduction in temperature-related complaints has been experienced.

Mechanical services contractor: Westside Mechanical Contracting

Pumps: BKB Grundfos VSDs: Danfoss

THE PEOPLE Controls: Air Con Serve Electrical contractor: AC Electrical Mechanical services consultant: Aurecon

Future-proofing refrigeration Refrigeration 2017 Conference

AIRAH’s Refrigeration 2017 Conference will be held March 27–28 in Melbourne. Held at a pivotal moment for the industry, the conference will explore the state of the industry, how it may respond to the future challenges initiated by COP 21 and the global HFC phase-down, and how this will impact upon educators, legislators, regulators, end users, engineers, consultants and technicians. If you work in refrigeration, you cannot afford to miss the Refrigeration 2017 Conference.

For more information, go to www.airah.org.au/conferences

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

➲ Around the nation 2

HOMEOWNERS PREFER COOL OVER CLEAN

A recent ServiceSeeking.com.au survey has found that 69 per cent of homeowners admit the cost of running their air conditioners weighs more heavily on their mind than the impacts extra energy usage will have on the environment. Despite being more educated on the impacts we have on the environment, 63 per cent admitted to not feeling guilty about running their air conditioner to cool down in summer. “It’s a fine line at times – juggling your own comfort and the well-being of the environment,” says Serviceseeking. com.au CEO Jeremy Levitt. “But most people are prepared to use the advantages of modern technology to escape a stifling Aussie summer by flicking a switch to cool down in comfort. And particularly for the very young and the ageing generation, it is important to keep out of the intense heat when the mercury really starts to rise for health and safety reasons.” Statistics were gathered from a survey of more than 2,800 ServiceSeeking.com.au clients. n

MARKETING MANAGER MOVEMENT

AIRAH company member Fujitsu General has it expanded its sales and marketing team with two new appointments. Edward Jackson joins Fujitsu General in the newly created position of national retail sales manager, while Katherine Bond has been appointed as brand manager – trade marketing. “We are delighted to finish 2016 with two new appointments to the sales and marketing team,” says general manager - sales and marketing Dave Smith. “With an extensive background in channel sales and enterprise marketing, we are confident Ed and Katherine will deliver significant value to the

business as Fujitsu General continues to grow its presence in the retail, commercial and dealer markets.”

Coast University Hospital, leading to $30,000 worth of drugs being destroyed.

Jackson brings more than 16 years’ experience in consumer electronics and appliances to the new sales team role. Most recently he held the position of national accounts manager – retail for Smeg Australia.

Sunshine Coast Hospital and Health Service CEO Kevin Hegarty says air conditioning systems at the hospital were being continually tested, with the hospital scheduled to take its first patients in April.

In her new role, Bond will be responsible for managing all trade marketing activities. Prior to joining Fujitsu General, she held a number of roles within the marketing department at Fuji Xerox Australia. n

"The sheer size and complexity of the hospital – a surface area equal to around 100 football fields – means it takes time to regulate the temperature balance of the facility," says Hegarty. "Technicians are continually testing and improving the ventilation until it is satisfactory. We are undertaking commissioning to ensure the hospital is safe and ready for patients when it opens."

TRAFALGAR HONOURS 30-YEAR VET

Having been with Trafalgar for nearly 30 years, much-loved employee Jan Nowoczynski will embark on the next stage of his life – retirement. Jan began work at Trafalgar on June 30, 1989 in Revesby, making first-aid kits, fire extinguisher, fire-hose reel, and dangerous goods cabinets. However, he has proven himself as a jack-of-all-trades over the years, doing work such as creating brass access panels for Parliament House, in addition to his work on Trafalgar’s cabinet range. “Jan has been an outstanding employee,” Trafalgar’s production manager Anthony Hill. “His contributions to Trafalgar have been exemplary and we will be sad to see him go. The knowledge he has passed on to our apprentices and the next generation at Trafalgar will be appreciated for many years to come.” Jan’s partying days are not over just yet – Trafalgar workers say you will find him at the local pub enjoying a cold “bevvy” on a hot afternoon, as he escapes his wife’s suggestion of gardening as a new hobby in his retirement. n

FAULTY A/C DESTROYS HOSPITAL DRUGS

A heatwave on the Sunshine Coast has contributed to an air conditioning failure at the new Sunshine

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

A supply of medicine with a long shelf life had been installed, but had to be removed after the storage area they were in was found to be too warm. "Temperature variance in certain parts of the hospital during this testing period has impacted some initial medicine stocks, which have since been removed from the facility, and will be replaced before the hospital opens," says Hegarty Hegarty also revealed that there would be no cost to taxpayers from this loss, as the incident would be covered by insurance. n

LEGIONNAIRES' SCARE IN SA

Hundreds of air conditioning units across buildings in Adelaide's CBD and inner-city suburbs were assessed after a spate of Legionnaires' Disease cases in January. SA Health's acting chief public health officer Dr Ken Buckett says the disease was contracted by breathing in bacteria, which may have been released from air conditioning cooling towers. "We think it may have something to do with the strange weather we've been having," says Buckett. "It's going from very hot to pretty mild, which means that air conditioners are being put under a heavy load, and then stopping again. The bacterium that causes

Around the nation 5

the illness lives in a biofilm on the inside of pipes and when water flows through, cooling flows through, they can sometimes be dislodged."

The purchase aims to complement ENGIE Services’ strategic direction of providing multi-technical services, projects and solutions.

All cases were in the inner-metropolitan CBD and near suburbs, but no common location. n

“This is another positive step for ENGIE Services as we continue to seek growth opportunities in Australia and New Zealand, while leveraging the ENGIE Group’s global presence and expertise to meet the needs of our customers,” says ENGIE Services CEO Corinne Ong. “WAMS has an outstanding reputation for quality and delivery in its markets, and will benefit from drawing on ENGIE’s extensive expertise, both through our Australian and New Zealand business and the Group’s global platform.”

SOLAR HEATING PROVIDES HEALTH BENEFITS

A construction professor from Massey University in New Zealand has been presented with a prestigious industry award for a solar heating project in Kiwi schools. Professor Robyn Phipps was awarded in the James Hardie Innovation category at the 2016 New Zealand Institute of Building Awards for the project, which looked at improving health and indoor climate in a low-decile classroom with a low-cost solar ventilation unit. Professor Phipps’ research team installed roof-mounted Solarventi solar air-heater panels to heat fresh air and ventilate 12 classrooms in Palmerston North, New Zealand. Results revealed that classrooms with roof-mounted solar ventilation units used less conventional heaters than adjacent classrooms, reducing the cost of heating by more than double. “As schools’ operating hours coincide with peak daylight hours needed for solar heating, it is common sense to use free solar energy for heating the air,” says Phipps. “However, this is a novel concept in most countries.” n

ENGIE LOOKS WEST

ENGIE Services has announced its acquisition of HVAC&R business West Australian Mechanical Services (WAMS).

While WAMS will continue to trade under its current branding, its 80-plus staff will join the ENGIE Services business, which now employs about 1,100 people in more than 25 locations across Australia and New Zealand. n

ARC ISSUES TIMELY LICENCE REMINDER

The Australian Refrigeration Council (ARC) has communicated with all restricted “split system installation” licence holders Australia-wide to remind them of the limitations of the entitlements of their licence – the work they can and can’t do. ARC says it is critical that restricted heat pump, split systems – installation and decommissioning licence holders do not work beyond the scope of works permitted on the restricted licence as they are not competent to do so. “The ARCTick licence scheme is a qualifications-based scheme. That’s how licence holders prove their competency to perform services to the ARC,” says ARC CEO Glenn Evans. “A person with a ‘split system installation’ licence has provided a Certificate II level qualification and the Ozone regulations state this is the requirement to demonstrate their abilities to perform installations of split systems up to 18Kw. They have not demonstrated their ability to perform repairs, servicing or maintenance. That’s the domain of Certificate III level licence holders – and rightly so.”

It is an offence to handle refrigeration and air conditioning equipment without an appropriate refrigerant handling licence and a penalty of up to $1,800 may apply. Working outside the scope of a licence could also result in the cancellation or suspension of a licence. “Summer is the business-end of the year for our sector so let’s make it a safe, legal and prosperous one for industry and consumers alike,” says Evans. n

HYDROCHEM’S NEW HUB

After two years of planning, Hydrochem has moved to a new factory just minutes away from its old location in Cheltenham, Melbourne. “Our processes and equipment at Viking Court (the old address) had experienced the same organic growth as our real estate,” says CEO Nick Duncan, M.AIRAH. “It was time for a major overhaul, a modernisation if you will, and it became clear early on that this presented significant hurdles.” Located in the suburb of Braeside, the new facility makes use of two separate warehouse structures, which were knocked through to produce a 4,000 m2 manufacturing and storage space under one roof. The new factory incorporates state-of-the-art technologies, including robotic equipment and processes that are designed to significantly reduce the inherent risks when mixing, packing and transporting chemicals. The factory also includes a new Toyota Automatic Guided Vehicle (AGV) driverless forklift – believed to be the first deployed in Australia. The forklift contains unique autopilot technology that allows for driverless operation. Complex programming and factory-wide laser reflectors enable the AGV to safely pick, measure, and mix chemicals without a human hand ever touching the process. n

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

➲ AIRAH Q&A

BRIDGING THE GAP

Part one

Portfolio manager at Perth’s South Metropolitan TAFE in Perth, Graham Boyle, M.AIRAH, has nearly 50 years in the industry under his belt, including 36 years in the training system. Amid the much-talked-about skills shortage plaguing the industry, HVAC&R Nation caught up with the industry veteran to pick his brain on the heated debate. HVAC&R Nation: We often hear that employers struggle to attract and retain suitable employees. Why do you think this is the case?

technicians. This issue is as old as the apprenticeship system. Apprentices are trained through a mix of “on the job” and “off the job” training. Although the apprenticeship contract has a time allocated to it – around four years – we are supposed to be in a “competency-based training system”, so time served can vary.

Graham Boyle: There are several possible reasons for this. The obvious ones are pay and conditions, which can also lead to issues such as working hours, the type of work, the flexibility of the workplace, and the availability of promotion and further training.

This is understandable as the people coming into apprenticeships come with a range of skills and experience, and a variety of ages. I had one student who had already completed an electrical apprenticeship and a Certificate IV in Instrumentation, and was adding R&AC to his CV. Obviously, someone that is so highly skilled is not going to need a further four years of training.

If there is a shortage of skilled technicians, and training is based on an apprenticeship system, then surely either there are not enough apprentices trained – or if there are enough trained, then as an industry we are not doing enough to retain them. Either way, the shortage sits at the door of the industry that doesn’t employ enough apprentices or give them the career pathways and incentives to stay.

HVAC&R Nation: What do you suggest we do to alleviate this? GB: Maybe we need to look at alternative methods for training future technicians. The apprenticeship system has been around longer than modern Australia. However, for obvious reasons, new apprenticeship numbers reduce when the economy is sluggish. And due to the time required to train an apprentice, that reduction in numbers stays with us for years. There is an argument that many of the candidates for apprenticeships are unsuitable either through literacy and numeracy issues, or because of a lack of understanding of the requirements and demands of the industry. I was stunned to realise that some states don’t offer pre-apprenticeship courses in refrigeration and air conditioning. These courses are an ideal way to allow prospective technicians to “test the water”, complete some applicable TAFE training, and experience some formal work experience with HVAC&R employers. In Western Australia, many employers recruit from the work experience candidates, and some of the pre-apprentices find that the industry is not for them and go seek other opportunities.

HVAC&R Nation: A common criticism of our industry is that it is a largely hidden one. How much of an issue is the visibility of the industry? GB: There may be an issue with the visibility of the industry and I believe there is an argument for taking an industry-wide approach to promotion of careers in HVAC&R. However, there is also an issue with recruitment. Not many of our employers are professional recruiters.

Graham Boyle, M.AIRAH

For example, in the days before government departments started to outsource many of their functions, a lot of our best apprentices came through government. This was because the training and job were valued, there was a career path, and the apprentices were professionally selected.

In Australia, we have a national competency-based training system, but that doesn’t guarantee that graduates will all have the same skills. Much will depend on this diverse industry that they trained in. Some may have worked in supermarket refrigeration or transport refrigeration, industrial refrigeration, commercial or domestic air conditioning – it would be uncommon for new graduates to have gained experience in all these areas. So, depending upon the requirements of the new position, their skills and experience may be lacking. You can read part two of our Q&A with Graham Boyle, M.AIRAH in the April issue of HVAC&R Nation. n

Perhaps an ideal solution would be a selection pool of suitable candidates – some form of “group scheme” to select and place prospective apprentices. Dual-trade options already exist but generally in the form of completing one apprenticeship after another. In my experience, because of the politics involved, this works better for an electrician dual training into HVAC&R with appropriate Recognition of Prior Learning (RPL) for the skills gained in electrical. Generally, the skills recognition is not reciprocated in any realistic way for a qualified HVAC&R technician gaining credit into an electrical apprenticeship with the general rule of one semester of credit in a four-year apprenticeship – this is my understanding having discussed this with many HVAC&R technicians.

HVAC&R Nation: Do you think qualified technicians are getting the right training? GB: In the recent “Mind the Gap” feature in last October’s HVAC&R Nation, there was a noticeable concern expressed about the skills of qualified

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

This interview is a response to the cover feature of HVAC&R Nation, October 2016. You can read that article, plus many more at www.airah.org.au/nation

Smoko with . . .

Name: Mick Drage Company : Oldmate ACT

rcial refrigeration mechanic. Occupation: Head comme The food industry. industry do you work in? &R AC HV the of t par at Wh &R industry? ut working in the HVAC What's the bes t thing abo ving. The challenge of problem sol rs. d in the industry? 30 yea How long have you worke . Favourite tool? Apprentice HVAC &R industry, If you didn't work in the uld be doing? Rock star. wo what do you think you The Lighter Side. tion of HVAC &R Nation? What's your favourite sec Dream car? V12 Jaguar. Dream date? Halle Berry.

Boat rock 'n' roll festival. Dream Holiday? Rock the 43. Drink: Bundy Red or Licor by Keith Urban. Las t song: “Wasted Time” in.” Favourite saying: “Ya jok onion sandwich. Toasted ham, cheese and Favourite smoko snack: ge. Sporting Hero: Luke Hod years. Fishing with my wife of 30 When not working I’m …

March 2017 | www.airah.org.au/nation | HVAC&R Nation | 27

➲ AIRAH News

MOVEMENT UP TOP Following a special meeting of AIRAH’s board, Ian Harwood, M.AIRAH, has been elected to the prestigious position of President. He replaces Ania Hampton, M.AIRAH, who has stepped aside from the position due to ill health. An AIRAH board director for the past two years, Perth-based Harwood has been an AIRAH member for more than a decade. He previously served as President of AIRAH’s WA division committee, helping to re-energise its monthly seminar program and to grow its membership. AIRAH CEO Tony Gleeson, M.AIRAH, says Harwood’s director experience and knowledge of the industry will serve the 97-year-old Institute very well. “Having worked with Ian over the past 12 months, I’ve seen the passion, experience and strategic nous he brings to the board,” Gleeson says. “I have no doubt his energy, ideas and oversight will serve him and AIRAH well as he assumes this essential role.” The first female president in AIRAH’s storied history, Hampton has reluctantly left the post. Recently

diagnosed with Ross River Fever, she has stepped aside from all her official Institute duties in order to recover as quickly as possible. “AIRAH owes Ania a debt of gratitude for her commitment, competence and enthusiasm she brought to the role, especially in the sponsorship of the new website and membership platform, and the introduction of the Women of AIRAH initiative,” Gleeson says. “The timing of her illness is really unfortunate, and we all wish her the best in her return to health.” Boasting 22 years’ experience in the building services industry, including time spent working abroad, Harwood is an Associate Director with Norman Disney & Young, based in NDY’s Perth office.

Ian Harwood, M.AIRAH

With an avid interest in the technical side of the industry, he has also been active in the design and management of high-profile projects. “Change is the status quo, and the landscape is very different today to what it was even five years ago” Harwood says. “Assisting our industry adapt to and embrace this is a continuing challenge, but one that AIRAH is well prepared to address.” n For more AIRAH news, go to www.airah.org.au

Advertise in HVAC&R Nation in 2017

Contact: Glenn or John 03 8623 3000 28 | HVAC&R Nation | www.airah.org.au/nation | March 2017

AIRAH and industry classifieds EVENTS Port Macquarie Trade Night

Tasmania Golf Day

Refrigeration 2017 Conference

The AIRAH Tasmania division invites members and guests to its annual Golf Day – the Bob Lewer Memorial.

The Refrigeration 2017 Conference will look at the current state of the industry, how it may respond to the future challenges initiated by COP 21 and the global HFC phase-down.

Date: Friday, March 10.

AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations.

Time: Registration and briefing at 11am, tee-off at 11.30am. A barbecue dinner, refreshments and prize presentation will be held in the function room at approximately 5pm.

Date: Thursday, March 2 Time: 4.00pm–7.00pm Venue: Rydges, 1 Hay Street Cost: Free

Venue: Claremont Golf Club, 1 Bourneville Crescent, Claremont.

Hobart Trade Night AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations.

Time: 4.00pm–7.00pm Venue: Etihad Stadium, Gate 6, Level D, Melbourne Cost: Free

Rockhampton Trade Night

Wagga Wagga Trade Night AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations.

Date: Thursday, March 9 Time: 4.00pm–7.00pm Venue: Wrest Point Casino, 410 Sandy Bay Rd Cost: Free

Date: Monday and Tuesday, March 27–28

AIRAH Trade Nights are a great opportunity to broaden your networks and see the HVAC&R industry's latest innovations. Date: Thursday, March 30 Time: 4.00pm–7.00pm Venue: Rockhampton Leagues Club, Cambridge Street

Date: Thursday, March 16 Time: 4.00pm–7.00pm

WA Golf Day

Venue: Rules Club, Corner Fernleigh and Glenfield Roads

The AIRAH Western Australia division invites members and guests to its annual Golf Day.

Cost: Free

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SA – Refrigeration Standards Update

Send in your submissions, text only – no images or logos. Send your submissions to: boon@airah.org.au or c/o AIRAH, Level 3, 1 Elizabeth St, Melbourne Vic 3000.

HVAC Hygiene ES

Date: Wednesday, March 1 Time: 7.30am Venue: Quality Hotel Ambassador, 196 Adelaide Terrace, Perth Cost: $165 for members, $220 for non-members.

HVAC&R Nation is offering a free industry classified service!

Classified Ads

IN ID EL

AIRAH and Standards Australia are pleased to present a seminar series on the recently adopted and published refrigeration safety and environmental standards.

Whether you are looking, selling, trading or tendering – HVAC&R Nation classifieds is the best way to spread the word!

FREE

Venue: Maylands Peninsula Golf Course, Swanbank Road, Maylands WA.

WA – Refrigeration Standards Update

Date: Thursday, March 2 Time: 7.30am Venue: The Hackney Hotel & Function Centre, 95 Hackney Road, Hackney Cost: $165 for members, $220 for non-members.

Date: Thursday, March 9. Time: Registration and briefing at 12 noon, tee-off at 1pm. A barbecue dinner, refreshments and prize presentation will be held in the function room at approximately 5pm.

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AIRAH’s HVAC Hygiene Best Practice Guidelines is available to purchase in hard copy. n Establishes the criteria for evaluating the internal cleanliness of HVAC system components n Clearly determines when cleaning is required, according to the building use n Describes the components of HVAC systems to be evaluated n Describes the types of contamination likely to be encountered and includes for post fire and flood damage assessments

n Specifies minimum inspection frequencies for various HVAC systems and components for scheduled maintenance programs

Purchase online at www.airah.org.au/store March 2017 | www.airah.org.au/nation | HVAC&R Nation | 29

➲ The Lighter Side RALIA

This month’s Lighter Side is brought to you by DA19.

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Equipment Air conditionin ) life of equipm g unit – Room ent type Air conditionin g unit – Split Economic units (up to life (years) Air conditionin 10 kW) g unit – Package (10 kW – 100 Air conditionin 7 – 10 kW) g unit – Split ountered package (10 commonly enc Air handling 7 – 10 kW – 100 ns are a problem g out unit – Proprietary kW) rs when carryin lineAccess limitatio Air handling central station service provide intenance 10 – 15 unit – Custom g buildings. Ma esbuilt by maintenance single or multiple tivities in existin 10 – 15 Air filters procedur central zone shooting maintenance ac e in two forms: station – Dry media itored 7.5.1. Trouble disposable access limitations generally com tain 20 – 25 Airmplaint or mon dequately main an occupant co filters – HEPA hould e provided to a In the event of nce the cause s 20 – 30 Air 1. Insufficient spacuipment. ystem performafilters – Kitchen ms of unsatisfactory s ted that symptohood rovide the installed eq grease filters . It should be no e and a s/occupiers to p 0.5 – 1.5 Automatic be investigated r to be the caus ability of tenant controls and ay at first appea ired. 2. Reluctance or in instrument the problem m stigation is requ Boilers 2–5 ation access to the plant. – Fire tube oach to the inve systematic appr intenance e Boilers steps should b resolved for ma 3–6 – sues need to be ace ch the following Water tube Both of these is re insufficient sp As a first approa Boilers – Cast t correctly. Whe vider 20 – 25 iron to be carried ou ance service pro undertaken: by the mainten rs and 15 – 20 Boilers – Finned ing is encountered e system owne ing user regard ighlighted to th er to find laint. copper tube heat exchanger 1. Talk to the buildure of the comp this should be h to work togeth 25 Boilers – Electrode arties then need ble the – 30 the specific nat area. managers. All p ce access to ena 25 – 30 Chilled beams ccupants of the rove maintenan ailable.

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www.airah.org.au/damanuals

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You can check out the full suite of AIRAH DA Manuals at

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Table 2.1

Centrifug rol in and arou DA01 Cont itioning Application Manual Noise for air cond ENANCE DA02 s HVAC&R MAINT Duct work introduction an hrometric recovery DA03 te HVAC&R ation and psyc rational. t to remain ope DA08 condensa r the equipmen Load Estim ibution and • Priority given fo tion profile. DA09 ication – distr • Seasonal opera n ent tolerance Steam and appl exibility a time 7.1.6. Equipm applicatio racticality and fl with DA11 ed selec tion t in accordance For reasons of p d. Recommend tion and t and equipmen Fans – ould be specifie nce ing for frequency sh • Maintain all plan of the operating and maintena .1. DA13 rs – selec et out in Table 7 the instructions condition tolerances are s air Air Filte for 5 nance manual. service frequencies DA1 entative mainte Piping tolerance for ufacturer’s prev Table 7.1 Time Water • Follow the man ns for all plant and equipment DA16 Towers time recommendatio Tolerance on t of the system. Cooling t at least provided as par 7 scheduled locks regularly, schedule DA1 ntrols and inter on if the Treatmen nce Frequency of • Test all safety cot the commencement of a seas Water re once a year or a nal. Maintena Omit for no mo DA18 itioning nt is only seaso ture plant requireme than one week HVAC&R air cond re and tempera Weekly tion of all pressu DA19 Tropical • Have the calibra at least once a year. re tion Humid Omit for no mo tion. gauges checked noise and vibra Refrigera DA20 than two weeks ment for undue Fortnightly • Check all equip re parts. Ammonia em Balancing of essential spa DA21 • Check the stock One week Syst Water lity Monthly (4 weekly) training DA24 Air Qua Two weeks 7.1.7. Safety and ities as appropriate to the Indoor 6 Quarterly ate first aid facil DA2 weeks) Maintain adequ (3 months – 12 THE

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Maintenan design, ins ce in and handovtallation er

3.1 Gene ral

To allow the maintenanc and efficiently e of it is essential plant to be carried out accessible, that all of the quickly all plant is safely are available. items are identified and design and This should have been all services required constructio resolved during n period. the Maintenanc e issues need lifecycle of to be considered an throughou of maintenanc HVAC&R system. As t the a guide the e considerati following during the ons should design, constructio be accommod list project. ated n and handover stages of a

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Operation All HVAC&R systems should Project timeline and handover reliable and be designed sustainable Figure 3.1 to be as purpose and as possible Relative cost while being simple, of changes providing during a construction the required particularly fit true function. This for project spare parts HVAC&R systems.of control systems is also needs associated to be considered selection to with help ensure during equipment System designers systems are that the life minimized. cycle costs are best maintenanc of the e philosophy placed to develop the Similarly considerati maintenanc design/ for a building e philosophy or system. on should specialist or the maintenanc should be be given to non-specia developed The the use of list plant and origins. The based on design should e objectives of the availability local owner and of local maintenancor exotic plant equipment the refer section take full account of (spares), the maintenanc final 4. system maintainab training and support e knowledge, e policy, can ility The maintainab improve both and sustainabili established ility of plant technology determinan design may rather than ty. The use of an t in how energy and systems is an important a new technology be more appropriate will be over and water unavailabili in a their whole efficient the in some cases ty of future life cycle. Something to maintain systems maintenanc due to the and e skills and that is difficult Designers efficiently and tune will be much less resources. can likely as intended by using high reduce or minimise maintain. Designers than something to operate quality componen future maintenanc that is easier should carefully between failure), of the systems e to ts (reduced consider the by using componen mean time requiring no complexity and operating they conceive with respect maintenanc ts or systems requiremen to maintenanc duplicate services e (passive ability to properly ts and e systems) or (run/standb maintain these the maintenance provider’s by using y pumps). services. Designers Maintainab should ility system. Commissioconsider the commission selection and also relates to issues of ability nability the design Considerati ongoing maintenanc equipment and installation relates to the extent of the e cost and on should be given to convenienc to which system balancing common componen of HVAC&R e. the standardiza systems facilitates and tuning ts in a new type of pumps, tion of to required installation valves, performanc Designers , same and the like and type of should consider e. ••• accessed. to reduce the make/ spare parts monitoring “building in” and systems for The ability that are required to be number 51 designs. Built feedback of plant to readily and held operation in monitors cost effectively or into their manageme can be linked access nt systems to building and can be condition monitoring associated with future maintenanc e strategies.

••• 21

3000 of urne VIC Institute , Melbo 8949 eth Street 3 39614 1 Elizab Fax: +61 Level 3, 3000 3 8623 Tel: +61

Australian

h.org.au www.aira

1 WINNER

FOR A PUMP? SHere’s TUMPED a condensate drain install on a new unit – through the master bedroom via a drilled hole in the wall. No need for a condensate pump! Spotted by Kane from WA. n

TROUBLE IN LITTLE CHINA BGreg IGfrom Tasmania spotted this shoddy, brand new install at a Chinese restaurant. No quality duct support, lack of weather proofing of all external duct joints, and to top things off – the fresh air intakes are too close to the toilet exhaust fan and sewer vent pipe. n

AMick MPHIBI-FAILURE from the ACT was called out to this job to find out why this AC had croaked it. n

POWER PROBLEMS PToo UZZLING lazy to extend the power, so the original installer simply drilled a hole though the cover for service ports. Spotted by Liam from NSW. n

O“Compressors N TILT don't work very well laying on their side,” says Bill from Victoria. The unit also had no bracing and the holding screws weren’t long enough. n

HAVE YOU COME ACROSS SOMETHING SCARY, UGLY OR JUST PLAIN FUNNY? If your entry is deemed the monthly winner, a bottle of Jim Beam bourbon 750ml will be on its way to your door. Please include a postal address with your entry. Entrants must be aged 18 years or over. Send submissions to editor Boon Mark Souphanh at boon@airah.org.au.

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

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